Gelcasting: From laboratory development toward industrial production

Abstract

Gelcasting, a ceramic forming process, was developed to overcome some of the limitations of current complex-shape forming techniques such as injection molding and slip casting while reducing the costs of shaping advanced ceramics. Gelcasting is based on the separation of the mold filling step from the setting step in these forming processes by utilizing the polvmerization of organic monomers into a chemical gel which holds the ceramic powder in place after the mold is filled. The simplicity of the process has attracted industrial partners and by collaboration between them and the developers, the process is being advanced from the laboratory toward industrial production. IntroductionThe advantages of advanced ceramics over metals in harsh environments have lead to extensive research in the last three decades to improve their reliability. Although the research resulted in the development of toughened, more reliable

Tailoring magnetic properties of self-biased hexaferrites using an alternative copolymer of isobutylene and maleic anhydride

“…Generally, in order to keep adequate fluidity and sufficient strength, various kinds of dispersants and binders had been introduced simultaneously, which inevitably causes the preparation process complication. 8,9 Furthermore, the environmental and safety aspects need to be taken into account. Therefore, utilizing a single copolymer acting simultaneously as a dispersant and binder would be desirable.…”

Thermoanalytical studies of the ceramic-metal composites obtained by gel-centrifugal casting

“…The concept of gel-casting, belonging to shaping methods based on colloidal processes, was first presented by researchers from Oak Ridge National Laboratory in 1990 [4,5]. This method is a well-known colloidal technique in the preparation of high-quality, complex-shape, tough green bodies by means of polymerization of organic monomers in the ceramic suspensions [6][7][8][9][10].…”

“…This method is a well-known colloidal technique in the preparation of high-quality, complex-shape, tough green bodies by means of polymerization of organic monomers in the ceramic suspensions [6][7][8][9][10]. The method does not require the use of sophisticated equipment as in case of injection molding [4]. Gel-casting method allows also manufacturing metal parts [11], ceramic matrix composites such as zirconia-toughened alumina (ZTA) [12], or ceramic-metal composites [13].…”

3D Printing of ZrO2 Ceramic using Nano-zirconia Suspension as a Binder

“…Usually, the fabrication of molds for complex shaped ZrO 2 ceramic green parts using slip casting, gel casting, injection molding powder metallurgy or machining is labor-intensive and time-consuming [5].…”