In this paper we report a novel process for the production of ultralight ce
llular ceramics. The foams are generated by the heat treatment of crystals
of the aluminum chloride isopropyl ether complex [AlCl3((Pr2O)-O-i)]. The c
rystals, which are the only foam precursor, are obtained from concentrated
solutions of AlC3, (Pr2O)-O-i, and CH2Cl2. The foams consist of an arrangem
ent of closed cells, 50-300 mu m in diameter, having cell walls approximate
ly 1-2 mu m thick. An exceptionally high porosity is obtained ranging from
94 to 99%, and the cellular structure is retained during heating at 1500 de
grees C. The foaming mechanism involves two consecutive nonhydrolytic sol-g
el chemical reactions and physical processes including crystal dissociation
, solvation, phase separation, and foaming, While other foaming mechanisms
cited in the literature utilize one or more of the processes above, no anal
og mechanism exists in the organic, ceramic, or metal foam production proce
sses, The effectiveness of the process originates from an initial precursor
which contains all the necessary foaming components in such a way that the
application of mild heating accelerates its transformation to a solid, dry
, ultralight foamed material.