Strength Of Ceramics Research Articles

The connection between the accumulation of structural defects caused by proton irradiation and the destruction of the near-surface layer of Li4SiO4 – Li2TiO3 ceramics

The key problem of using lithium-containing ceramics as materials of breeders for the propagation of tritium in thermonuclear reactors is phase stability, as well as the preservation of strength and thermophysical parameters of ceramics during their operation, which is accompanied by the accumulation of fission products in the near-surface layers, alongside mechanical influences from the outside. Moreover, in contrast to other types of ceramics, the presence of lithium in the composition of the samples under study leads to limitations in the use of classical analysis methods (scanning electron microscopy, energy dispersive analysis or optical spectroscopy) of structural changes caused by the accumulation of radiation damage, which requires the use of more complex methods for the assessment of the defect concentration in the structure, as well as establishing their relationship with the deterioration of strength and thermophysical parameters, playing a key role in determining the stability mechanisms and further exploitation of ceramics for tritium production. In this regard, the aim of the study is to determine the kinetics of changes in the near-surface layer of two-phase Li4SiO4 – Li2TiO3 ceramics associated with the accumulation of structural distortions caused by irradiation, as well as their relationship with strain embrittlement and disorder. During the studies, it was found that the accumulation of implanted hydrogen in the near-surface layer under high-dose irradiation initiates deformation distortion processes, the intensity of which depends on the ratio of components in the ceramics, according to which the optimal compositions of two-phase ceramics are ratios of components from 0.3 to 0.6. Determination of the type of defects in the composition of the damaged layer, as well as their concentration, was carried out using the electron spin resonance (ESP) method. During the studies, it was found that at low irradiation fluences, the dominant role in the accumulation of structural defects is played by vacancy defects associated with E′-centers, the formation of which is associated with structural distortions, while as the fluence grows, the structure is dominated by deformation disordering caused by the accumulation of Ti3+ defects and HC2 centers (SiO43-), the concentrations of which have a clear dependence on the phase composition of the ceramics.

Does the surface conditioning of glass and hybrid ceramics with self‐etching silane present a bond strength similar to that of conventional bonding? Systematic review and meta‐analysis of in vitro studies

AbstractPurposeTo evaluate, through in vitro studies, the bond strength of vitreous and hybrid ceramics with self‐etching surface treatment compared to conventional treatment.MethodsThis systematic review followed the preferred reporting items for systematic reviews and meta‐analyses (PRISMA) and was registered on the open science framework (OSF) platform for in vitro studies. A population, intervention, control, and outcome (PICO) question was formulated: “Does the surface conditioning of glass and hybrid ceramics with self‐etching silane present a bond strength similar to that of conventional bonding?”. A literature search was carried out in the PubMed, Embase, Web of Science, Cochrane Library, and ProQuest databases until September 2023. The Joanna Briggs Institute (JBI) critical appraisal guidelines for quasi‐experimental studies were used for risk assessment of bias. The meta‐analysis was based on the inverse variance (IV) method (p < 0.05).ResultsA total of 29 in vitro studies published between 2017 and 2022 were included in this systematic review, totaling 1889 ceramic samples. The meta‐analysis indicated a significant decrease in the bond strength of HF 4%–5% with silane compared to self‐etching (p < 0.05; MD: 0.34; 95% CI: 0.13–0.35; I2 = 3%, p = 0.42), while it indicated that there was no significant difference between self‐etching compared to 9%–10% HF with silane (p = 0.92; MD: 0.02; 95% CI: −0.32 to 0.36; I2 = 14%, p = 0.32).ConclusionSelf‐etching primer presents bond strength that is superior to or similar to conventional surface treatment on glass and hybrid ceramics.

Effect of SiO2/AlOOH double-coated SiC powders on the properties of SiC ceramics by vat photopolymerization

Vat Photopolymerization (VPP) technology is expected to address the challenges of preparing high-strength, precise, and complex SiC ceramics. However, the poor printability of SiC powders and the low strength of the resulting SiC ceramics remain significant obstacles. To overcome these issues, this study proposes a SiO2/AlOOH double-coating method for modifying SiC powders. The effects of AlOOH content in the double coating on the properties of SiC powders, slurries, and ceramics were investigated. Additionally, the impact of sintering additives on the densification behavior and mechanical properties of SiC ceramics was examined. The results indicated that increasing the AlOOH content in the double coating decreased the UV absorption of the powders and increased the curing depth of the slurries, but also increased the viscosity of the pastes. Moreover, while increasing the AlOOH content in the double coating improved the densification and flexural strength of the ceramics, the effect was significantly less compared to optimizing the sintering additive. Using SiO2/AlOOH double-coated SiC powders containing 2.5 wt% AlOOH and 10 wt% Al2O3-Y2O3-MgO (mass ratio 1:8:1) sintering additives, SiC ceramics were prepared with a relative density of 91.1 ± 3.5 %, a Vickers hardness of 1685.6 ± 86.4 HV, and a flexural strength of 281.7 ± 14.4 MPa, much higher than that of other SiC ceramic prepared using the same process. This represents the highest flexural strength of SiC ceramics prepared by VPP technology to date, providing a new method for the preparation of high-strength SiC ceramics via VPP.

Effect of sintering temperature on feature resolution and flexural strength of ceramics fabricated through vat photopolymerization additive manufacturing

PurposeAlthough ceramic additive manufacturing (AM) could be used to fabricate complex, high-resolution parts for diverse, functional applications, one ongoing challenge is optimizing the post-process, particularly sintering, conditions to consistently produce geometrically accurate and mechanically robust parts. This study aims to investigate how sintering temperature affects feature resolution and flexural properties of silica-based parts formed by vat photopolymerization (VPP) AM.Design/methodology/approachTest artifacts were designed to evaluate features of different sizes, shapes and orientations, and three-point bend specimens printed in multiple orientations were used to evaluate mechanical properties. Sintering temperatures were varied between 1000°C and 1300°C.FindingsDeviations from designed dimensions often increased with higher sintering temperatures and/or larger features. Higher sintering temperatures yielded parts with higher strength and lower strain at break. Many features exhibited defects, often dependent on geometry and sintering temperature, highlighting the need for further analysis of debinding and sintering parameters.Originality/valueTo the best of the authors’ knowledge, this is the first time test artifacts have been designed for ceramic VPP. This work also offers insights into the effect of sintering temperature and print orientation on flexural properties. These results provide design guidelines for a particular material, while the methodology outlined for assessing feature resolution and flexural strength is broadly applicable to other ceramics, enabling more predictable part performance when considering the future design and manufacture of complex ceramic parts.

Improved mechanical properties of porous Si3N4 ceramics strengthened by β-Si3N4 seeds fabricated by vat photopolymerization

Porous Si3N4 ceramics are widely applied in aerospace and mechanical fields owing to their excellent properties. Furthermore, vat photopolymerization (VPP) technology can fabricate Si3N4 components with complicated structures and high precision, but its layer-by-layer printing method leads to poor mechanical properties of ceramics. In this study, porous Si3N4 ceramics with a porosity of 28.41 % strengthened by directional β-Si3N4 were fabricated by combining VPP technology and seeding method. Rheological behavior and curing properties of the slurry were explored, and the influence of β-Si3N4 content on the mechanical properties of printed Si3N4 ceramics was investigated systematically. With the increase of β-Si3N4 content, the orientation degree of β-Si3N4 grains increased gradually, while fracture toughness and flexural strength of the ceramics exhibited a trend of increased first and then decreased and Vickers hardness gradually decreased. As β-Si3N4 content increased to 5 wt%, the fracture toughness and flexural strength of porous Si3N4 ceramics were improved from 4.23 MPa m1/2 and 214.7 MPa–5.65 MPa m1/2 and 272.0 MPa, respectively. Therefore, this work indicates that vat photopolymerization combined with seeding method is a promising approach for the fabrication of porous Si3N4 ceramics with high performance and complex structures.

Mechanical properties and multi-field ferroelastic response of Nb/Mn Co-doped CaBi4Ti4O15 high-temperature ferroelectric ceramics

CaBi4Ti4O15 (CBT) ceramics are promising piezoelectric materials that have been widely studied for high-temperature applications. Despite significant advancements in the electrical performance of CBT ceramics, the understanding of their mechanical behaviors remains limited, which is unfavorable for designing ceramics with high stability and reliability during high-temperature service. This work investigated the mechanical properties and fracture behaviors of Nb/Mn co-doped CaBi4Ti4O15 (CBTNM) with various doping levels, focusing on stress-strain responses and ferroelastic deformation behaviors under uniaxial compression and multi-field coupling conditions. HRTEM analysis reveals small-scale layered domain wall structures on the surface of plate-like grains. The fracture and compressive strengths of CBTNM ceramics initially decrease and then increase with an increase in doping content, and the underlying mechanisms are related to grain size, defects, and densification. CBTNM ceramics exhibit nonlinear stress-strain responses due to ferroelastic deformation under compressive loading, and the resultant irreversible domain switching strain increases with an increase in doping content, while poling can further increase the residual strain. Under multi-field loading conditions, CBTNM ceramics undergo more ferroelastic deformation events and exhibit larger residual strain. The micro-cracks, pores, complicated fracture modes, and degraded fracture surfaces with fragmental and rough features are mainly responsible for the lower elastic modulus and inferior mechanical response. This work enhances our understanding of the mechanical behaviors of high-temperature piezoelectric ceramics and provides guidance for designing high-performance piezoelectric materials for complex environmental applications.

Does a relationship exist between hardness and compression strength for advanced ceramics?

Does a relationship exist between hardness and compression strength for advanced ceramics?

High strength of SiC–AlN–TiB2–VC multiphase ceramics induced by interface reactions

In this work, SiC–AlN–TiB2–VC multiphase ceramics with high bending strength were prepared via spark plasma sintering (SPS) at 1900 °C-2100 °C. The effects of interface reactions and solid solution reactions on microstructure and mechanical properties of these multiphase ceramics were investigated. Results show that the densification of multiphase ceramics is promoted effectively by the addition of Y2O3. Yttrium aluminum oxide with low melting point is formed due to the reaction between Al2O3 (on the surface of AlN) and Y2O3, which promotes the densification of SiC multiphase ceramics. Solid-solution reaction and interface reaction occur between matrix (SiC) and reinforcing phases (AlN, TiB2, and VC). Furthermore, solid-solution reactions occur between SiC and AlN, between AlN and TiB2, and between TiB2 and VC. Al5C3N phase is generated by interfacial reaction between SiC and AlN. Layered, rod-like BN(C) phase is formed at grain boundaries due to the reaction between AlN and B2O3 on the surface of TiB2 particles. Mechanical strength of multiphase ceramics is improved by the formation of solid solutions and the occurrence of these interfacial reactions. When sintered at 2000 °C, SiC multiphase ceramics with added Y2O3 exhibit excellent properties, including relative density of 99.8 %, Vickers hardness of 27.1 GPa, and bending strength of 666 MPa.

Influence of grain size and grain edge phase on the flexural strength of aluminum nitride ceramics with Y2O3 sintering additive

The necessity for efficient heat dissipation compels AlN packaging materials towards a thinner profile. In response to the ensuing concerns regarding the reliability of strength, the effects of the grain edge phases and grain size on flexural strength are investigated in this study. Different preparation processes, including (hot-pressed sintering, pressureless sintering, and annealing) are employed to prepare AlN ceramics with different grain edge phases and grain sizes. After classifying the morphology of the grain edge phases and fitting the Hall-Petch relationship, it is found that the grain edge phases had a more significant influence on the flexural strength. Depending on the morphology, the negative effects can be divided into three degrees. While the finer grain size proves advantageous for the flexural strength. Consequently, in the non-additive system, the flexural strength of AlN ceramic is 422 MPa, with an average grain size of 8.47 μm. For the additive-doped system, the maximum flexural strength can reach 532 MPa, which can be attributed to the limited average grain size resulting from the hot-pressed sintering process, approximately 1.32 μm. These results could potentially be employed in the microstructural design of high-strength AlN ceramics.

The impact of aging and thickness on flexural strength of various zirconia ceramics

BackgroundEffects of the aging process on the flexural strength of Y-TZP and different Y-PSZ ceramics of different thicknesses were investigated.Methods300 disc-shaped samples (12 mm diameter, 0.8 and 1.5 mm thicknesses) were made from 5 different zirconia materials 3Y-TZP LA, 4Y-PSZ, 5Y-PSZ, 3 + 5Y-PSZ and 4 + 5Y-PSZ. Experimental groups were artificially aged in an autoclave at 134 °C, 2 bar pressure for 1 and 5 h; control groups were not subjected to any treatment. Microstructural analysis was conducted using Scanning Electron Microscopy, and X-Ray Diffraction analysis determined the crystalline phase content. The impact of aging on flexural strength was investigated with the use of the biaxial flexural strength test. Data were analyzed using three-way ANOVA tests with a significance level of p < 0.05, applying Bonferroni correction for multiple comparisons.ResultsStatistically significant differences in flexural strength were observed among the materials and the material thicknesses (p < 0.05), while there were no significant differences among the aging times (p > 0.05). The highest mean flexural strength values were recorded in the case of the 3 Y-TZP-1.5 mm–5 h group (744.1 ± 61.2 MPa), which was attributed to phase-transformation toughening. The lowest values were observed in the case of the 5 Y-PSZ-1.5 mm–5 h (338.3 ± 34.8 MPa) group.ConclusionsBoth material type and thickness significantly affect the flexural strength of zirconia ceramics, whereas aging time does not; thus, material selection and thickness are crucial considerations for clinicians.

Impact of Er,Cr:YSGG Laser Debonding on the Mechanical Properties of Aged and Non-aged Lithium Disilicate Ceramics

Aim: The aim of this study is to evaluate the effects of Er,Cr:YSGG laser debonding on the mechanical properties of aged and non-aged lithium disilicate ceramics. Material and Methods: A total of 36 lithium disilicate samples with dimensions of 14x4x1 mm were prepared. Half of the samples underwent 5000 thermal cycles to simulate artificial aging. The aged and non-aged samples were divided into two subgroups: one subgroup was designated as the control group and did not receive laser treatment, while the other subgroup was treated with Er,Cr:YSGG laser for debonding (n=9). The flexural strength and modulus of the lithium disilicate samples were assessed using three-point bending tests before and after artificial aging. The surface roughness of a sample that did not undergo the three-point bending test was measured with AFM, its microhardness was assessed using Vickers hardness tests, and surface morphology was examined with FESEM. Two-way ANOVA and Bonferroni correction to determine the significance of the results were used for statistical analysis. Results: The results indicated that aging significantly reduced the flexural strength (p=0.031), however, laser debonding did not have a significant effect on the flexural strength or modulus of either aged or non-aged samples. Conclusion: Laser debonding effectively removes lithium disilicate restorations without compromising their mechanical properties, supporting their reuse in clinical practice. It is important to note that aging reduces the flexural strength of lithium disilicate ceramics.

Strength comparison for fully dense zirconium diboride ceramics tested by different methods

AbstractThe strength of zirconium diboride ceramics was tested by three different methods, 3‐point flexure, 4‐point flexure, and compression. Nearly full‐density ceramics were obtained by hot pressing commercial ZrB2 powder with the addition of .5 wt.% carbon as a sintering aid. The thermal properties and hardness were studied for ZrB2 milled with ZrB2 and WC media. Based on phase purity and higher thermal conductivity, ZrB2 ceramics prepared from powders milled with ZrB2 media were selected for mechanical property studies. The strength in 3‐point flexure was 546 ± 55 MPa. The flexure strength was 476 ± 41 MPa in 4‐point bending, which was ∼20% higher than the previously reported value of 398 MPa for ZrB2 with similar grain sizes due to higher relative density and lower impurity contents. Compression testing was performed at room temperature, and the strength was 1110 ± 358 MPa. Finally, the fracture toughness of pure ZrB2 ceramics was determined by the chevron‐notched beam method to be 3.6 ± .7 MPa m1/2. The strength and fracture toughness values are higher than those previously published for ZrB2 ceramics and can be attributed to higher density and lower grain size. The strength‐limiting flaw sizes were comparable to the grain size, suggesting that porosity and impurity phases did not play a significant role in the strength of these ceramics.

Influence of layer thickness and exposure on mechanical properties of additively manufactured polymer-derived SiOC ceramics

One significant hurdle in additively manufacturing polymer-derived ceramics lies in reconciling the lower mechanical properties of additively manufactured parts compared to traditionally manufactured ceramics and PDCs. Here, a methodology is presented for evaluating the influence of layer thickness and exposure on polymer-derived ceramics within the constraints of commercially available software and hardware. Maximizing exposure within printable limitation of DLP processes, produced green bodies with the highest conversion, and resulted in improved pyrolysis outcomes, manufacturability, and most importantly ceramic strengths comparable to traditionally manufactured SiOC PDCs. Decreasing layer thickness and increasing total dwell time had a dramatic impact on mechanical properties, increasing flexural strength by more than 6x from 18 MPa at 100 μm layer thickness to 111 MPa at 10 μm layer thickness. Density of resultant ceramic also increased from 1.62 ± 0.03 g/cc to 2.3 ± 0.05 g/cc. This represented a large increase in mechanical strengths of PDCs produced via DLP in literature.

Residual strength of porous alumina ceramics and fractal characterization of their crack patterns after thermal shocks

Thermal shock behaviors of porous alumina samples with different porosities (4.6–16.0 %) and mean grain sizes (2.72–5.02 μm) were investigated under different quenching temperatures. The slit island method was used to analyze the structures of the pores. The effect of the pore structure on the thermal shock resistance of alumina ceramics was described quantitatively. The results revealed that the thermal shock resistance decreased when the fractal dimension of the pores increased. Alumina ceramic strips with a porosity and mean grain size of 4.6 % and 5.02 μm, respectively, were fabricated using raw powders with a mean particle size of ∼0.3 μm. These samples possessed the highest residual strength ratio (∼46.16 % at 600 °C) and critical temperature difference (∼262 °C). In addition, the fractal characterization of cracks on the surfaces of the alumina ceramics after thermal shock was carried out using the box-counting dimension method. In addition, we investigated the correlation between the mechanical properties and fractal dimensions of the surface cracks. The box-counting dimension increased with crack propagation and negatively correlated with the residual strength. Furthermore, the propagation rate of the surface cracks decreased as the temperature difference increased, resulting in a decrease in the growth rate of the fractal dimension.

High temperature deformation behaviour and recrystallization mechanism of TiC/Ti6Al4V gradient material fabricated by laser directed energy deposition

Metal-ceramic gradient materials are of considerable interest due to their unique capability to integrate the ductility of metals with the mechanical strength and high-temperature resistance of ceramics, thereby reducing the risk of cracking induced by thermal stress. In this article, TiC/Ti6Al4V gradient materials were prepared through the laser directed energy deposition (LDED) process. Subsequently, high-temperature compression tests were performed at various temperatures to investigate the deformation behaviour and recrystallization mechanism of the gradient materials. The Zener-Holomon constitutive equation was then used to calculate the gradient material at 750–900 °C and 0.001–0.1 s−1 to obtain a deformation activation energy of 362.36 KJ·mol−1. The EBSD was used to analyze the microstructural evolution of the gradient material. The results indicate a significant reduction in the average grain size of the specimens after high-temperature compression, and a more random crystal orientation due to the occurrence of dynamic recrystallisation (DRX). The primary softening mechanism of TiC/Ti6Al4V gradient materials is discontinuous dynamic recrystallisation, with TiC primarily affecting the nucleation of discontinuous dynamic recrystallisation (DDRX) and the subsequent grain growth. The nucleation becomes easier with increasing TiC content. However, the TiC hinders the migration of grain boundaries, resulting in a smaller DDRX grain size. After high-temperature compression, the main slip system of the crystal is converted from Pri to Bas. Pyr is difficult to activate due to its high critical resolved shear stress.

Effect of Veneering Technique on Shear Strength of Porcelain Veneered Zirconia (PVZ): Finite Element Analysis

Veneering technique is discussed as one of the reasons for chipping of porcelain veneered zirconia (PVZ) restorations, which impacts their longevity and success. This study aims to evaluate the effect of veneering technique; heat-pressed, and hand-layered, on the shear bond strength of PVZ ceramics through finite element analysis. Six cylindrical bilayer material model configurations were analysed; two types of zirconia, IPS e.max® ZirCad (Z) and Luxen Zr (L) and each veneered with three porcelain types, Shofu Vintage ZR (V), IPS e.max® Ceram (C), IPS e.max® Zirpress (P), with dimensions of (10 mm x 1.2 mm) and (5 mm x 3 mm), respectively. The force for threedimensional model configurations were fixed at 5 kN. The results show that heat-pressed groups (ZP and LP) have slightly higher bond strength value 49.12 MPa and 49.03 MPa, compared to hand-layered groups (ZC, LC, ZV, and LV), measuring 48.87 MPa with 0.5% difference at maximum. Bond strength in MPa underwent variance analysis, revealing a significant influence of ceramic material on mean values (p = 0.0017). Thus, the highest stress concentrations occur at the edges of the load application points, gradually decreasing as the distance from the point of load application increases. Results indicate that heat-pressed technique is better than hand-layered veneering technique due to its effectiveness in strong adhering veneer to the zirconia core.

Effects of plasma surface treatment on the bond strength of zirconia with an adhesive resin luting agent.

The purpose of this study was to evaluate the effect of the atmospheric pressure plasma treatment as a surface treatment method on the contact angle and shear bond strength (SBS) of zirconia ceramics and the failure mode between the self-adhesive resin luting agent and zirconia. The zirconia specimens were divided into eight groups based on the surface treatment method: alumina blasting, air plasma, argon plasma (AP), Katana cleaner, ozonated water, ozonated water+AP, Katana cleaner+AP, and tap water+AP. The contact angles, SBS, and fracture modes were tested. AP treatment significantly reduced the contact angle (p<0.0001). The combination of AP and other cleaning methods showed a higher bond strength and more mixed fractures. Our findings indicate that using atmospheric pressure plasma with argon gas, combined with other cleaning methods, results in a stronger bond than when using alumina blasting alone.

ZrO2 reinforced porous Si3N4-based ceramics with improved mechanical properties fabricated via vat photopolymerization (VPP)

Porous Si3N4 ceramics are widely applied in many fields owing to their excellent properties such as high electromagnetic wave permeability, oxidation resistance, and wear resistance. Besides, the vat photopolymerization (VPP) technique can fabricate porous Si3N4-based ceramics with complex shapes and high precision. Nevertheless, The high absorptivity and refractive index of Si3N4 to ultraviolet light make it difficult to form porous Si3N4-based ceramics with the VPP technique. In this work, the addition of ZrO2 simultaneously improved the printability of Si3N4 slurries and the performance of Si3N4 ceramics via VPP technology. Rheological behavior and curing properties of the slurries were investigated, and the influence of ZrO2 content on the mechanical properties of printed Si3N4-based ceramics was investigated systematically. The addition of ZrO2 decreased the UV absorptivity of composite powder, thus improving the curing depth from 25.2 ± 2.6 μm to 64.8 ± 3.7 μm. XRD analysis revealed that ZrO2 in the composite ceramics mainly exists as the phase of yttria-stabilized tetragonal zirconia (Zr0.92Y0.08O1.96), which could ensure the effect of phase transformation toughening. With the increase of ZrO2 content, flexural strength and fracture toughness of porous Si3N4-based ceramics exhibited a trend of increase first and then decrease. As ZrO2 content increased to 10 wt%, the flexural strength and fracture toughness of porous Si3N4-based ceramics were improved from 214.7 MPa and 4.23 MPa·m1/2 to 345.0 MPa and 5.69 MPa·m1/2, respectively. Therefore, this work provided an important reference for the fabrication of high-performance porous Si3N4-based ceramic components with complex structures.

Digital light processing of high-purity SiC ceramic membrane support modified by SiC whisker

High-purity SiC ceramic membrane has gained tremendous attention in the treatment of various corrosive wastewaters. Additive manufacturing technique makes it possible to fabricate high-purity SiC ceramic membrane with complex configurations. Here, we proposed a route for the preparation of high-purity SiC ceramic membrane support using digital light processing and SiC whisker reinforcement. With the increase of whisker content, the viscosity of SiCw/SiC photosensitive slurry increased due to the formation of whiskers agglomerations; the average pore size shifted from 3.15 μm to 1.35 μm with the occupation of large pores by SiC whiskers. In addition, the compressive strength of the ceramic support increased from 10.7 MPa to 16.7 MPa because of the decline in pore size and the toughening effects by SiC whiskers. So, the introduced SiC whiskers enhanced the pore connectivity and mechanical strength of the porous ceramics. This work provides a feasible path to manufacture high-purity SiC ceramic membrane support with complex configuration, high pore-connectivity and excellent mechanical properties.

Low-toxic gelcasting of zircon ceramics

Zircon (ZrSiO4) ceramics are highly valued in various industries due to their exceptional physical and chemical properties. In the present work, zircon ceramics with high-density and desirable mechanical properties were successfully prepared using an aqueous gelcasting method, involving the use of a low-toxic and water-soluble monomer, N,N-dimethylacrylamide (DMAA), as the binder. A high solid loading and low viscosity zircon slurry was achieved by optimizing the pH and the dosage of the ammonium polyacrylate (PAA-NH3) dispersant. Zircon green bodies fabricated through the gelcasting method exhibited uniform microstructures and relatively high mechanical strength exceeding 11.0 MPa. The impact of solid loading on the density, decomposition, flexural strength, micro-hardness, and microstructure of the final ceramics were carefully studied. Notably, the ceramics, prepared by solidifying the slurry with a 45 vol% solid loading and sintering the green body at 1550 °C for 2 h, exhibited a relative density of 96.3 %, high phase purity, a uniform microstructure, and the highest flexural strength of 407.9 MPa. The results demonstrate that mechanically robust dense zircon ceramics can be effectively prepared using the low-toxic gelcasting method.