Chapter 1 Aqueous Colloidal Injection Molding of Ceramics
Based on Gelation .................................... 1
1.1 Colloidal Injection Molding ................................ 2
1.1.1 The Concept of CIMC ................................. 2
1.1.2 The Flowchart of CIMC ............................... 3
1.1.3 The Machine of CIMC ................................. 4
1.2 Pressure Induced Forming ................................... 6
1.2.1 Effect of Hydrostatic Pressure on Solidification .... 6
1.2.2 Homogeneity of the Green Bodies ..................... 6
1.2.3 Controlling the Inner Stress in the Green Body ...... 7
1.3 Storage Stability of Ceramic Slurries ...................... 9
1.3.1 The Importance of Storage Stability of Slurry ....... 9
1.3.2 Chemical Stability .................................. 9
1.3.3 Inhibitor for Slurry Storage ....................... 11
1.4 To Prepare High Reliability Ceramic Parts with Complex
Shapes: Aqueous Colloidal Injection Molding ............... 12
References ................................................ 14
Chapter 2 Gel-Tape-Casting of Ceramic Substrates ............. 16
2.1 Fundamental Principle and Processing of Aqueous Gel-
Tape-Casting .............................................. 18
2.1.1 Tape Casting Types and the Raw Materials ........... 18
2.1.2 Polymerization of the Monomer ...................... 22
2.1.3 Influence Factors on Polymerization of the
Monomer ............................................ 30
2.1.4 Processing of the Gel-Tape-Casting ................. 36
2.2 The Characteristics of Slurries Used for Aqueous Gel-
Tape-Casting .............................................. 39
2.2.1 The Properties of the Aqueous Ceramic Slurries
with Binder ........................................ 39
2.2.2 The Influence of Dispersants on Stability and
Rheology of Aqueous Ceramic Slurries with Organic
Monomer ............................................ 44
2.2.3 The Influence of Plasticizer on Properties of
Aqueous Ceramic Slurry with Organic Monomer ........ 47
2.2.4 The Influence of pH on the Properties of Slurries
with Organic Monomer ............................... 49
2.2.5 The Effect of Surfactant on Wetting and Green
Tape Releasing (Separating) ........................ 49
2.2.6 Foam and Pore Elimination .......................... 50
2.2.7 Sintering of Green Tape Prepared by Slurry ......... 52
2.3 Aqueous Gel-Tape-Casting with Styrene-Acrylic Latex
Binder .................................................... 53
2.3.1 The Importance of Binders in Gel-Tape-Casting
Process ............................................ 53
2.3.2 The Forming Film Mechanism of Latex Binder ......... 55
2.3.3 Rheological Properties of the Alumina Slurries
with Binder ........................................ 57
2.3.4 The Physical Properties and Microstracture of
Green Tapes with Latex Binder ...................... 57
2.4 A Gel-Tape-Casting Process Based on Gelation of Sodium
Alginate .................................................. 59
2.4.1 Why Study on Tape Casting of Sodium Alginate ....... 59
2.4.2 The Preparation of Aqueous Alumina Suspensions
with Sodium Alginate and Calcium Phosphere
Tribasic ........................................... 61
2.4.3 Control of the Gelation of Sodium Alginate ......... 63
2.4.4 Characterization of Green Tapes .................... 64
2.5 The Spray Trigger Fast-Curing for the Gel-Tape-Casting
Process ................................................... 66
2.5.1 The Idea of the Spray Trigger Fast-Curing .......... 66
2.5.2 Outline of the New Process ......................... 66
2.6 The Features and Prospects of the Aqueous Tape-Casting .... 68
References ................................................ 70
Chapter 3 Gelation Forming Process for Low Toxicity System .... 74
3.1 Gelation Forming of Ceramic Suspension with Agarose ....... 75
3.1.1 Characteristics of Agarose ......................... 75
3.1.2 The Effect of Agarose Contents on the Rheology of
Aqueous Ceramic Suspensions ........................ 77
3.1.3 The Forming Courses of the Aqueous Ceramic
Suspensions with Agarose ........................... 79
3.2 Alumina Casting Based on Gelation of Gelatine ............. 83
3.2.1 Characteristics of Gelatine ........................ 83
3.2.2 The Gelation Process of the Ceramic Slurry with
Gelatine Solution .................................. 86
3.2.3 The Preparation of Green Body Using Slurry with
Gelatine Solution .................................. 88
3.3 A Casting Forming for Ceramics by Gelatine and Enzyme
Catalysis ................................................. 90
3.3.1 Research Background ................................ 90
3.3.2 The Gelation Mechanism of Gelatine Solution with
Urea under Enzyme Catalysis ........................ 91
3.3.3 The Rheology and Zeta Potential of Alumina
Suspension Containing Gelatine and Urea ............ 93
3.3.4 The Coagulation Forming and Microstructure of
Green Body ......................................... 95
3.4 The Alumina Forming Based on Gelation of Sodium
Alginate .................................................. 96
3.4.1 Research Background ................................ 96
3.4.2 The Gelation Principle of Sodium Alginate .......... 97
3.4.3 The Preparation Process of Alumina Green Bodies
and Samples by Sodium Alginate .................... 100
3.5 The Gel-Casting of SiC Based on Gelation of Sodium
Alginate ................................................. 103
3.5.1 Introduction of the Research ...................... 103
3.5.2 The Effect of Dispersant on the Colloidal
Behaviors of the SiC Suspension ................... 104
3.5.3 The Rheological Property of SiC Suspension ........ 105
3.5.4 The Sedimentation Behavior of the SiC
Suspension ........................................ 107
3.5.5 The Gelation Principle and Process of the
Alginate Solution ................................. 108
3.5.6 The Gelation of the SiC Suspension with
Alginate .......................................... 108
3.6 The Alumina Gel-Casting with a Low-Toxicity System of
НЕМА ..................................................... 111
3.6.1 The Academic Idea and Research Program ............ 111
3.6.2 The Colloidal Chemistry and Rheological
Property .......................................... 111
3.6.3 The Binder Burnout and Application of the New
System ............................................ 113
3.7 The Synergistic Low-Toxicity Gel-Casting System by
Using НЕМА and PVP ....................................... 115
3.7.1 The Academic Idea and Research Program ............ 115
3.7.2 Zeta Potentials and Rheological Properties ........ 116
3.7.3 The Activation Energy and Solidification .......... 120
3.7.4 The Green Strengths and Microstructures ........... 121
3.7.5 The Exfoliation Elimination Effect and Analysis
of the Interaction between PVP and НЕМА
Molecules ......................................... 123
References ............................................... 125
Chapter 4 Generation, Development, Inheritance, and Control
of the Defects during the Transformation from
Suspension to Green Body ........................... 129
4.1 The Rheological Behaviors of Aqueous Ceramic
Suspensions .............................................. 131
4.1.1 The Rheological Behaviors of Aqueous Alumina
Suspensions ....................................... 132
4.1.2 The Effect of Rheological Properties of
Suspension on Mechanical Strength of Ceramics ..... 135
4.1.3 The Effect of Solid Loading on Colloidal
Forming ........................................... 142
4.2 The Generation and Development of Defects ................ 147
4.2.1 The Generation Mechanisms of Agglomerations in
Ceramic Suspensions ............................... 147
4.2.2 The Influences of Idle Time on Microstructures
and Mechanical Properties of Green Bodies by
Direct Coagulation Casting ........................ 154
4.3 The Effect of Ionic Conductance on Preparation of
Highly Concentrated Suspension ........................... 163
4.3.1 The Academic Idea and Research Program ............ 163
4.3.2 The Relationship Between Ion Conductivity
Constants and Solid Loading ....................... 165
4.4 Control of Inner Stress in Green Body .................... 170
4.4.1 Origin, Transformation and Control of Inner
Stress in Green Body .............................. 170
4.4.2 The Release and Control of Inner Stresses in
Ceramic Green Body ................................ 175
4.5 The Suppression of Surface-Exfoliation with the
Addition of Organic Agents ............................... 183
4.5.1 The Suppression of Surface-Exfoliation by
Introducing РАМ into Monomer System in
Suspension ........................................ 183
4.5.2 The Suppression of Surface-Exfoliation by
Introducing Polyethylene Glycol into Monomer
System in Suspension .............................. 190
4.5.3 The Suppression of Surface-Exfoliation by
Introducing Poly-vinylpyrrolidone (PVP) into
Monomer System in Suspension ...................... 198
References ............................................... 207
Chapter 5 The Gel-Casting of Non-Oxide Ceramics .............. 211
5.1 The Effects of Powder Surface Modification on
Concentrated Suspensions Properties of Si3N4 ............. 212
5.1.1 The Contributing Factor and Elimination of
Macropores in Si3N4 Green Bodies .................. 212
5.1.2 The Effect of Foreign Ions on Concentrated
Suspension of Si3N4 ............................... 217
5.1.3 The Effect of Acid Cleaning and Calcinations
on the Suspension Properties of Si3N4 ............. 223
5.1.4 The Effect of Liquid Medium and Surface Group
on Dispersibility of Si3N4 Powder ................. 232
5.2 The Gel-Casting of Si3N4 Ceramics ........................ 238
5.2.1 The Preparation of Si3N4 Ceramics with Surface-
Coated Si3N4 Powder ............................... 238
5.2.2 The Preparation of Si3N4 Ceramics with Surface-
Oxidized Si3N4 Powder ............................. 248
5.2.3 The Preparation of Si3N4 Ceramics with
Combination Processing ............................ 253
5.3 The Gel-Casting of SiC Ceramic and Si3N4 Bonded SiC
Ceramic .................................................. 262
5.3.1 The Gel-Casting of Concentrated Aqueous SiC
Ceramic ........................................... 262
5.3.2 The Gel-Casting of Aqueous Slurry with Si3N4
Bonded SiC ........................................ 268
References ............................................... 279
Chapter 6 Application of New Colloidal Forming ............... 283
6.1 Ceramic Microbeads ....................................... 283
6.1.1 The Forming Principle of Ceramic Microbeads
Based on Gel-Casting .............................. 283
6.1.2 The Processing of Microbeads ...................... 286
6.1.3 The Properties of Ceramic Microbeads .............. 287
6.2 Improving the Breakdown Strength of Rutile Capacitor ..... 298
6.2.1 The Influence of Sintering Additives on the Flow
Behavior .......................................... 299
6.2.2 The Calcining of the Rutile Mixture ............... 301
6.2.3 The Rheological Behavior of the Calcined Rutile
Mixture ........................................... 303
6.2.4 The Gel-Casting of the Calcined Rutile Mixture .... 304
6.3 The Thin-Wall Rutile Tube for Ozone Generator with
High Dielectric Constant ................................. 306
6.3.1 The Experiment Results ........................... 306
6.4 The Refractory Nozzle of Zirconia ........................ 309
6.4.1 The Rehological Behaviors of ZrO2 Suspensions
with Different Dispersants ........................ 310
6.4.2 The Sediment Stability of ZrO2 Suspension with
Different Dispersants ............................. 312
6.4.3 The Preparation of ZrO2 Refractory Nozzles ....... 313
6.5 Water Based Gel-Casting of PZT ........................... 314
6.5.1 The Colloidal Chemistry and Rheological
Behavior .......................................... 316
6.5.2 The Microstructure and Properties ................. 319
References ............................................... 323
Chapter 7 The New Methods and Techniques Based on Gel-
Casting ............................................ 325
7.1 Development Overview and Application of SFF .............. 327
7.1.1 Development Overview of SFF ....................... 327
7.1.2 Application of SFF ................................ 328
7.2 Development Overview and Application of Freeze-Gel-
Casting .................................................. 336
7.2.1 The Combination of Gel-Casting and Freeze-
Casting Technique ................................. 336
7.2.2 Fabrication of Ceramics with Special Porous
Structures ........................................ 338
7.2.3 The Microstructure and Properties of Porous
Alumina Ceramics .................................. 343
7.2.4 The Mechanical Properties and Applications of
Alumina Ceramics with Ultra Low Density ........... 350
7.3 The Solidification of Concentrated Si3N4 Suspensions
for Gelcasting by Ultrasonic Effects ..................... 352
7.3.1 Gelcasting by Ultrasonic Effects .................. 352
7.3.2 The Preparation of Concentrated Si3N4
Suspensions ....................................... 354
7.3.3 The Ultrasonic Accelerated Solidification ......... 355
7.3.4 The Comparison between Thermal and Ultrasonic
Activated Solidifications ......................... 358
7.4 Novel Laser Machining Technology for A12O3 Green
Ceramic .................................................. 360
7.4.1 Laser Machining Technology ........................ 360
7.4.2 Practical Application of Laser Machining
Technology ............................................... 361
References ............................................... 368
Appendix 1 The Testing and Analyzing Methods Used in
Authors' Research ................................. 371
Appendix 2 The Raw Materials Used in Authors' Research ....... 372
Index of Terms ................................................ 373
Index of Scholars ............................................. 377
Postscript .................................................... 384
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