Novel ceramic supports for catalyst with hierarchical pore structures fabricated via additive manufacturing-direct ink writing

The use of direct ink writing technology, combined with in-situ grown whiskers, has facilitated the development of 3D-printed ceramic catalyst supports-aluminum borate porous ceramics (ABPCs) with hierarchical pore structures. The optimal slurry consists of 0.2 wt% polycarboxylate, 19 wt% water addition, and 1.2 wt% sodium alginate. The most effective printing parameters are determined to be a 1.0 mm nozzle diameter, 10 mm/s printing speed, 4.0 kPa air pressure, and 0.4 mm layer height. After sintering at 1100 degree celsius, pure-phase aluminum borate (Al18B4O33) ceramics are achieved, leading to the formation of needle-like aluminum borate whiskers. The aspect ratio of whiskers, flexural strength, BET-specific surface area, and photocatalytic activity of ABPCs increase initially and then decrease with increasing sintering temperature. The ABPCs coated with a titanium oxide layer display a photocatalytic degradation rate of 83.92% for methyl orange solution. These results underscore the immense potential of ABPCs in high-temperature catalyst support applications.