China's advanced ceramic manufacturer JSZK cooperates with the Chinese Academy of Sciences, based on the spontaneous gelation system of polyfunctional copolymers of isobutylene and maleic anhydride copolymer (PIBM) with independent intellectual property rights, breaking through the drying process of large-sized ceramic wet greens during the drying process. The key bottlenecks such as deformation and cracking in the process have successfully prepared large-size high-purity alumina ceramic grinding discs with a diameter of 360mm to 600mm.
Large-sized structural ceramic components have been widely used in semiconductor manufacturing equipment and other fields, but the molding of large-sized ceramic components is extremely challenging. Compared with classic cold isostatic pressing and grouting, gelcasting (or gel injection molding) has outstanding advantages: the uniform microstructure of the green body, which fundamentally guarantees the reliability of ceramic components; The strength and density of the billet are high, and it is easy to handle, which can effectively reduce the risk of sintering shrinkage and cracking; the near-net shape molding can greatly reduce the machining cost. In addition, the injection molding process is simple in equipment, which can effectively reduce the production investment cost, and has huge application potential in the preparation of large-sized ceramic parts. However, gel systems based on free radical polymerization have problems such as toxic monomers, oxygen polymerization inhibition, various types of additives, and large amounts of additives; in addition, the drying mechanism of ceramic gels has not been clearly explained, which seriously hinders the application of the gelation technology Widely used in the preparation and industrialization of large-sized structural ceramic parts.
Wang Shiwei's research team has been exploring new gel curing systems since 2003. First developed a water-soluble epoxy resin-polyamine gel system based on nucleophilic addition polymerization (J. Am. Ceram. Soc., 2008), which has been successfully applied to dense Al2O3, AlN and SiC, translucent Al2O3, Molding of advanced ceramics such as transparent Y2O3, YAG and AlON and foamed Al2O3. In 2011, the team discovered the phenomenon of spontaneous solidification in the research of preparing Al2O3 ceramic slurry using PIBM (J. Mater. Res., 2013). Subsequently, the work was focused on the universality of PIBM's spontaneous solidification system, the drying mechanism of ceramic gels, the internal stress of the green body during the pre-firing process, and the development of large-sized ceramic component preparation technology.
Compared with other gel systems, PIBM spontaneous coagulation system has significant advantages such as fewer types of additives, less addition amount, and simple operation. Under normal temperature and atmospheric environment, only one kind of organic copolymer can be used to achieve the spontaneous solidification molding of Al2O3, and the prepared Al2O3 ceramic wet billet has good flexibility. At the same time, the solidification system has a wide range of universality, and has been successfully applied to the preparation of porous, dense and transparent ceramics in various oxide and non-oxide systems. By comparing the drying process of the epoxy-polyamine gel system and the PIBM spontaneous solidification system, the team found that the degree of denseness of the organic network significantly affected the drying behavior of ceramic wet greens. The organic network formed by PIBM's spontaneous solidification system is conducive to moisture transport, the drying stress is more easily released, and the body is not deformed after drying; while the organic network formed by the epoxy resin-polyamine gel system hinders moisture transport, and the drying stress is large, The body is easy to dry and deform.
In the past five years, the research team has published more than 20 research papers related to PIBM's spontaneous solidification molding in internationally renowned journals on materials and ceramics. The core technology has been authorized 6 Chinese invention patents. Since the report, PIBM's spontaneous solidification molding system has attracted widespread attention from domestic and foreign counterparts. For example, Tsinghua University, Wuhan University of Science and Technology, Sichuan University, University of Electronic Science and Technology of China, Beijing Institute of Aerospace Materials and Technology, Beijing University of Aeronautics and Astronautics, China Academy of Engineering Physics, and the U.S. Army Laboratories abroad, Alfred University, Iran Nearly twenty research institutes and research groups such as Lazig University of Technology have used this solidification system to carry out research on injection molding of various advanced ceramics.
At the same time, the research team has been committed to the promotion and application of new molding technologies. In July 2017, with the new PIBM spontaneous solidification system as the core technology, Shanghai Institute of Ceramics and JSZK jointly established JSZK Porcelain New Materials Co., Ltd. to carry out the industrialization of large-sized high-purity alumina ceramic parts. . At present, the company has built a pilot production line, mastered the key technologies such as drying, debonding and high-temperature sintering of spontaneously solidified large-size alumina grinding discs, and prepared high-purity alumina grinding discs with a variety of diameters from 360mm to 600mm. It has laid a solid foundation for large-scale production.
High-purity alumina ceramic grinding discs with a variety of diameters from 360mm to 600 mm
PIBM's spontaneous solidification molding technology is applied to the preparation of large-sized advanced ceramic materials. It has significant originality and advancedness, and will provide a new low-cost manufacturing method for the large-sized ceramic components required for the domestic production of semiconductor manufacturing equipment in China. The research was supported by the Pinghu New Materials Center Project of the Chinese Academy of Sciences, the Shanghai Outstanding Technology Leader Project, the National Natural Science Foundation Project, and the Ministry of Science and Technology Key R & D Program.
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