Abstract
The monomer content in the gelcasting process affects the kinetics of cross-linking reactions which determines the quality of the gel network structure and the final properties of the material. The main purpose of this study was to optimize the monomer contents in the gelcasting process to achieve a dense Si3N4 body by using pressureless sintering. Si3N4 bodies with a relative density of 95.9 ± 0.5% and 605 ± 4 MPa flexural strength were successfully prepared by employing the gelcasting technique using high-solid load slurry of 76 wt%. Acrylamide (AM) and N, N′-methylenebisarylamide (MBAM) were adopted as the monomeric system. The quality of gel structures was characterized by measuring idle time, green flexural strength, and linear shrinkage. Phase composition and microstructure of sintered samples were identified using XRD and SEM analysis, respectively. The linear drying shrinkage and Idle time decreased by increasing the monomer content. However, flexural green strength did not monotonically change with monomer content. The slurry with a 6 wt% monomer and AM/MBAM ratio of 3 produced the optimized gel structure. Besides, it resulted in a higher amount of β-Si3N4 phase which gives better mechanical strength.
Similar content being viewed by others
Data Availability Statement
All data generated or analyzed during this study are included in this published article.
References
Riley FL (2000) Silicon nitride and related materials. J Am Ceram Soc 83(2):245–265
Petzow G, Herrmann M (2002) Silicon Nitride Ceramics. In: Jansen M (ed) High Performance Non-Oxide Ceramics II. Springer, Berlin, pp 47–167
Cao L, Wang Z, Yin Z, Liu K, Yuan J (2018) Investigation on mechanical properties and microstructure of silicon nitride ceramics fabricated by spark plasma sintering. Mater Sci Eng A 731:595–602
Li Y, Chen F, Li L, Zhang W, Yu H, Shan Y, Shen Q, Jiang H (2010) Gas pressure sintering of arbitrary porous silicon nitride ceramics with high mechanical strength. J Am Ceram Soc 93(6):1565–1568
Li JL, Chen F, Niu JY (2011) Low temperature sintering of Si3N4 ceramics by spark plasma sintering technique. Adv Appl Ceram 110(1):20–24
Bocanegra-Bernal MH, Matovic B (2010) Mechanical properties of silicon nitride-based ceramics and its use in structural applications at high temperatures. Mater Sci Eng A 527(6):1314–1338
Klemm H (2010) Silicon nitride for high-temperature applications. J Am Ceram Soc 93(6):1501–1522
Pollinger JP (ed.) (1995) Improved Silicon Nitride Materials and Component Fabrication Processes for Aerospace and Industrial Gas Turbine Applications. ASME 1995 International Gas Turbine and Aeroengine Congress and Exposition; V005T13A004
Okada A (2009) Ceramic technologies for automotive industry: Current status and perspectives. Mater Sci Eng B 161(1):182–187
Drouet C, Leriche A, Hampshire S, Kashani M, Stamboulis A, Iafisco M et al (2017) 2 - Types of ceramics: Material class. In: Palmero P, Cambier F, De Barra E (eds) Advances in Ceramic Biomaterials. Woodhead Publishing, pp 21–82
Mazzocchi M, Bellosi A (2008) On the possibility of silicon nitride as a ceramic for structural orthopaedic implants. Part I: processing, microstructure, mechanical properties. Cytotoxicity 19(8):2881–2887
Li J-Q, Luo F, Zhu D-M, Zhou W-C (2006) Preparation and dielectric properties of porous silicon nitride ceramics. Trans Nonferrous Metals Soc China 16:s487–s4s9
Omatete OO (1991) Gelcasting-a new ceramic forming process. Am Ceram Soc Bull 70:1641
Bocanegra-Bernal MH, Matovic B (2009) Dense and near-net-shape fabrication of Si3N4 ceramics. Mater Sci Eng A 500(1):130–149
Yin S, Jiang S, Pan L, Guo L, Zhang Z, Zhang J et al (2019) Effects of solid loading and calcination temperature on microstructure and properties of porous Si3N4 ceramics by aqueous gelcasting using DMAA system. Ceram Int 45(16):19925–19933
Liu P-F, Li Z, Xiao P, Liu Y, Liu Z-Y, Luo H et al (2018) Effect of the molecular weight and concentration of PEG solution on microstructure and mechanical properties of Si3N4 ceramics fabricated by gel-casting. Ceram Int 44(8):8800–8808
Parsi A, Golestani-Fard F, Mirkazemi SM (2019) The effect of gelcasting parameters on microstructural optimization of porous Si3N4 ceramics. Ceram Int 45(8):9719–9725
Kastyl J, Chlup Z, Stastny P, Trunec M (2020) Machinability and properties of zirconia ceramics prepared by gelcasting method. Adv Appl Ceram 119(5-6):252–60
Li L, Wang H, Su S (2015) Porous Si3N4 Ceramics Prepared by TBA-based Gel-casting. J Mater Sci Technol 31(3):295–299
Vandeperre L, De Wilde A, Luyten J (2003) Gelatin gelcasting of ceramic components. J Mater Process Technol 135(2–3):312–316
Colonetti VC, Sanches MF, de Souza VC, Fernandes CP, Hotza D, Quadri MGN (2018) Cellular ceramics obtained by a combination of direct foaming of soybean oil emulsified alumina suspensions with gel consolidation using gelatin. Ceram Int 44(2):2436–2445
Adolfsson E (2006) Gelcasting of zirconia using agarose. J Am Ceram Soc 89(6):1897–1902
Ewais EMM, Ahmed YMZ (2002) Consolidation of silicon carbide in aqueous medium based on gelation of agarose. Br Ceram Trans 101(6):255–258
Jia Y, Kanno Y, Xie Z-P (2002) New gel-casting process for alumina ceramics based on gelation of alginate. J Eur Ceram Soc 22(12):1911–1916
Olhero SM, Tari G, Coimbra MA, Ferreira JMF (2000) Synergy of polysaccharide mixtures in gelcasting of alumina. J Eur Ceram Soc 20(4):423–429
Khanghah NS, Sani MAF (2010) Idle Time and Gelation Behavior in Gelcasting Process of PSZ in Acrylamide System. In: Zuhair A. Munir TO, Yuji Hotta, Mrityunjay Singh, editor. Innovative Processing and Manufacturing of Advanced Ceramics and Composites. 1st Edition ed: Wiley-American Ceramic Society; p. 105-13
Montanaro L, Coppola B, Palmero P, Tulliani J-M (2019) A review on aqueous gelcasting: A versatile and low-toxic technique to shape ceramics. Ceram Int 45(7 Part B):9653–9673
Millán AJ, Moreno R, Nieto MAI (2002) Thermogelling polysaccharides for aqueous gelcasting—part I: a comparative study of gelling additives. J Eur Ceram Soc 22(13):2209–2215
Ortega FS, Valenzuela FAO, Scuracchio CH, Pandolfelli VC (2003) Alternative gelling agents for the gelcasting of ceramic foams. J Eur Ceram Soc 23(1):75–80
Yu J, Wang H, Zeng H, Zhang J (2009) Effect of monomer content on physical properties of silicon nitride ceramic green body prepared by gelcasting. Ceram Int 35(3):1039–1044
Yu J, Wang H, Zhang J, Zhang D, Yan Y (2010) Gelcasting preparation of porous silicon nitride ceramics by adjusting the content of monomers. J Sol-Gel Sci Technol 53(3):515–523
Huang Y, Yang J (2010) The Gel-Casting of Non-Oxide Ceramics. In: Huang Y, Yang J (eds) Novel Colloidal Forming of Ceramics. Springer, Berlin, pp 211–282
Lin X, Shi J, Gong H, Zhang Y, Feng Y, Guo X et al (2018) Preparation and Properties of Pressureless-Sintered Porous Si3N4 Ceramics. Advanced Functional Materials. Springer, Singapore
Wang H, Yu J, Zhang J, Zhang D (2010) Preparation and properties of pressureless-sintered porous Si3N4. J Mater Sci 45(13):3671–3676
Kawai C, Yamakawa A (1997) Effect of porosity and microstructure on the strength of Si3N4: designed microstructure for high strength, high thermal shock resistance, and facile machining. J Am Ceram Soc 80(10):2705–2708
Xuejian L, Liping H, Xin X, Xiren F, Hongchen G (2000) Optimizing the rheological behavior of silicon nitride aqueous suspensions. Ceram Int 26(3):337–340
Gu YP (2015) Encyclopedia of Surface and Colloid Science3rd edn. CRC Press 9781351252386
Zeng W, Gan X, Li Z, Zhou K (2016) The preparation of silicon nitride ceramics by gelcasting and pressureless sintering. Ceram Int 42(10):11593–11597
Janney M, Nunn S, Walls C, Omatete O, Ogle R, Kirby G et al (1998). Gelcasting:1–15
Yang Z, Yu J, Li C, Zhong Y, Deng K, Ren Z, Wang Q, Dai Y, Wang H (2016) Effect of β-Si3N4 initial powder size on texture development of porous Si3N4 ceramics prepared by gel-casting in a magnetic field. Trans Indian Ceram Soc 75(4):256–262
Wan T, Yao D, Yin J, Xia Y, Zuo K, Zeng Y (2015) The microstructure and mechanical properties of porous silicon nitride ceramics prepared via novel aqueous Gelcasting. Int J Appl Ceram Technol 12(5):932–938
Yang X, Li B, Zhang C, Wang S, Liu K, Zou C (2016) Fabrication and properties of porous silicon nitride wave-transparent ceramics via gel-casting and pressureless sintering. Mater Sci Eng A 663:174–180
Bressiani JC, Izhevskyi V, Bressiani AH (1999) Development of the microstructure of the silicon nitride based ceramics. J Eur Ceram Soc 2(3):165–172
Acknowledgments
The authors gratefully acknowledge Dr. Alireza Mirhabibi, Aba Raha, and other collaborators at the Synthesis Laboratory of the IUST.
Funding
The authors did not receive any financial support from any agency/organization for the submitted work.
Author information
Authors and Affiliations
Contributions
Not applicable.
Corresponding author
Ethics declarations
Conflict of Interest
The authors declare no conflict of interest related to this study.
Ethics Approval
Not applicable.
Consent to Participate
Not applicable.
Consent for Publication
Not applicable.
Additional information
Publisher’s Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Sharifi, O., Alizadeh, S.M., Golmohammad, M. et al. Studying the Role of Gelation Agents in Gelcasting Non-porous Si3N4 Bodies by Pressureless Sintering. Silicon 14, 10447–10457 (2022). https://doi.org/10.1007/s12633-022-01798-1
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12633-022-01798-1