| Lamination of ceramics is an important process in the manufacturing of layered structures, such as multiplayer capacitors, inductance, heat exchangers, solid oxide fuel cells (SOFC), etc. Tape casting is the wide and crucial technique for fabrication of green sheets for laminated object manufacturing (LOM). On the base of latex dope technology, the study overcomes some defects of traditional aqueous tape casting by selecting latex binder, and gets a smooth-surface and high-strength green tape to lamination of ceramics at room temperature.This paper focuses systematically on the relationship with the preparation of slurry, the forming film mechanism of latex binder and the rheological behaviors of the suspensions. The aqueous tape casting process can produce green tapes with smooth surface, homogenous structure, high toughness and strength, easy lamination and sintering by improving technique parameters of tape casting process. The technology without toxin and pollution has already arrived at an advanced level with great economic benefits and social benefits on the world.The influences of the characteristics of ceramic powders, PH value of slurries, latex binder, dispersants and plasticizers on water-based tape casting process were studied systematically. Aqueous ceramic slurry with good stability, suitable fluidity, and high powder loading was prepared successfully. The best range of slurry composition was determined by experiments.The drying process of the alumina suspensions is shown to follow a two-stage mechanism (the first stage: evaporation controlled process; and the second stage: diffusion controlled process). The latex binder fraction, plasticizers ratio and casting thickness are not influence of the first stage, but influence of the resistance of diffusion on the second stage. The drying temperature is mostly influence of the first stage. During the drying stage of suspensions, the compressive force compressed the latex particles distortion, which results in cross-linking structures in contacted latex particles of the solidified tapes. Glycerol and TBP improve the film quality by decreasing the Tg of latex binder systems.Ceramic green tapes, with thickness vary from 60-1000jnm and with the relative density about 54%, were fabricated by aqueous tape casting process with latex binder. The relative density of sintered tapes arrived at 96.5% on the sintering condition of 1580℃ for 2h, which were fabricated by ALCOA alumina powders. The sintered sample has not warped and deformed.A new method that allows the green tapes lamination at room temperature without any adhesive to laminate ceramics is described in this paper. Because the Tg of styrene-acrylic latex binder is very low, then the latex binders possess some pressure sensitive adhesion characteristic at room temperature, which the green tapes can adhere to a part at room temperature and low pressure. The laminated green parts densities and deformation significantly depended on the lamination pressure. The green body of laminated pressure of 16 MPa has homogenous microstructure and good sintering behavior, and the relative density can reach 97%. The interfacial of sintered laminated sample was disappeared. The bonding strength between green tapes was influenced by the characteristic of latex, fraction of binder and plasticizers ratio et al.
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