Abstract
Abstract Room-temperature injection molding, a novel, environmentally benign ceramic processing method, produced dense, near-net shape alumina rings by utilizing unique flow properties of aqueous, highly loaded (>50 vol.%) ceramic suspensions with ≤5 vol.% polyvinylpyrrolidone (PVP) dispersed using Darvan 821A. The rheological behavior of suspensions along with microstructural and mechanical properties of resulting specimens were evaluated by varying PVP content to determine the optimal composition for forming. Parallel-plate rheometry revealed that suspensions containing ≤5 vol.% PVP were yield pseudoplastic at room temperature, which facilitated processing without heating or complex chemical reactions. Alumina rings with high green densities (>60% true density (TD)) were machined before binder removal, and increasing PVP content was observed to enhance green machinability. After binder burnout and sintering, bulk densities were ∼98%TD with
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