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Effect of Manufacturing Processes on Design
Published in Mahmoud M. Farag, Materials and Process Selection for Engineering Design, 2020
The raw materials used for making ceramic parts are usually in the form of particles or powder. After mixing and blending the appropriate ingredients, processing is carried out either in a dry, semidry, or liquid state and either cold or hot condition. Forming processes include slip casting, molding, jiggering, extrusion, and pressing. After forming the plastic ceramic mass into the required shape, it is dried to remove the water and then fired to sinter the ceramic powder into a final product.
Shape-Forming Processes
Published in David W. Richerson, William E. Lee, Modern Ceramic Engineering, 2018
David W. Richerson, William E. Lee
Most commercial slip casting involves ceramic particles suspended in water and cast into porous plaster molds. Figure 13.22 identifies the critical process steps in slip casting and some of the process parameters that must be carefully controlled to optimize strength or other critical properties.
Advances in the Processing and Fabrication of Bioinspired Materials and Implications by Way of Applications
Published in T. S. Srivatsan, T. S. Sudarshan, K. Manigandan, Manufacturing Techniques for Materials, 2018
Lakshminath Kundanati, Nicola M. Pugno
Casting process is a manufacturing process in which liquefied metals are poured in a mold to obtain a solid cast. Similarly, films were produced by mixing graphene oxide with polyvinylalcohol as a solution and casting on a polyethylene sheet. The graphene oxide is then reduced using hydroiodic acid to obtain the final nacre-like material (Li et al. 2012). Freeze casting is a variation in which ice formation direction is used to control the solidification direction. As shown in Figure 6.11, the freeze casting technique was used to assemble platelet-like particles to obtain directionally solidified and highly porous material similar to that of nacre (Hunger et al. 2013). Slip casting is a type of casting process that was traditionally used to manufacture ceramic materials. Recently, slip casting process was used to create bioinspired materials made of ceramic, metal, and polymers, in which particles are assembled using a magnetic field to tailor the microstructure (Le Ferrand et al. 2015).
Preparation of modified silicon carbide powder with high dispersibility for slip casting
Published in Journal of Dispersion Science and Technology, 2020
Youxing Liu, Jiaxiang Liu, Tianyu Yang
Slip casting is one of the common methods for the preparation of ceramic materials.[7,8] The key step of slip casting is the preparation of SiC slurry with high solid content and low viscosity using modified SiC powder with high dispersibility.[9] So far, Saint-Gobain's modified SiC (SG SiC) powder has achieved the requirements of slip casting. SiC powders are very prone to agglomeration and show poor dispersibility in water due to their high surface energy.[10] To breakdown the agglomeration of particles and improve the dispersibility of particles in water, the technology of surface modification, as an effective method, is commonly used.[11,12] Surface modification methods for SiC powder can be divided into two classes: physical and chemical.[13,14]
Yttria-stabilized tetragonal zirconia prepared using gel casting and two-stage sintering
Published in Journal of Asian Ceramic Societies, 2023
Jing-Siang Jhan, Chih-Cheng Chen, Yu-Chi Liu, Hsing-I Hsiang
The ceramic forming methods can be classified into dry [13] and wet forming processes [14]. Complex-shaped ceramics have been prepared using wet forming processes such as slip casting and gel casting [14–17]. The slip casting method has some drawbacks, such as the need for a plaster mold for dehydration, a long molding time, and low green strength, making it unsuitable for making thick sections. Gel-casting is a wet-forming technology developed by the Oak Ridge National Laboratory (ORNL) that produces high-density ceramics with complex shapes [14]. It has the advantages of having a short molding time, no mold material restrictions, a high green strength, and the ability to apply thick sections. Compared to the solvent system, the aqueous gel casting process is less expensive and more environmentally friendly [18]. For aqueous-based gel-casting, the ceramic powder is first dispersed in water. Then monomer and initiator are added and mixed to form a dispersed slurry, which is poured into the mold and polymerized at high temperatures to create a green body with fewer defects, higher density, and better mechanical properties than other alternatives[19]. Acrylamide (AM) is commonly used as a gelling agent[19]. Due to AM neurotoxicity, gel-casting is not widely employed in the industry. Xie et al. [20] recently reported on the ethylene glycol diglycidyl ether (EGDGE) system as a potential nontoxic monomer for producing a low-viscosity slurry with high green strength. The slurry dispersion affects the green microstructure and, as a result, the microstructure, mechanical strength, and optical properties of sintered ceramics during the wet-forming process. Dolapix CE64 has been identified as the most effective dispersant for aqueous zirconia slurry [21]. However, it was found that Dolapix CE64 was added to the epoxy monomer, tending to induce gelling, leading to a sudden increase in slurry viscosity. To the best of our knowledge, the influence of the dispersant used in this work (Dolapix CE64) on the behavior of the gelling agent (EGDGE) adopted for this research has not been investigated yet.