| Colloidal Isopressing is a new processing method for shaping compacts from particulate suspensions. The study of interparticle interactions within a suspension, and their effect on the overall slurry behavior, has led to the prior discovery of a plastic-to-brittle transition in powder compacts formed by pressure filtration. Colloidal Isopressing utilizes this pressure dependent behavior for slurries with a short-range repulsive potential to rapidly transform plastic consolidated bodies into more complex shapes. The first results are presented for aqueous alumina suspensions where electrostatic double layer repulsion is compressed to short interparticle separations by the addition of ammonium chloride. Consolidation at low pressures produces a high relative density slurry that is plastic and can be extruded into a rubber mold. The application of an hydrostatic pressure forces a small amount of liquid into a porous portion of the mold and pushes particles together into a rigid network. As the pressure is released, the newly formed powder compact will partially separate from the lower modulus rubber mold. The body can then be ejected from the mold, dried, and densified to produce the final ceramic component.; Colloidal Isopressing has been successfully modeled as a special case of consolidation via pressure filtration. Theoretical analyses have accurately predicted the time required for the rapid transformation from plastic slurry to elastic powder compact.; The effects of slurry composition on processing were studied. The electrolyte concentration, powder particle size, slurry pH, and polymer concentration were shown to alter the flow behavior of filter pressed and liquefied compacts. As the free volume of liquid decreased and/or the relative attraction between particles increased, the concentrated slurry became more difficult to process.; Finally, drying of compacts formed by Colloidal Isopressing did not result in any shrinkage during drying, thus allowing for very rapid heating rates to be used. In fact, the drying, burnout, and densification could be combined into one step, with final densities approaching the theoretical limit. |
