注凝成型(gelcasting)工艺及其新发展

简要概括了注凝成型的工艺过程及其特点 ,着重介绍了低毒性凝胶系统的选择、注凝成型技术的扩大应用 2个方面。分析了注凝成型现阶段存在的问题 ,并指出了新的发展方向。

Effect of gelcasting conditions on quality of porous Al-Cu alloy

The porous A1-Cu alloy was prepared by the gelcasting process. And the effects of gelcasting conditions, such as monomer, the volume ratio of cross-linker and monomer, dispersant and redox initiating system on the height, gelling time and the quality of green body were investigated. （It was found that the dispersant and monomer played significant roles in the height and quality of green bodies, respectively.） The optimal conditions were 10% monomer, 2% cross-linker, 0.2% initiator （volume fraction）, and 1.2 g dispersant, in which the green body exhibited the best quality. The mechanisms of process conditions in eliminating the cracks and forming the pores of in the five stages were proposed. Mercury porosimetry provided a description of pore diameter ranging from 10 to 10000 nm and open porosity of 38.78 %.

Rheological property and drying mechanism of thermoresponsive gelcasting of ZnO

To solve the problem of drying gelcast green body, the thermoresponsive gel system which contains macromonomer graft chains was used in gelcasting of ZnO. The effects of the amount and length of graft chains macromonomer PIPAAm, the total amount of organic matters, and the solid loading on the rheological properties of suspensions were investigated, and the drying mechanism of gelcast green body was analyzed. The results show that ZnO suspensions with the gel system still display shear- thinning rheological behavior, but its viscosity increases with increasing the addition amount and relative molecular mass of PIPAAm graft chain, and the total organic matter content. The PIPAAm graft chains inhibit or even eliminate the formation of the ＂dense layer” on the surface of gelcast ZnO green bodies, and accelerate the drying of green bodies. The introduction of PIPAAm graft chains facilitates the shrinkage of the gelcast ZnO green bodies, which is a feasible method to increase the relative density of green bodies.

Porosity and mechanical properties of porous titanium fabricated by gelcasting

Porous Ti compacts with large size and complex shape for biomedical applications were fabricated in the porosity range from 40.5% to 53.8% by controlling gelcasting parameters and sintering conditions. The experimental results show that the total porosity and open porosity of porous titanium compacts gelcast from the Ti slurry with 34 vol.% solid loading and sintered at 1100℃ for 1.5 h are 46.5% and 40.7%, respectively, and the mechanical properties are as follows： compressive strength 158.6 MPa and Young＇s modulus 8.5 GPa, which are similar to those of human cortical bone and appropriate for implanting purpose.

GELCASTING OF NANO-SIZE Y-TZP

The green specimens of nano-size Y-TZP are formed by gelcasting method. Using polymer electrolytes NaPAA and NH_4PAA, we have studied the rheological properties of slurry.The optimum pH range is between 8 to 10. The proper amount of dispersant changes with the solid content.The rheological measurements of suspension containing NH_4PAA show lower viscosity.The theoretical green density has been calculated.

Gelcasting of 316L stainless steel

A novel near-net process, gelcasting, was successfully used to prepare larger size 316L stainless steel parts with complex shape. In this study, the effects of process parameters on the viscosity of the slurry and the dry green strength were investigated. The results show that gas atomization （GA） powder is more suitable for gelcasting compared with water atomization （WA） powder. The maximum solid loading is 55vo1% for ball-milled slurry with GA powders. And the optimum amounts of monomers （acrylamide （AM）＋methylenebisacrylamide （MBAM）; the mass ratio, 30：1） and initiator in the AM system are 1.8% （based on the weight of metal powder） and 0.8%-1.4% （based on the weight of monomers）, respectively, at which, the maximum green strength obtained is 33.7 MPa. The mechanical properties of the sintered specimen are as follows： ultimate tensile strength, 493 MPa; yield strength, 162 MPa; and HRB, 72.

Near-net shaped Al/SiCP composites via vacuum-pressure infiltration combined with gelcasting

To solve the problem of difficult machining, the near-net shaped Al/SiCP composites with high volume fraction of SiC particles were fabricated by vacuum-pressure infiltration. The SiCP preform with a complex shape was prepared by gelcasting. Pure Al, Al4Mg, and Al4Mg2Si were used as the matrices, respectively. The results indicate that the optimal parameters of SiCP suspension in gelcasting process are pH value of 10, TMAH content of 0.5 wt.%, and solid loading of 52 vol.%. The Al matrix alloyed with Mg contributes to improving the interfacial wettability of the matrix and SiC particles, which increases the relative density of the composite. The Al matrix alloyed with Si is beneficial to inhibiting the formation of the detrimental Al4C3 phases. The Al4Mg2Si/SiCP composite exhibits high relative density of 99.2%, good thermal conductivity of 150 W·m^-1·K^-1, low coefficient of thermal expansion of 10.1×10^-6 K^-1, and excellent bending strength of 489 MPa.

Preparation and Properties of Sialon-SiC Suspension for Gelcasting

The raw materials of Al, Si, SiO2, and SiC were used to prepare Sialon-SiC suspeusion for gelcasting by adjuting the pH value and content of SiC particle and controlling the milling time. The result shows that the stable suspension for gelcasting coald be got by adding 40wt% SiC particle at pH = 8. Al would eusily hydralyze to deteriorate the suspension when the milling time was too long, so the optimum milling time should be less than 100 minutes. At last, a well-dispersed suspension with a viseosity of less than 0.32Pa· s was obtained and the solid looming was 54vol% .

Near-net shape processing of spherical high Nb-TiAl alloy powder by gelcasting

Spherical Ti-45A1-8.5Nb-（W,B,Y） alloy powder prepared by an argon plasma process was near-net shape by gelcasting. In the non-aqueous system, methaerylate-2-hydroxy ethyl, toluene, benzoyl peroxide, and N,N-dimethylaniline were used as the monomer, solvent, initiator, and catalyst, respectively. To improve sintering and forming behaviors, many additives were included in the suspension. The concentrated suspension with a solid loading of 70vo1% was prepared. The high Nb-TiA1 powder was analyzed by electron microscopy and X-ray diffraction. It was found that the green bodies had a smooth surface and homogeneous microstructure, exhibiting a bending strength as high as 50 MPa. After sintering at 1480℃ for 2 h in vacuum, uniform complex-shaped high Nb-TiA1 parts were successfully produced.

Effect of Sintering Additive on the Properties of Sialon-SiC by Gelcasting

Sintering additives to gelcasting Sialon-SiC were decided by the optimizing experiments. The results show that Sialon-SiC can be sintered under 1450℃ and sintering temperature decreases by 100℃, when 2%～3% TiO 2 or Guangxi clay is used as sintering additive.

Porous alumina ceramic via gelcasting based on2-hydroxyethyl methacrylate dissolved in tert-butyl alcohol

To obtain porous alumina ceramic with high strength,a novel gelcasting system based on 2-hydroxyethyl methacrylate(HEMA)dissolved in tert-butyl alcohol(TBA)was developed.The polymerization of the HEMA-TBA gelcasting system,the thermal behavior of obtained green body,and the microstructures and mechanical properties of the sintered bodies were investigated by rheometer,TG-DSC,SEM and bending strength testing,respectively.The results show that,(1)10 mg/mL of the initiator(benzoyl peroxide)is the optimal amount for polymerization of this gelscasting system at 25 ℃;(2)The alumina suspension of the HEMA-TBA gelcasting system showing shear-thinning behavior is sufficiently low for gelcasting process;(3)The bending strength of porous alumina ceramic samples,whose porosities range from 42% to 56%,is from(8±0.5)to(91±4.5)MPa.

Effects of process parameters on nonaqueous gelcasting for copper powder

An approach to fabricate sintered copper with high green strength and high sintered density using nonaqueous gelcasting technol- ogy is presented in this study. The effects of various gelcasting processing parameters such as monomer content, monomer/crosslinker ratio, initiator content, dispersant dosage, and temperature on the flexural strength of dried green bodies and the relative density of sintered bodies were studied to obtain better microstructures and properties. The appropriate process parameters obtained for copper gelcasting are as follows monomer content, 20vol%-30vol% （based on the total volume of reagents）; monomer/crosslinker ratio, 10：1 to 20：1; initiator content, 3vol%-4vol% （based on the volume of the monomer）; dispersant dosage, 1.5wt%-2.5wt% （based on the mass of the copper powder）; and reaction temperature, 65-75℃.

Research on Gelcasting Formation of SiC-Al_2O_3-Y_2O_3-La_2O_3 Systems

The rheological behavior and gelcasting of composite suspensions of SiC and synthesized Al 2O 3-Y 2O 3-La 2O 3 powder as sintering aid were investigated. It was found that the rheological behavior of SiC particles could be modified with a slightly oxidized surface that was similar to silica in colloidal behavior. The smaller the particles were, the more similar to silica the SiC powder was. The pH value of Al 2O 3-Y 2O 3-La 2O 3 synthesized powder slurry at isoelectric points (IEP) is higher than that of SiC powder. The dispersant PAA-NH 4 changes the IEP of both SiC and Al 2O 3-Y 2O 3-La 2O 3 powder slurry to higher pH values. The experimental results indicate that the composite suspension could possess satisfactory stability and lower viscosity at pH =10.1 and PAA-NH 4 as dispersant. The optimum solid loading was 550 0 in volume. Machinable green bodies with uniform complex shape are gained after molding.

酚醛/环氧树脂凝胶注模成型制备反应烧结碳化硅

为了探究一种低成本、环保的反应烧结碳化硅材料成型方法,以SiC细粉和微粉、酚醛树脂和环氧树脂为主要原料,四甲基氢氧化铵为分散剂,配制固相质量分数为55%,酚醛树脂质量分数分别为13.5%、18%、22.5%及27%的SiC陶瓷泥浆,采用凝胶注模成型制成坯体,坯体经固化、800℃保温2 h热处理后,在真空条件下1760℃保温3 h制备反应烧结碳化硅材料。研究了坯体的固化机制及酚醛树脂加入量对试样显微结构、物相组成和物理性能的影响。结果表明:1)坯体固化机制为酚醛/环氧树脂中羟甲基与芳环的邻对位氢发生缩合反应交联,形成了较高强度的结合网络。2)随着酚醛树脂加入量的增加,树脂体系裂解残碳与熔融硅反应,烧后试样的常温抗折强度先增加然后降低。当酚醛树脂加入量为18%(w)时,烧后试样常温抗折强度最高,为79.9 MPa,此时试样的显气孔率和体积密度分别为1.1%、2.88 g·cm^(-3)。

Liquid drying of BeO gelcast green bodies using ethanol as liquid desiccant

BeO gelcast green bodies were dried by liquid drying method with liquid desiccant ethanol.Effects of ethanol concentration,solids loading and aspect ratio of green body on the moisture and shrinkage of green bodies were studied through measuring mass and dimension.Additionally,liquid drying stress was analyzed and a model of the initial stage drying stress was established.The results show that higher ethanol concentration,lower solids loading and higher aspect ratio of gelcast green bodies increase the drying rate.Increasing the ethanol concentration decreases the shrinkage rate.Liquid drying stress is generated due to a non-uniform drying rate.During the process of liquid drying,the inner drying stress of the green body changes from compressive stress to tensile stress,while the outer drying stress changes from tensile stress to compressive stress.

Si粉特性对反应烧结Si_(3)N_(4)多孔陶瓷的强韧性及介电性能的调控作用

Si_(3)N_(4)多孔陶瓷具有优异的力学性能、介电性能、热学性能和化学稳定性等,特别适用于高温、大载荷、强侵蚀环境下的宽频透波材料。反应烧结Si3N4多孔陶瓷在性能、工艺和成本方面优势显著,原料Si粉特性显著控制着其物相、显微结构、力学和介电性能。本文以不同粒径和纯度的Si粉为原料制备注凝成形、反应烧结Si_(3)N_(4)多孔陶瓷。结果表明,双粒径配料使素坯产生紧密堆积效应,其遗传并进一步演化出两级显微组织强韧化机制,双粒径配料5&45μm时的弯曲强度和断裂功获得最大值109.94 MPa和990.74 J/m^(2)。该值分别比单粒径配料5和45μm时的值提高了111.42%、25.97%和46.55%、20.46%;介电常数和介电损耗分别约为4.20和0.007。注凝成形、反应烧结Si_(3)N_(4)多孔陶瓷可以兼顾力学性能和介电性能,适用于透波罩等异形、大尺寸构件。

陶瓷的凝胶注模成型及其研究现状

阐述了陶瓷凝胶注模成型 (gelcasting)的工艺过程及关键影响因素 ,介绍了最近几年该技术的研发动态 ,指出环境友好型凝胶体系的开发 。

凝胶注模成型技术的研究与进展

对凝胶注模成型技术的研究与进展情况进行综述。阐述成型原理和工艺过程;总结凝胶体系,并根据凝胶体系的来源将其分为合成凝胶体系和天然凝胶体系两类;介绍该技术在粗颗粒粉体材料、复合材料、多孔材料、功能材料和粉末冶金等领域的应用研究情况;探讨凝胶注模成型技术存在的问题和研究发展方向。

凝胶注模成型制备高性能氮化硅陶瓷(Ⅰ)──助烧剂包覆氮化硅粉料对材料性能的影响

用无机盐共沉淀法在氯化硅颗粒表面包覆一层纳米级的钇铝氧化物后，粉料的分散性大大提高，可用来制备团相体积分数为５０％的悬浮体，利用凝胶注模成型和气压烧结制备了氮化硅陶瓷，与机械混合加入助烧剂相比。