Effective colloidal processing for densification before SPS

Conference Dates

March 10-15, 2019


In conventional dry processing, fine particles tend to agglomerate spontaneously due to Van der Waals attractive forces. Since the agglomeration of particles forms large residual pores in green bodies, elevated temperatures are necessary for densification. Colloidal processing is a very effective technique for controlling the pore size distribution in green compacts before sintering. The green compacts having small residual pores with a narrow size distribution is expected to enhance the densification at low sintering temperature during SPS. We already reported that colloidal processing for controlling the packing structure in green compact is effective for densification in SPS in the case of SiC. A commercially available SiC (6H) powder with the average particle size of 0.55 mm was used as the starting materials. When using the dry processing for consolidation, the density of the sample sintered by SPS in a vacuum atmosphere at 1950°C was 92% of the theoretical value. Aqueous suspensions with dispersed particles were prepared by adjusting pH and consolidated by slip casting to prepare the dense green compacts. The relative density of SiC prepared by SPS was increased with increasing temperature and reached more than 97% at 1950°C as shown in Fig. 1. In this presentation, this processing was applied to fabrication of transparent alumina. Commercially available Al2O3 powder with the average particle size of 0.4 mm was used as the starting materials. Suspensions with 30 vol% solid were consolidated by slip casting. The green compacts before sintering were further densified by cold isostatic pressing at 392 MPa for 10 min and calcined at 500°C for 1 h in air in order to burn off the dispersant. Final sintering was carried out at 1150°C under a uniaxial pressure of 100 MPa using an SPS. After rapid heating to 600°C, the temperature was raised from 600°C to 1150°C using a heating rate of 5°C/min. After holding samples at the sintering temperature for 10 min and then subsequently annealing them at 1000°C for 10 min, we obtained a sintered disk with a diameter of 25 mm and a thickness of 2 mm. Fig. 2(a) shows the photograph of the sample from the green compact prepared by slip casting, Fig2(b) is the sample densified by SPS from the as-received powder directly. The transparency of the sample prepared by slip casting is clearer than that of the sample by SPS from the as-received powder directly.

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