Gelcasting

Last updated

Gel casting is a direct foaming technique used to produce ceramic and polymeric scaffolds.

Contents

History

Gel casting was developed in Canada in the 1960s [1] and ever since it became an interesting manufacturing forming process for near-net-shape, very large, high-quality, complex ceramic parts with specified threshold strength. [2]

Process

In this technique, the precursor materials typically consist of a monomer, cross linker, free radical initiator or catalysts are placed into an aqueous suspension. Such precursor conforms to a slurry that is then foamed before it undergoes a direct consolidation step. In this step, the binder becomes polymerized to consolidate the particle structure within the precursor slurry. The process then forms a gel type of mixture, which is then cast into a proper mould. The next step, after the gel solidification, it is removed from the mould in a controlled manner and then being dried to form a green body. The outcome here has interesting mechanical properties and is capable of being machined at this step. Eventually, the binder is burnt out and the final scaffold sintering will take place. [3]

Related Research Articles

<span class="mw-page-title-main">Guar gum</span> Vegetable gum from the guar bean, Cyamopsis tetragonoloba

Guar gum, also called guaran, is a galactomannan polysaccharide extracted from guar beans that has thickening and stabilizing properties useful in food, feed, and industrial applications. The guar seeds are mechanically dehusked, hydrated, milled and screened according to application. It is typically produced as a free-flowing, off-white powder.

<span class="mw-page-title-main">Bronze sculpture</span> Sculpture cast in bronze

Bronze is the most popular metal for cast metal sculptures; a cast bronze sculpture is often called simply "a bronze". It can be used for statues, singly or in groups, reliefs, and small statuettes and figurines, as well as bronze elements to be fitted to other objects such as furniture. It is often gilded to give gilt-bronze or ormolu.

<span class="mw-page-title-main">Soft matter</span>

Soft matter or soft condensed matter is a subfield of condensed matter comprising a variety of physical systems that are deformed or structurally altered by thermal or mechanical stress of the magnitude of thermal fluctuations. These materials share an important common feature in that predominant physical behaviors occur at an energy scale comparable with room temperature thermal energy, and that entropy is considered the dominant factor. At these temperatures, quantum aspects are generally unimportant. Soft materials include liquids, colloids, polymers, foams, gels, granular materials, liquid crystals, flesh, and a number of biomaterials. When soft materials interact favorably with surfaces, they become squashed without an external compressive force. Pierre-Gilles de Gennes, who has been called the "founding father of soft matter," received the Nobel Prize in Physics in 1991 for discovering that methods developed for studying order phenomena in simple systems can be generalized to the more complex cases found in soft matter, in particular, to the behaviors of liquid crystals and polymers.

<span class="mw-page-title-main">Lost-wax casting</span> Process by which a duplicate metal sculpture is cast from an original sculpture

Lost-wax casting – also called investment casting, precision casting, or cire perdue – is the process by which a duplicate sculpture is cast from an original sculpture. Intricate works can be achieved by this method.

In materials science, the sol–gel process is a method for producing solid materials from small molecules. The method is used for the fabrication of metal oxides, especially the oxides of silicon (Si) and titanium (Ti). The process involves conversion of monomers into a colloidal solution (sol) that acts as the precursor for an integrated network of either discrete particles or network polymers. Typical precursors are metal alkoxides. Sol-gel process is used to produce ceramic nanoparticles.

<span class="mw-page-title-main">Slip casting</span> Technique for forming pottery

Slip casting, or slipcasting, is a ceramic forming technique, and is widely used for shapes that can not easily be formed by other techniques. The technique involves a clay body slip, usually prepared in a blunger, being poured into plaster moulds and allowed to form a layer, the cast, on the internal walls of the mould.

<span class="mw-page-title-main">Bioactive glass</span>

Bioactive glasses are a group of surface reactive glass-ceramic biomaterials and include the original bioactive glass, Bioglass. The biocompatibility and bioactivity of these glasses has led them to be used as implant devices in the human body to repair and replace diseased or damaged bones. Most bioactive glasses are silicate based glasses that are degradable in body fluids and can act as a vehicle for delivering ions beneficial for healing. Bioactive glass is differentiated from other synthetic bone grafting biomaterials, in that it is the only one with anti-infective and angiogenic properties.

Ceramic forming techniques are ways of forming ceramics, which are used to make everything from tableware such as teapots to engineering ceramics such as computer parts. Pottery techniques include the potter's wheel, slip casting and many others.

<span class="mw-page-title-main">Dip-coating</span> Industrial coating process

Dip coating is an industrial coating process which is used, for example, to manufacture bulk products such as coated fabrics and condoms and specialised coatings for example in the biomedical field. Dip coating is also commonly used in academic research, where many chemical and nano material engineering research projects use the dip coating technique to create thin-film coatings.

<span class="mw-page-title-main">Ceramic engineering</span> Science and technology of creating objects from inorganic, non-metallic materials

Ceramic engineering is the science and technology of creating objects from inorganic, non-metallic materials. This is done either by the action of heat, or at lower temperatures using precipitation reactions from high-purity chemical solutions. The term includes the purification of raw materials, the study and production of the chemical compounds concerned, their formation into components and the study of their structure, composition and properties.

<span class="mw-page-title-main">Investment casting</span> Industrial process based on lost-wax casting

Investment casting is an industrial process based on lost-wax casting, one of the oldest known metal-forming techniques. The term "lost-wax casting" can also refer to modern investment casting processes.

Ceramic foam is a tough foam made from ceramics. Manufacturing techniques include impregnating open-cell polymer foams internally with ceramic slurry and then firing in a kiln, leaving only ceramic material. The foams may consist of several ceramic materials such as aluminium oxide, a common high-temperature ceramic, and gets insulating properties from the many tiny air-filled voids within the material.

<span class="mw-page-title-main">Fire retardant gel</span>

Fire-retardant gels are superabsorbent polymer slurries with a "consistency almost like petroleum jelly." Fire-retardant gels can also be slurries that are composed of a combination of water, starch, and clay. Used as fire retardants, they can be used for structure protection and in direct-attack applications against wildfires.

The ceramic molding process is a production method which guarantees the precision required, and gives a good surface finish. It uses a high temperature method to better structure and shape parts. This process also gives a low grade of toleration.

<span class="mw-page-title-main">Casting</span> Manufacturing process in which a liquid is poured into a mold to solidify

Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting materials are usually metals or various time setting materials that cure after mixing two or more components together; examples are epoxy, concrete, plaster and clay. Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods. Heavy equipment like machine tool beds, ships' propellers, etc. can be cast easily in the required size, rather than fabricating by joining several small pieces. Casting is a 7,000-year-old process. The oldest surviving casting is a copper frog from 3200 BC.

Tape casting is a casting process used in the manufacture of thin ceramic tapes and sheets from ceramic slurry. The ceramic slurry is cast in a thin layer onto a flat surface and then dried and sintered. It's a part of powder metallurgy.

<span class="mw-page-title-main">Ceramic nanoparticle</span>

Ceramic nanoparticle is a type of nanoparticle that is composed of ceramics, which are generally classified as inorganic, heat-resistant, nonmetallic solids that can be made of both metallic and nonmetallic compounds. The material offers unique properties. Macroscale ceramics are brittle and rigid and break upon impact. However, Ceramic nanoparticles take on a larger variety of functions, including dielectric, ferroelectric, piezoelectric, pyroelectric, ferromagnetic, magnetoresistive, superconductive and electro-optical.

<span class="mw-page-title-main">Freeze-casting</span>

Freeze-casting, also frequently referred to as ice-templating, or freeze alignment, is a technique that exploits the highly anisotropic solidification behavior of a solvent in a well-dispersed slurry to controllably template a directionally porous ceramic. By subjecting an aqueous slurry to a directional temperature gradient, ice crystals will nucleate on one side of the slurry and grow along the temperature gradient. The ice crystals will redistribute the suspended ceramic particles as they grow within the slurry, effectively templating the ceramic.

Robocasting is an additive manufacturing technique analogous to Direct Ink Writing and other extrusion-based 3D-printing techniques in which a filament of a paste-like material is extruded from a small nozzle while the nozzle is moved across a platform. The object is thus built by printing the required shape layer by layer. The technique was first developed in the United States in 1996 as a method to allow geometrically complex ceramic green bodies to be produced by additive manufacturing. In robocasting, a 3D CAD model is divided up into layers in a similar manner to other additive manufacturing techniques. The material is then extruded through a small nozzle as the nozzle's position is controlled, drawing out the shape of each layer of the CAD model. The material exits the nozzle in a liquid-like state but retains its shape immediately, exploiting the rheological property of shear thinning. It is distinct from fused deposition modelling as it does not rely on the solidification or drying to retain its shape after extrusion.

The term preceramic polymer refers to one of various polymeric compounds, which through pyrolysis under appropriate conditions are converted to ceramic compounds, having high thermal and chemical stability. Ceramics resulting from the pyrolysis of preceramic polymers are known as polymer derived ceramics, or PDCs. Polymer derived ceramics are most often silicon based and include silicon carbide, silicon oxycarbide, silicon nitride and silicon oxynitride. Such PDCs are most commonly amorphous, lacking long-range crystalline order.

References

  1. Somiya, Shigeyuki (May 2013). Handbook of Advanced Ceramics | ScienceDirect. ISBN   9780123854698 . Retrieved 10 January 2021.
  2. Si, W; Graule, TJ; Baader, FH; Gauckler, LJ (1999). "Direct coagulation casting of silicon carbide components". Journal of the American Ceramic Society. 82 (5): 1129–1136. doi:10.1111/j.1151-2916.1999.tb01886.x.
  3. Kajal, Mallick (21 July 2014). Bone Substitute Biomaterials | ScienceDirect. Elsevier Science. ISBN   9780857094971 . Retrieved 10 January 2021.

Further reading

See also