Published online by Cambridge University Press: 21 February 2011
This paper describes a novel colloidal route for the preparation of hollow mullite ceramic microspheres with sizes in the range of 10 μm. An emulsion technique was combined with a water extraction sol-gel process, to form an aqueous droplet dispersion and gel the resulting droplets by extracting water with a dehydrating liquid. The liquid-filled gelled microcapsules were then dried and fired to form hollow ceramic microspheres. Important processing variables controlling the microspherc morphology were determined and a formation mechanism was proposed. Due to its potential applications in microelectronic packaging, mullite was selected as the model material for the present work, but the synthesis technique may be used for making other single or multiphase ceramic compositions