I am trying to produce either Al2O3 or Fe2O3 monoliths from epoxides (propyleneoxide + FeCl3*6H2O), but they keep breaking and cracking during the curing phase. Is there a way of avoiding this excessive cracking?
Cracking occurs because of inhomogeneous shrinkage. Do you materials shrink much ?
This can be reduced by solvent exchange, replacing water in the porosity by diethyl ether for example, having much lower surface tension. The drying must also be slow, for example in an almost cosed vessel. You can also replace water by tert-butanol and freeze-dry your sample. More examples can be found in my RG profile.