CERAMIC CASTING

Slip Casting
Slip casting- process of filling porous (gypsum or plaster of paris) mould with ceramic slurry Water is removed from the slurry via capillary action Collection of ceramic particles in the surface of the mould required thickness Green body is dried further and removed from mould

Sintering and final machining parts

Slip is a suspension of fine powder in a liquid such as water or alcohol with small amounts of dispersants, surfactants and binders

Cont

The setting rate will be all the higher as the permeability of the deposited layer

increases (low Rd).

The powder grain size distribution, which will influence the arrangement of the particles during the consolidation, varies considerably according to the type of ceramic and the final properties desired. The rheological behaviour and the viscosity of the suspensions in fact depend directly on the grain size of the powders, the inter- particle interactions (state of dispersion) and the particle concentration.

Mold Properties
Low toughness. High porosity, which lowers the strength. If the strength is increased some porosity must be sacrificed to increase the strength.

Low strength gypsum molds wear out with time because the pores are eroded from
the water that goes through them. Good for producing complex shapes because as the green body loses water and begins to dry out it shrinks away at edges of the mold for easy removal.

Advantages Low capital investment has to be made for the products Highly homogeneous slurries can be produced Wide variety of complex shapes can be produced that could not be produced using other conventional methods. Disadvantages Low dimensional precision Low production rate

Differential shrinkage becoz of packing factor gradient

low toughness mold- large mould inventory

Pressure casting
The supply of an additional pressure, compared to the low capillary pressure of the mold (< 0.2 mpa for plaster), decreases the setting time. The pressure casting consists of applying a pressure, generally Lower than 5 mpa, to the suspension in the porous mold The pressure gradient thus created (p) will force the fluid through the porous network and the formed layer, considerably reducing the setting time compared to traditional casting. Pressure casting reduces the water content in the green part and increases its density and its cohesion They do not require drying between the various castings it provides high productivity.

Tape Casting Technology

Tape Casting Technology

Also known as Doctor Blading, Knife Coating As the name indicates, thin tapes from varying range, 5 micron to 500 micron are produced. Thin layers of ceramic loaded polymers used as single layer or stacked and laminated into multilayer can be fabricated.

Why Tape Casting is required

Create large, thin and flat ceramic or metallic parts. Used for fabrication of components which are impossible to produce by

pressing and/or extrusion techniques.

Can be produced in large quantity and in single operation.

To increase capacitance (or to reduce voltage for getting same amount of

strain). Example: actuators

Advantage is high surface area for same volume high reactivity.

Example : Fuel cells, batteries, armor plate