A Novel Method of Copper Green Bodies Production: Through a Low Toxicity Gelling System in a Non-Aqueous Based Gelcasting Process

Abstract

The importance of gelcasting process is related to producing strong de-mouldable complex shape green bodies through polymerization of monomer in colloidal suspensions. As such, research in modeling of viscosity, stability, casting, polymerization, dispersion and toxicity of colloidal suspension is of particular importance as these factors affect the resultant green bodies. The current study uses a low toxicity gelling systems based on 2-hydroxypropyl methacrylate (HPMA), 2-hydroxyethyl methacrylate (HEMA), and N,N-dimethylacrylamide (DMAA) in the synthesis of copper green bodies through a non-aqueous gelcasting process. The monomers are polymerized in 1,2-propanediol and cross-linked by diethylene glycol diacrylate to form three dimensional network structures that hold the copper particles. Viscosity, polymerization time, flexural strength, and relative density of the resultant colloidal suspension having copper particles suspension are investigated in details. Their flexural strength and density values strongly depend on optimum gelcasting process parameters and the chemical character of the monomer used.