Viscoelastic properties, gelation behavior and percolation theory model for the temperature induced forming (TIF) ceramic slurries

Controlled ceramic processing is required to produce ceramic parts with few strength-limiting defects and the economic forming of near net shape components. Temperature induced forming (TIF) is a novel ceramic forming process that uses colloidal processing to form ceramic green bodies by physical gelation. The dissertation research shows that TIF alumina suspensions (>40vol%) can be successfully fabricated by using 0.4wt% of ammonium citrate powder and <0.1wt% poly (acrylic acid) (PAA). It is found that increasing the volume fraction of alumina or the molecular weight of polymer will increase the shear viscosity and shear modulus. Larger molecular weight PAA tends to decrease the volume fraction gelation threshold of the alumina suspensions. The author is the first in this field to utilize the continuous percolation theory to interpret the evolution of the storage modulus with temperature for the TIF alumina suspensions. A model that relates the storage modulus with temperature and the volume fraction of solids is proposed. Calculated results using this percolation model show that the storage modulus of the suspensions can be affected by the volume fraction of solids, temperature, volume fraction gelation threshold and the percolation nature. The parameters in this model have been derived from the experimental data. The calculated results fit the measured data well. For the PAA-free TIF alumina suspensions, it is found that the ionization reaction of the magnesium citrate, which is induced by the pH or temperature of the suspensions, controls the flocculation of the suspensions. The percolation theory model was successfully applied to this type of suspension. Compared with the PAA addition TIF suspensions, these suspensions reflect a higher degree of percolation nature, as indicated by a larger value of percolation exponent. These results show that the percolation model proposed in this dissertation can be used to predict the gelation degree of the TIF suspensions. Complex-shape engineering ceramic parts have been successfully fabricated by direct casting using the TIF alumina suspensions, which has a relative density of ∼65%. The sintered sample at 1550°C for 2h is translucent and has a uniform grain size.