Colloidal processing of ceramics offers a high potential to achieve homogeneous microstructures with improved material properties. In this study, a novel forming method is investigated, which was already applied successfully for the fabrication of ceramic matrix composites (CMC), but is also considered to be a suitable direct casting technique for the fabrication of advanced ceramics with tailored microstructure and properties. The so-called nanoparticle assisted coagulation method (NPAC) represents a modification of the hydrolysis-assisted solidification (HAS) technique. It promises green components with high green strength, uniform density as well as homogeneous and tailored microstructure. Electrostatically stabilized colloidal suspensions with high solid loadings were produced by dispersing various fractions of submicron alumina powder and aluminium hydroxide nano-powder in water without use of any organic binder. Rheology and coagulation kinetics of suspensions and green part properties were studied regarding to modifications of pH value, setting temperature, amount of setting agent, amount of nano-powder, solids loading and process parameters like ultrasound treatment. It could be revealed that the homogeneous core-shell arrangement of submicron and nanoparticles in the colloidal state can be transmitted to the green state, which improves the microstructure and green density of the green parts. For this, the NPAC method is seen as a promising technique for the fabrication of advanced ceramics with tailored microstructure and properties.
direct casting; ceramic forming; rheology; green strength; cryo TEM; nano-particles; zeta potential; coagulation kinetics
