Abstract
The effects of compositions of binders on the rheological properties of mixtures and the preparation conditions on the formation of defects and the debinding characteristics of compacts for the injection molding of ceramic powders (65 wt% aluminaㆍ35 wt% feldspar) were studied. Ceramic powders were coated with 2 wt% of stearic acid and then mixed with 15, 20, and 25 wt% of Paraffin Wax (PW) and High Density Polyethylene (HDPE) as binders at $160^{\circ}C$ for 2 h. Rheological properties were investigated by using capillary rheometer. Apparent viscosities of mixtures were 80∼300 Paㆍs at 1,000$s^{-1}$ of a shear rate, it was good for the injection molding and depending on the compositions of binders. Short shot was formed at 15H5P5 (the ratio of HDPE : PW=5 : 5 in 15 wt% of binders) compacts without injection pressures and any noticeable defects were not formed at 45 kgf/$cm^{2}$ in 20H5P5 compacts. PW and HDPE were removed by the solvent extraction and thermal debinding method. Thermal debinding of HDPE at $450^{\circ}C$ for 5 h, which followed the extraction of PW was using n-heptane solvent at $70^{\circ}C$ for 5 h. Continuous pores in compacts, which facilitate the removal of HDPE by the thermal debinding, were found to form in the compacts when PW was removed by the solvent extraction. The optimum composition of binder at which binder was removed by thermal debinding without defects while maintaining the compact strength was 20H5P5. Bulk density, porosity and 3-point bending strength of 20H5P5 compact sintered at 1,30$0^{\circ}C$ for 5 h were 2.8, < 3%, and 2,400 kgf/$cm^{2}$, respectively, and can be used as a structural materials.
세라믹 사출성형시 결합체의 조성에 따른 혼합물의 유동학적 특성과 제조조건에 따른 시편의 결함 생성 및 탈지공정에 대하여 조사하였다. 2wt%의 stearic acid를 코팅한 세라믹 분말(65wt% $Al_{2}O_{3}$ㆍ35 wt% 장석)에 결합체로 15,20 및 25wt%의 Paraffin Wax (PW)와 High Density Polyethylene(HDPE)을 첨가하여 $160^{\circ}C$에서 2시간 혼합하였다. Capillary rheometer로 측정한 혼합물의 겉보기 점도는 shear rate가 $1000s_{-1}$일 때 80~300Pa.s로 사출성형에 적합한 유동성을 나타내었으며, 결합제의 조성에 의존하였다. 결합제의 조성이 15H5P5(총 15wt%의 결합체중, HDPE/PW 비=5:5)인 사출성형 시편은 사출압력과 관계없이 short shot가 생성되었으나, 사출압력이 45kgf/$cm^{2}$인 10H5P5 사출성형 시편은 결함이 관찰되지 않았다. 사출성형 시편 중의 pw를 $70^{\circ}C$의 n-heptane 용매에서 5시간동안 침지하여 제거한 후, $450^{\circ}C$에서 5시간 열처리하여 HDPE를 제거하였다. PW의 추출에 의해 형성된 연속기공을 통하여 HDPE의 효과적인 제거와 기계적 강도의 손상없이 사출성형이 가능한 결합체 조성은 20H5P5이었다. $1300^{\circ}C$에서 5시간 소결한 20H5P5 시편의 부피비중은 2.8, 기공률은 3% 이하 및 3점곡강도는 약 2,400kgf/$cm^{2}$으로 구조용 재료로서 사용이 가능하였다.
