Abstract
Zirconia structures with controlled surface porosity may be used in several biomedical and engineering applications. This work aimed at developing a processing route for the production of zirconia structures with porous surfaces, using the dip coating method and without pore forming additives. Zirconia powders (~ 40 µm diameter) were used in the dip coating suspensions in three different forms: agglomerates (as received), pre-sintered (1150 °C, 1 h) and sintered (1500 °C, 2 h). The addition of fine particles (< 10 µm diameter) to the suspensions, in different contents, were tested to act as binder for the larger particles. Zirconia disk-shape compacts were dipped in the different suspensions and sintered. Pre-sintered powders were found to be the most adequate for producing the porous surface. The optimized binder content was determined as a function of the porous layer strength. A feasible route could be successfully established for the production of zirconia structures with porous surface.
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