Abstract
The article presents computer‐aided design approach and discusses an integrated manufacturing protocol to fabricate ZrO2‐toughened Al2O3 (ZTA) prototype with excellent geometrical conformity. In particular, a powder mixture of 95 wt% Al2O3–5 wt% ZrO2 with 800 ppm MgO sinter aid is uniaxially compacted at 200 kN, followed by pre‐sintering‐machining‐final sintering. The finishing of ZTA socket to obtain submicron surface roughness (Ra ≈ 0.01 μm) is accomplished using polymer rheological medium with silicon carbide abrasives. Summarizing, the uniqueness of uniaxial compaction‐based processing approach is established to fabricate scalable near‐net‐shaped acetabular ceramic sockets having uniform ZrO2 distribution in 3D microstructure of ZTA, as analyzing using microcomputed tomography.
Published Version
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