Controlling the rheological behavior of ceramic slurries and consolidated bodies: Interpenetrating networks and ion size effects

Colloidal processing has been demonstrated as an effective technique for increasing the reliability of ceramic components by reducing the flaw populations in sintered bodies. The formation of long-range repulsive potentials produces a dispersed slurry which can be filtered to remove heterogeneities and truncate the flaw size distribution. When the pair potentials are changed from repulsive to weakly attractive, a short-range repulsive potential can be developed in the slurry state which prevents mass segregation, allows particles to consolidate to high volume fractions, and produces plastic consolidated bodies. Plastic behavior in saturated ceramic compacts would allow plastic shape forming technologies to be implemented on advanced ceramic powders.; Two networks of different interparticle potential have been mixed to control the rheological properties of slurries and develop clay-like plasticity in consolidated bodies. The elastic modulus and yield stress of slurries were found to increase with volume fraction in a power law fashion. Consolidated bodies containing mixtures of alkylated and non-alkylated powder pack to high volume fraction and exhibit similar flow properties to clay. The mixing of aqueous networks of different pair potential can also be effective in tailoring the flow properties. The flow stress of saturated compacts has been adjusted by the addition of a second network of uncoated particles which is stabilized electrostatically.; The influence of the addition of silica of various sizes on the viscosity and zeta potentials of alumina suspensions has been investigated. The adsorption of nano-silica to the surface of alumina shifts the iep. The amount of silica at which the maximum shift in zeta potential occurs is consistent with the silica required to produce the minimum viscosity. This level of silica on the surface is consistent with calculations of the amount necessary for dense random parking of silica spheres around alumina.; The influence of counterion size on short range repulsive forces at high salt concentrations was investigated with alumina and silica slurries coagulated with the chlorides of Li+, Na+, K+, Cs+ and TMA+ (tetramethylammonium+). The results clearly show that the range of the repulsive forces correlated with the size of the unhydrated ion, namely stronger particle networks are achieved with smaller counterions. The findings are contradictory to the widely accepted hydration force model. Silica and alumina slurries were also studied at and below the iep where the indifferent electrolyte cations would not be expected to adsorb. It appears that a lyotropic sequence for excluded ions exists and is correlated to the hydration of ions and surfaces.