Extrusion and rheology of fine particulate ceramic pastes

A rheological study was conducted on an extruded blend of two alumina powders, Alcoa A-3500-SG and Reynolds ERC. These extruded blends were mixed in four compositions, varying in distribution modulus. This work focuses on the interaction of the composition components, mainly particle size distribution and amount of water at a constant binder amount. The rheological parameters of extruded pastes, Sigma, Tau, alpha and beta, were determined by using capillary rheometry modeling by the methodology set forth by Benbow and Bridgwater. This methodology makes use of capillary rheometer to determine extrusion parameters, which describe the flow behavior of a paste. The parameter values are indirectly determined by extrapolating high shear rate information obtained by the extrusion process. A goal of this research was to determine fundamental rheological properties directly from fundamental rheological equations of state. This was accomplished by assessing the material properties by using a dynamic stress rheometer. The rheological parameters used in this study to characterize the paste are elastic modulus, viscosity, tan delta, and relaxation time. This technique approaches a step closer in understanding the microstructural influence on flow behavior of a paste. This method directly determines rheological properties by using linear viscoelastic theory, giving a quantitative analysis of material properties. A strong correlation between the elastic modulus and sigma, and viscosity and alpha is shown to exist, indicating a relationship between these two techniques.; Predictive process control methodology, based on particle packing modeling, quantitatively determined structural parameters useful in evaluating a composition. The determined parameters are: distribution modulus, interparticle separation distance, porosity, and particle crowding index, which are important to understand the extrudates packed state. A connection between the physical structure of the extrudate and its rheological behavior, can lead to a better understanding of what conditions and parameters are necessary to characterize the extrusion process. This study shows how particle packing and particle size influences the rheological behavior of the paste.; Results showed that an optimally packed system was found to occur at a distribution modulus of 0.51. This system was determined both experimentally and quantitatively to exhibit the lowest porosity at any water content. The 0.51 system required a lower amount of water to extrude and the parameters of both rheological techniques agreed well, in which all parameters are influenced by the packing state of the paste, and a consistent trend was generally found. The capillary rheometry results can be explained by the strong interaction of particles that occurs at high shear rates. The dynamic stress rheometer results can be explained by the particle packing characteristics, interparticle separation distance and particle-crowding index, and the capillary forces between particles. The excess amount of liquid that is present in the structure decreases the role of the capillary attraction between particles and an increase in the particle size role on the rheological behavior of the pastes occurs.