Cenospheres are hollow particles in fly-ash, a by-product of coal burning, and are widely used as reinforcement for developing low density composites called syntactic foams. This study investigates the physical, chemical, and thermal properties of cenospheres obtained from 3 different sources, CS1, CS2, and CS3, for the development of syntactic foams. Description of floatation method to separate broken particles is given, and it was seen that up to 11 % of the particles were damaged. Post heat treatment samples show development of SiO2 phase in the cenosphere, which is not present in the as received product. CS3 had the highest quantity of Si element, compared to the other two, showing the difference in the source quality. The particle size distribution for CS2 is very narrow while for the others is much broader. All censopheres have porous walls but the morphology of CS2 is the most uniform and smooth. For the application of metallic layer and subsequent consolidation via spark plasma sintering, CS2 was deemed the most physically, thermally, and chemically suitable.

Present study focuses on the synthesis and characterisation of a lightweight ceramic material with electromagnetic interference (EMI) shielding properties, achieved using mullite containing micrometer-sized hollow spheres (cenospheres) and CoFe2O4 nanoparticles. The research explores compositions with varying CoFe2O4 content, ranging from 0 up to 20 wt.%. Сonventional sintering in an air atmosphere is carried out at a temperature between 1100-1300 °C. The addition of ferrite nanoparticles was found to enhance the sintering process of cenospheres, resulting in improved material density and mechanical properties. Furthermore, the study reveals a direct correlation between the concentration of ferrite nanoparticles and the electromagnetic properties of the. By increasing the concentration of ferrite nanoparticles, the electromagnetic shielding effect of the material (saturation magnetization (Ms) and remanent magnetization (Mr)) was observed to strengthen. These findings provide valuable insights into the design and development of lightweight ceramic materials with enhanced electromagnetic shielding capabilities. The synthesized ceramic material holds promise for various applications that require effective electromagnetic shielding, such as in electronics, telecommunications, and aerospace industries.

The current investigation presents porous ceramic materials prepared of cenospheres prepared by spark plasma sintering. The impact of sintering temperature, mould diameter (20 and 30 mm diameter) and cenosphere size on the properties of the sintered material was investigated. Shrinkage of the samples during sintering started at 900 °C. Sample shrinkage during sintering increases with increasing temperature and decreases with increasing mould size; increasing sample sintering temperature increases the apparent density of all sample series CS 63-150 µm in 20 mm mould from 0.97 to 2.3 g·cm-3 at 1050 - 1300 °C, in 30 mm mould 0.81 - 1.87 g·cm-3 at 1050 - 1200 °C, in 50 mm mould 0.54 - 0.75 g·cm-3 at 1050 - 1150 °C, while CS 150-250 µm in 20 mm mould 0.93 - 1.96 g·cm-3 at 1050 - 1200 °C. Total porosity decreases from 61.5% to 3.9% with increasing sintering temperature from 1050 to 1250 °C, while open porosity reduces at lower temperatures, with closed porosity being highest in samples sintered at 1150 °C. When the sintering temperature increases from 1050 to 1300 °C, the compressive strength of the CS 63-150 samples produced in a 20 mm mould increases from 11 MPa to 312 MPa. These results correlate with the Rice model, which describes an exponential dependence of compressive strength on material porosity and fully dense material compressive strength.