Effect of Microshaping Parameters on Mechanical Properties of Alumina Ceramics
BORTOT COELHO F. 1, STUER M. 1
1 Laboratory for High Performance Ceramics, Empa, Überlandstrasse 129, 8600 Dübendorf, Switzerland, Dübendorf, Switzerland
Micro and nanofabrication of ceramic materials are rapidly growing fields own to their important technological applications in microfluidics, photonics, electronics, and biomedical devices. In particular, ceramic surface microstructuring is of enormous interest due to its possibility to achieve outstanding thermal, mechanical, and tribological properties. However, there are limitations to large-area microstructuring and industrial fabrication of three-dimensional micro free forms. In this work, we discuss the effects of various parameters (e.g. particle size, orientation, mould material, solid loading, slurry viscosity, sintering parameters, doping) on the final properties of micro-shaped alumina (Al2O3) parts, such as surface roughness, mechanical properties, and shrinkage. First, it is discussed the effect of the particle size of the raw material used in the shaping process. Smaller particle sizes have been shown to improve the final surface finish and reduce the amount of shrinkage during sintering. However, obtaining nanoparticle slurries with high solid content adds several challenges to the process. In addition, the orientation of the particles during shaping also plays a significant role in the final properties of the parts, with a preferred orientation resulting in improved mechanical properties. Next, it is studied how the solid loading and slurry viscosity affect the ease of shaping and the final properties of the parts. High solid loading can lead to increased strength and stiffness of the final parts, but can also increase the risk of cracking and reduce the surface finish. Higher slurry viscosity can result in more precise shaping, but can also increase the difficulty of removing the shaped parts from the mould. It should be noticed that the choice of mould material also has a significant impact on the final properties of micro-shaped parts, for instance, mould materials with a low surface energy can prevent adhesion of the shaped parts to the mould, which can result in defects and poor surface finish. Then, the effects of sintering parameters, such as temperature and duration, on the densification process are discussed. It is desired a reduced porosity and increased mechanical properties, but excessive sintering can cause shrinkage and deformation of the parts, leading to poor dimensional accuracy and surface finish. Finally, it is investigated the doping of the raw materials as a way to alter the thermal and mechanical properties of the parts, resulting in improved strength, toughness, and resistance to wear and corrosion. Overall, micro-shaping is a promising technique for the fabrication of precise and intricate parts with dimensions. Careful control and optimization of these parameters are critical to achieving the desired final properties, such as surface roughness, mechanical properties, and other important parameters.