Synthesis of Porous Alumina Using Carbon Sacrificial Template Via UHS: Process, Structure, and Mechanical Properties

This study introduces an innovative method for manufacturing porous alumina using ultra‐fast high‐temperature sintering (UHS) combined with a carbon‐based sacrificial template. The aim is to develop a versatile process that tailors the physical, structural, and mechanical properties of alumina. The porous samples were fabricated using 5, 10, 15, and 20 wt.% of carbon. Their structure and the mechanical properties were compared after the two methods of thermal consolidation: 60 s in UHS and 2 h in tubular furnace (TUB). Structural characterization, performed via computer‐aided tomography, revealed highly porous structures with 96% pore interconnectivity. Mechanical properties, examined by uniaxial compression, showed a decrease of Young's modulus from 5.5 to 1.0 GPa and strength from 30 to 5 MPa with increasing porosity. UHS samples with final TUB treatment showed structural and mechanical properties suitable for biomedical applications.