The impact of powder properties on powder flow and rheological characteristics for high-purity alumina.
VALENZUELA-HEEGER E. 1, BINNER J. 1
1 University of Birmingham, Birmingham, United Kingdom
It is well known that perfecting ceramic slurries is both a science and an art. When considering this, the determination of trends regarding the initial ceramic material is imperative for rapid development and minimal material waste. Within this research 4 different ultra-high purity alumina powders were analysed for their as-received properties, including their particle shape, porosity and size. Two methods of powder flow characteristics (powder shear and Halls flow) were applied and compared with the aim to further develop an understanding of powder packing and its impact on processing. The results from the mentioned analysis were studied to determine trends relating to particle properties, aspect ratio and flow; with the aim of establishing important links to advance ceramic powder processing. The 4 types of alumina were then used to formulate slurries for the processing of ceramic matrix composites (CMCs) at ~32% solid loading and ceramic slips for casting at ~54% solid loading. These ceramic systems were then analysed for their rheological results. The comparison of the rheological and powder flow characteristics establishes a way to begin the assessment of the influence of dry powder performance on wet ceramic processing. The highlighted trends established a need for the assessment of drying slips and slurries, and the characteristics and mechanisms that take place within the initial stages of green body forming - currently an understudied area of advanced ceramic processing. Upon the discovery of important trends, the progressive development of advanced ceramics can accelerate, reducing research and development time, as well as material waste, across ceramic systems as a whole.