Method for preparation of dense ceramic products
First Claim
1. A method of preparing a dense ceramic product, comprising:
- (1) forming a coagulated network of ceramic powder particles in water by adjustment of the pH of a dispersed slurry of said ceramic powder particles in water to a pH that produces a net surface charge and addition of a sufficient amount of a salt to the dispersed slurry to form said coagulated network;
(2) treating said coagulated network of ceramic powder particles in water to increase the volume fraction of said powder particles, thereby forming a water saturated powder compact; and
(3) firing the compact to provide said dense ceramic product.
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Abstract
A method of preparing dense ceramic product is described, wherein a coagulated network of ceramic powder particles in water is formed and then treated to increase the volume fraction of particles, thereby forming a water-saturated powder compact. The compact is formed into a desired shape and fired to provide the dense ceramic product. A coagulated network may advantageously be formed by mixing a ceramic powder with water at a pH that produces a net surface charge, to form a dispersed slurry and adding a sufficient amount of salt to the dispersed slurry to cause particles within the slurry to form the coagulated network. In view of the unique rheological properties of the powder compacts prepared from coagulated networks of ceramic powder particles, the compact may be processed into complex, near-net-shaped forms by introducing the compact into a mold and subjecting the mold to vibration, whereby the compact adopts the shape of the mold; once removed from the mold, the compact retains its shape without distortion.
28 Citations
17 Claims
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1. A method of preparing a dense ceramic product, comprising:
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(1) forming a coagulated network of ceramic powder particles in water by adjustment of the pH of a dispersed slurry of said ceramic powder particles in water to a pH that produces a net surface charge and addition of a sufficient amount of a salt to the dispersed slurry to form said coagulated network; (2) treating said coagulated network of ceramic powder particles in water to increase the volume fraction of said powder particles, thereby forming a water saturated powder compact; and (3) firing the compact to provide said dense ceramic product. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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Specification