Abstract

A boron carbide (B4C) gelcasting suspension involving melamine formaldehyde (MF) resin was developed to obtain green bodies with low carbon after pyrolysis. MF resin allows highly complicated B4C parts to be produced with little to no shrinkage when gelcast into molds. A MF binder content of ~7.5 wt % consistently produced green bodies with sufficient strength to withstand demolding and handling. Variations in B4C particle size, curing temperature, and pH were investigated in order to optimize the suspension for casting. Resin pyrolysis trials showed that 90.0 ± 0.9 wt % of resin mass was lost during pyrolysis, corresponding to < 1 wt % of binder residual in the overall green bodies. The minimal carbon content in the green bodies is favorable for the infiltration of aluminum into open pore spaces. Due to the high hardness of B4C and the ductility of aluminum, the ceramic-metal (cermet) composite formed is ideal for applications such as light-weight armors.

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