Simple routes from natural graphite to graphite foams: Preparation, structure and properties

Abstract Graphite foams were prepared using foaming method and template method with nature flake graphite powder as main raw materials, sucrose as a foaming agent or binder, as well sodium chloride as a template. The compositions, microstructure, thermal properties and mechanical performance of the fabricated graphite foams were investigated by X-ray fluorescence spectrometer, scanning electron microscope, laser thermal conductivity meter, and electronic universal testing machine, respectively. The results show that water in binder played an important role in forming process of graphite foams. Graphite foams with controllable pore structure can be obtained by template method. The porosity of graphite foams increased with increasing the concentration of templating agent. With a fixed concentration of the templating agent the thermal diffusivity of the foams deceased with increasing the concentration of binder. Moreover, the obtained graphite foams has a minimum density of 288 kg/m3, a maximum porosity of 78% and a maximum thermal diffusivity of 7.14 × 10−6 m2/s. Two binding models of graphite foams prepared using template method has been proposed in the first time. This work provided an optimized processing for graphite foams with simple preparation, low-cost recyclable raw materials, and a promising thermal management material for many applications.