Optimized Development of High-Porosity Structural and Thermal Insulation Foam Ceramics Based on Local Natural and Technogenic Raw Materials
Kuanyshbay A. Niyetbay S. Tashmukhanbetova I. Sadyrov R. Amangeldi N. Mustafa L. Nurakhova A. Rustemov I. Yesbolat A.
June 2025Multidisciplinary Digital Publishing Institute (MDPI)
Ceramics
2025#8Issue 2
This study explores the optimization of foam ceramic materials through experimental research and mathematical modeling. The goal was to enhance mechanical strength, thermal insulation, porosity, water absorption, and density by adjusting composition and firing conditions. Regression analysis and response surface methodology were used to assess the effects of loam, fly ash content, and the firing temperature. The optimal composition of 60–65% loam, 10% fly ash, and a firing temperature of 950–1000 °C yielded foam ceramics with a bulk density of 680–700 kg/m3, a compressive strength of 3.5–4 MPa, and a thermal conductivity of 0.135–0.140 W/(m·K). Controlled porosity (70–72%) enhanced insulation while maintaining structural integrity. X-ray diffraction confirmed mullite, quartz, and cristobalite phases, with mullite improving mechanical properties. This research demonstrates the potential of optimized foam ceramics for energy-efficient construction. Mathematical modeling and experimental validation provide a pathway for developing lightweight, high-performance ceramic materials. Future work should refine sintering processes, explore new additives, and evaluate the long-term performance.
foam ceramics , mathematical modeling , mechanical strength , optimization , porosity , thermal insulation , water absorption
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Faculty of General Construction, International Educational Corporation, Ryskulbekova Street, 28, Almaty, 050043, Kazakhstan
Construction and Building Materials Department, Institute of Architecture and Civil Engineering, Satbayev University, 22 Satbayev Street, Almaty, 050013, Kazakhstan
Faculty of Pre-University Education, Al Farabi Kazakh National University, Avenue Al—Farabi 71, Almaty, 050040, Kazakhstan
National Center of Space Research and Technology, 15, Shevchenko St., Almaty, 050010, Kazakhstan
Department of “Transport Construction and Production of Building Materials”, Kazakh Automobile and Road Institute Named After L.B. Goncharov, Raimbek Avenue, 415B, Almaty, 050061, Kazakhstan
Faculty of General Construction
Construction and Building Materials Department
Faculty of Pre-University Education
National Center of Space Research and Technology
Department of “Transport Construction and Production of Building Materials”
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