Novel lightweight cement-based materials foaming by secondary aluminum ash: microwave absorption, mechanical and thermal insulation properties

A novel lightweight foamed cement-based electromagnetic wave (EMW) absorbing material (Density<0.5 g/cm3) is prepared using secondary aluminum ash (SAA) as a foaming agent and carbon black (CB) as an efficient EMW absorbent, providing a new way to recycle SAA. The pore structure parameters, reflection loss (RL), mechanical strength and thermal conductivity are systematically investigated. The experimental test results indicate that the pore structure of cement matrix prepared by SAA exhibits better EMW loss performance than those prepared by traditional foaming agent. The analysis of the pore structure images indicates that the average pore size is reduced, and pore size distribution shifts towards smaller sizes due to the addition of CB. Furthermore, the roundness of pores is increased due to the formation of more irregular pores. Increasing CB content and thickness can reduce RL, enhance absorbing performance at low frequencies, and broaden effective absorbing bandwidth (EAB). The absorbing performance was tested using the arch reflection method in the frequency range of 1.1–18 GHz, the excellent absorbing performance and the widest EAB (RL<−10 dB) reach −36.34 dB and 14.46 GHz, respectively, at a thickness of 4 cm. Benefiting from excellent pore structure, the foamed cement-based material also exhibits better mechanical strength, and good thermal insulation properties are maintained after adding CB. The compressive and flexural strength can reach 2.18 MPa and 1.02 MPa, respectively, while the thermal conductivity remains below 0.122 W/(m·K).