Gelcasting of CRYSTAR{reg_sign} silicon carbide ceramics. CRADA final report

Abstract

This Cooperative Research and Development Agreement (CRADA) was undertaken to assess the applicability the gelcasting process for forming ceramic green bodies using Saint-Gobain/Norton Industrial Ceramics Corporation`s proprietary CRYSTAR{reg_sign} silicon carbide powder. A gelcasting process, specifically tailored to Saint-Gobain/Norton`s powder composition, was developed and used successfully to form green bodies for property evaluation. This preliminary evaluation showed that the gelcast material had characteristics and properties comparable to Norton`s baseline material. Wafer carrier molds were received from Norton for gelcasting a complex-shaped configuration with CRYSTAR{reg_sign} silicon carbide. Gelcasting experiments showed that Norton`s standard plaster of paris molds were incompatible with the gelcasting process. Mold surface treatments and the use of alternative castable mold materials were investigated, however, a successful process was not identified. The highest quality parts were cast in either glass or aluminum molds.