Production of Single-Layer and Multi-Layer Structures by Tape Casting Method

Yıl 2023, , 1807 - 1823, 15.12.2023

Emine Özlem Dengiz , Mevlüt Gürbüz

https://doi.org/10.31466/kfbd.1337108

Öz

The tape casting method is a technique used to produce thin films for ceramic, metal, and plastic materials. The tape casting method, classified as a liquid phase production technique, is technically different from other casting methods. The process is based on pouring the deaerated casting liquid onto the substrate and spreading it on the surface with the help of a scraper blade, also known as Doctor Blade, to form films of the desired thickness. During the casting process, either the substrate surface or the scraper blade is movable. Casting fluid; powder material consists of several components that balance the liquid, such as solvent, dispersant, plasticizer, and binder. The solvent evaporates after forming a uniform layer, and a solid tape remains. At this stage, the tape material is processed differently depending on the desired properties or the purpose of use, and the process is completed. Tape casting method is widely used in the preparation of single-layer and multi-layer composite materials. This method is an attractive application method because it is easily applicable and low-cost. In this study, studies carried out to create single-layer and multi-layer thin materials by tape casting method were examined. In addition, optimization of the casting fluid and determination of casting parameters were carried out to produce thin layers by tape casting method using Ti64 material.

Anahtar Kelimeler

Tape casting, single-layer structures, multi-layer structures, Doctor Blade

Proje Numarası

PYO.MUH.1901.22.003

Şerit Döküm Yöntemiyle Tek Katmanlı ve Çok Katmanlı Yapıda Malzeme Üretimi

Öz

Şerit döküm yöntemi seramik, metal ve plastik malzemeler için ince şerit yapıların üretiminde kullanılan bir imalat tekniğidir. Sıvı faz üretim tekniği olarak sınıflandırılan şerit döküm yöntemi, diğer döküm yöntemlerinden teknik olarak ayrışmaktadır. Yöntemin işleyişi, havası alınmış döküm sıvısının altlık yüzey üzerine dökülerek Doctor Blade olarak da bilinen sıyırıcı bıçak yardımıyla istenen kalınlıkta katmanlar oluşturulmak üzere yüzeye yayılmasına dayanır. Döküm sürecince ya altlık yüzey hareketlidir ya da sıyırıcı bıçak hareketlidir. Döküm sıvısı; toz malzeme, çözücü, dağıtıcı, plastikleştirici ve bağlayıcı gibi sıvı içerisindeki dengeyi sağlayan birtakım bileşenlerden oluşur. Yüksek eş dağılımlı bir katman oluştuktan sonra çözücü buharlaştırılır ve geriye sağlam bir şerit kalır. Bu aşamada istenen özelliklere ya da kullanıma amacına göre şerit malzeme farklı işlemden geçirilerek süreç tamamlanır. Tek katmanlı ve çok katmanlı kompozit malzemelerin hazırlanmasında şerit döküm yöntemi yaygın olarak kullanılmaktadır. Bu yöntem, kolay uygulanabilir ve düşük maliyetli olması dolayısıyla, cazip bir uygulama metodu konumundadır. Bu çalışmada şerit döküm yöntemiyle tek katmanlı ve çok katmanlı ince malzemeler oluşturmak üzere yapılmış çalışmalar irdelenmiştir. Ayrıca Ti64 malzeme kullanılarak şerit döküm yöntemiyle ince katmanların üretilmesi için döküm sıvısının optimizasyonu ve döküm parametrelerinin belirlenmesi gerçekleştirilmiştir.

Anahtar Kelimeler

Şerit döküm, tek katmanlı malzemeler, çok katmanlı malzemeler, Doctor Blade

Destekleyen Kurum

Ondokuz Mayıs Üniversitesi

Proje Numarası

PYO.MUH.1901.22.003

Teşekkür

Ondokuz Mayıs Üniversitesi Bilimsel Araştırma Projeleri Koordinasyon Birimine bu çalışmayı desteklediği için teşekkürlerimizi sunarız.

Kaynakça

• Arunkumar, K. V., Panicker, R. N., Vasanthakumari, K. G., Satheesh, M., Raghu, N., & Unnikrishnan, N. V. (2010). Dispersion and rheological characterization of TiO2 tape casting slurry. International Journal of Applied Ceramic Technology, 7(6), 902-908. https://doi.org/10.1111/j.1744-7402.2009.02386.x
• Bidaux, J. E., García-Gómez, J., Hamdan, H., Zufferey, D., Rodriguez-Arbaizar, M., Girard, H., & Carreño-Morelli, E. (2011). Tape casting of porous titanium thin sheets from titanium hydride. Proceedings of the Euro International Powder Metallurgy Congress and Exhibition, Euro PM 2011, 2(October).
• Bitterlich, B., & Heinrich, J. G. (2002). Aqueous tape casting of silicon nitride. Journal of the European Ceramic Society, 22(13), 2427-2434. https://doi.org/10.1016/S0955-2219(02)00029-8
• Boyer, R. R. (1996). An overview on the use of titanium in the aerospace industry. Materials Science and Engineering A, 213(1-2), 103-114. https://doi.org/10.1016/0921-5093(96)10233-1
• Buekenhoudt, A., Kovalevsky, A., Luyten, J., & Snijkers, F. (2010). Basic Aspects in Inorganic Membrane Preparation. Comprehensive Membrane Science and Engineering, 1, 217-252. https://doi.org/10.1016/B978-0-08-093250-7.00011-6
• Cans, M., Hamdam, H., & Öner, Y. (t.y.). Tape Casting of Copper Alloys for Tribological Applications.
• Chen, C. F., Baker, T. J., Synowicki, R., Tegtmeier, E. L., Forsyth, R. T., Bissell, A. L., Orlowski, A. G., Christopher, J. M., & Savrun, E. (2020). Tape casting and characterizations of MgO ceramics. Journal of the American Ceramic Society, 103(12), 6666-6676. https://doi.org/10.1111/JACE.17136
• Cheng, L., Sun, M., Ye, F., Bai, Y., Li, M., Fan, S., & Zhang, L. (2018). Structure design, fabrication, properties of laminated ceramics: A review. International Journal of Lightweight Materials and Manufacture, 1(3), 126-141. https://doi.org/10.1016/j.ijlmm.2018.08.002
• Daudt, N. F., Hackemüller, F. J., & Bram, M. (2019). Manufacturing of Ti-10Nb based metal sheets by tape casting. Materials Letters, 237, 161-164. https://doi.org/10.1016/j.matlet.2018.11.109
• Du, W., Lu, K., He, B., Zhou, X., Huang, X., Qi, J., & Lu, T. (2023). Direct tape casting of Al2O3/AlN slurry for AlON transparent ceramic wafers via one-step reaction sintering. Journal of the European Ceramic Society, 43(8), 3538-3543. https://doi.org/10.1016/J.JEURCERAMSOC.2023.01.056
• Gadow, R., & Kern, F. (2014). Advanced Manufacturing of Hard Ceramics. İçinde Comprehensive Hard Materials (ss. 207-230). Elsevier. https://doi.org/10.1016/B978-0-08-096527-7.00025-8
• Ghannadi, S., Abdizadeh, H., & Babaei, A. (2020). Fabrication of porous titania sheet via tape casting: Microstructure and water permeability study. Ceramics International, 46(7), 8689-8694. https://doi.org/10.1016/J.CERAMINT.2019.12.103
• Hackemüller, F. J., Borgardt, E., Panchenko, O., Müller, M., & Bram, M. (2019). Manufacturing of Large-Scale Titanium-Based Porous Transport Layers for Polymer Electrolyte Membrane Electrolysis by Tape Casting. Advanced Engineering Materials, 21(6), 1-10. https://doi.org/10.1002/adem.201801201
• Huang, Z., Yang, Y., Lv, H., Shi, C., Li, T., Ling, Y., Chen, T., & Wang, S. (2023). Large-area anode-supported protonic ceramic fuel cells combining with multilayer-tape casting and hot-pressing lamination technology. Journal of the European Ceramic Society, 43(2), 428-437. https://doi.org/10.1016/J.JEURCERAMSOC.2022.09.057
• Hubadillah, S. K., Othman, M. H. D., Matsuura, T., Ismail, A. F., Rahman, M. A., Harun, Z., Jaafar, J., & Nomura, M. (2018). Fabrications and applications of low cost ceramic membrane from kaolin: A comprehensive review. Ceramics International, 44(5), 4538-4560. https://doi.org/10.1016/J.CERAMINT.2017.12.215
• Jingxian, Z., Dongliang, J., Weisensel, L., & Greil, P. (2004). Binary solvent mixture for tape casting of TiO2 sheets. Journal of the European Ceramic Society, 24(1), 147-155. https://doi.org/10.1016/S0955-2219(03)00340-6
• Lobley, C. M., & Quo, Z. X. (1998). Processing of Ti-SiC metal matrix composites by tape casting. Materials Science and Technology, 14(9), 1024-1028. https://doi.org/10.1179/mst.1998.14.9-10.1024
• Niinomi, M. (1998). Mechanical properties of biomedical titanium alloys. Materials Science and Engineering A, 243(1-2), 231-236. https://doi.org/10.1016/s0921-5093(97)00806-x
• Rak, Z. S., & Walter, J. (2006). Porous titanium foil by tape casting technique. Journal of Materials Processing Technology, 175(1-3), 358-363. https://doi.org/10.1016/j.jmatprotec.2005.04.066
• Rauscher, M., Besendörfer, G., & Roosen, A. (2008). Steel-sheet fabrication by tape casting. International Journal of Powder Metallurgy (Princeton, New Jersey), 44(6), 39-48.
• Rincón, A., Moreno, R., Chinelatto, A. S. A., Gutierrez, C. F., Rayón, E., Salvador, M. D., & Borrell, A. (2014). Al2O3-3YTZP-Graphene multilayers produced by tape casting and spark plasma sintering. Journal of the European Ceramic Society, 34(10), 2427-2434. https://doi.org/10.1016/J.JEURCERAMSOC.2014.02.011
• Snel, M. D., Snijkers, F., Luyten, J., Kodentsov, A., & de With, G. (2008). Tape casting and reaction sintering of titanium-titanium oxide-nickel oxide mixtures. Journal of the European Ceramic Society, 28(6), 1185-1190. https://doi.org/10.1016/j.jeurceramsoc.2007.11.001
• Srinivasan, S. A.,& Sampath, S. (2023). 1-Flexible ceramics: an introduction. Advanced Flexible Ceramics, 3-11. https://doi.org/10.1016/B978-0-323-98824-7.00001-4
• Stastny, P., Chlup, Z., & Trunec, M. (2020). Gel-tape casting as a novel method for the production of flexible fine-grained alumina sheets. Journal of the European Ceramic Society, 40(7), 2542-2547. https://doi.org/10.1016/J.JEURCERAMSOC.2019.10.042
• Tian, T., Jiang, D., Zhang, J., & Lin, Q. (2007). Aqueous tape casting process for hydroxyapatite. Journal of the European Ceramic Society, 27(7), 2671-2677. https://doi.org/10.1016/J.JEURCERAMSOC.2006.10.009
• Trunec, M., & Maca, K. (2014). Advanced Ceramic Processes. İçinde Advanced Ceramics for Dentistry (ss. 123-150). Elsevier. https://doi.org/10.1016/B978-0-12-394619-5.00007-9
• Zeng, Y. P., Jiang, D. L., & Watanabe, T. (2000). Fabrication and properties of tape-cast laminated and functionally gradient alumina-titanium carbide materials. Journal of the American Ceramic Society, 83(12), 2999-3003. https://doi.org/10.1111/j.1151-2916.2000.tb01673.x
• Zuo, K. H., Jiang, D. L., Zhang, J. xian, & Lin, Q. L. (2007). Forming nanometer TiO2 sheets by nonaqueous tape casting. Ceramics International, 33(3), 477-481. https://doi.org/10.1016/J.CERAMINT.2005.10.013