Development of carbon coatings for cordierite foams: an alternative to cordierite honeycombs

Cordierite foams were prepared by replication of polyurethane foams and were coated with three types of carbon xerogels. The dip coating and synthesis conditions were optimized, and the coated foams were characterized exhaustively. The composition of the starting solution, coat loading, and carbonization temperature are the most important parameters determining both textural and mechanical properties. Carbon xerogel coatings obtained from aqueous solutions of resorcinol (R) and formaldehyde (F) are macro-, meso-, and microporous but present the greatest shrinkage, which causes a loss of adhesion between ceramic foams and carbon coatings. The coatings from polyfurfuryl alcohol (PFA) and RF-poly(vinyl butyral) (Butvar) resin are highly microporous and present very good adhesion even after carbonization. In all cases, coatings induce the improvement of the mechanical properties, which is related to the fact that the coating fills the defects present in the cordierite foams, thereby affecting both the rigidity and the way cracks propagate through the coated samples. These materials, due to the synergetic role of the highly porous coatings and the tortuous channels of the ceramic foams, are suitable materials for adsorption or catalytic treatments of fluids.