Texturation of model clay materials using tape casting and freezing

Abstract The present work aimed to investigate the processing of textural clay based materials using tape casting together with freezing. Two model raw materials were used, namely: BIP kaolin from France and ABM montmorillonite from Mediterranean region. The mixtures of both clays were studied, whereby, the amount of montmorillonite was 0, 5, 10, 20 or 50 mass%. After tape casting, the as-obtained green bands were frozen into liquid nitrogen, lyophilized and then fired at 1050 °C or 1200 °C. The amount of montmorillonite appeared as a critical parameter that controls the cohesion of the dry products. For montmorillonite content ≥20 mass%, the products exhibited multiple cracks after lyophilisation. With lower montmorillonite content, the cohesion of the dry products was satisfactorily and a macroscopic cross-linked surface texturation was observed. After calcination at 1050 °C or 1200 °C, the texturation appeared well defined. Moreover, calcination at 1200 °C increased the densification of products and the occurrence of a glassy phase was noted. The combination of both tape casting and freezing (freeze tape casting) is a promising way to develop various clay-based and composites materials exhibiting unique microstructure organization and characteristics with potential application in the field sustainable and environmentally friendly filtration, adsorption or catalysis.