Compositional effects in potassium metakaolin geopolymers containing alumina and glass frit

Geopolymers represent a distinct class of materials characterised by their X-ray amorphous nature and nanoporous, nanoparticulate structure. Geopolymers can be conveniently mixed, poured, and cured under ambient conditions. This makes this class of materials an interesting alternative to ordinary Portland cement for structural processes. Additionally, the addition of alumina can improve mechanical properties, while the addition of glass can form an impermeable glaze which could be useful for molten salt containment. Therefore, in this investigation, potassium metakaolin-based geopolymer composites with varying proportions of glass particles and alumina platelets were fabricated, cured, heat-treated, and analyzed to study the effects of composition on material properties. Various attributes including rheological properties, densities, mass loss, shrinkage, and porosities were compared. It was observed that certain compositions exhibited high viscosities, making high shear mixing challenging, while also displaying significant permeability that would hinder their ability to contain liquids without leakage. Additionally, certain samples showed reduced densities, suggesting potentially weaker mechanical properties; however, the investigation did not include a direct assessment of mechanical properties. The most promising candidates for containing liquids at high temperature contained 50 wt% KGP, 25 or 35 wt% glass powder, and 25 or 15 wt% alumina platelets, respectively. ASH-G slurries required a minimum of 65 vol% KGP to produce a homogenous material compatible with additive manufacturing. The minimum amount of glass phase to form surface glazes was 16 vol%. Only samples containing more glass phase than alumina phase produced glazed composites.