Abstract:The porous Al-Cu alloy was prepared by the gelcasting process. And the effects of gelcasting conditions, such as monomer, the volume ratio of cross-linker and monomer, dispersant and redox initiating system on the height, gelling time and the quality of green body were investigated. (It was found that the dispersant and monomer played significant roles in the height and quality of green bodies, respectively.) The optimal conditions were 10% monomer, 2% cross-linker, 0.2% initiator (volume fraction), and 1.2 g dispersant, in which the green body exhibited the best quality. The mechanisms of process conditions in eliminating the cracks and forming the pores of in the five stages were proposed. Mercury porosimetry provided a description of pore diameter ranging from 10 to 10000 nm and open porosity of 38.78 %.

Key words: porous Al-Cu alloy; non-aqueous gelcasting; process conditions; crack; pore