Investigation of Cenosphere-Based Lightweight Ceramic Matrixless Syntactic Foam Through Spark Plasma Sintering

The current study introduces porous ceramic materials fabricated from cenospheres through spark plasma sintering. The investigation delves into the impact of sintering temperature, mould diameter (20 and 30 mm), and cenosphere size on the resulting material properties. Notably, sample shrinkage initiates at 900 °C and demonstrates an upward trend with temperature escalation, while a larger mould diameter contributes to sample shrinkage. Elevated sintering temperature leads to increased apparent density across various sample series, such as CS 63–150 µm in a 20 mm mould (0.97 to 2.3 g/cm³ at 1050–1300 °C), CS 150–250 µm in a 20 mm mould (0.93 to 1.96 g/cm³ at 1050–1200 °C), and others in different mould sizes. Total porosity decreases from 61.5 % to 3.9 % with a rising sintering temperature (1050 to 1250 °C), while open porosity starts decreasing at lower temperatures. Closed porosity peaks in samples sintered at 1150 °C. Furthermore, an increase in sintering temperature from 1050 to 1300 °C boosts the compressive strength of CS 63–150 samples in a 20 mm mould from 11 MPa to 312 MPa. These findings align with the Rice model, illustrating an exponential relationship between compressive strength, material porosity, and fully dense material compressive strength.