Journal of the American Ceramic Society, Vol.99, No.11, 3533-3539, 2016
Porous Ni/ZrO2 Cermet from Highly Concentrated Composite Colloid
Rheology and shaping of concentrated cermet suspensions consisting of nickel (Ni) and yttria-stabilized zirconia (YSZ) nanoparticles in water have been examined over a broad range of volumetric solids concentration (phi = 0.1-0.4) and Ni fraction (f(Ni) = 0.15-0.45). Preferential adsorption of pyrogallol-poly(ethylene glycol) polymer (i.e., Gallol-PEG) on surface of the Ni and YSZ particles imparts steric hindrance between the suspending particles so that fluidity can be obtained under shear stress. The cermet suspensions exhibit shear-thinning flow behavior under steady-shear measurement over shear rates of 10(0)-10(3) s(-1). Yield stress and yield strain of the suspensions appear to vary pronouncedly with phi and f(Ni) under oscillatory shear over a shear-strain range of 10(-1)-10(3)%. With the Gallol-PEG adsorption, an apparent viscosity less than 6 x 10(-1) Pa.s at a shear rate of 10(2) s(-1) has been obtained for the highly concentrated composite suspension with phi of 0.40 and f(Ni) of 0.25. A high solids concentration effectively prohibits phase segregation during wet-shaping processes. Uniform green compacts have been obtained from slip casting of the concentrated cermet mixture (phi = 0.30) without use of binder and are then fired at 1200 degrees C under reducing atmosphere to form porous Ni/YSZ compacts. Relative sintered density increases from 65% to 75% of the theoretical value when f(Ni) was increased from 0.15 to 0.45, due mainly to the lower sintering temperature required for the Ni phase.