Rheological property and stress development during drying of tape-cast ceramic layers

Rheological property and stress development of tape-cast ceramic layers derived from nonaqueous alumina (Al₂O₃)-poly(vinyl butyral) (PVB) suspensions were observed during drying. Casting suspensions exhibited strong shear-thinning behavior, with a low shear Newtonian plateau apparent viscosity >10² Pa·s. The apparent suspension viscosity displayed a power-law dependence on the Al₂O₃ volume fraction during the initial stage of drying (<30% solvent loss). Stress development, measured by a cantilever deflection method, and parallel weight loss measurements were performed during the drying of tape-cast layers and pure binder coatings. Maximum drying stresses (σ_max) of 1.37-0.77 MPa were observed for plasticized tapes cast at gap heights of 150-400 μm. In contrast, nonplasticized tapes of similar thickness displayed a more gradual stress increase, with σ_max values approximately an order of magnitude higher than their plasticized counterparts. The stress histories of the corresponding binder coatings were quite similar to the tape-cast layers, albeit slightly lower σ_max values were observed. Stresses decayed beyond σ_max with a logarithmic time dependence to an almost constant value of 0.2-0.4 MPa for the plasticized tapes. Based on these observations, process methodologies have been offered to minimize stress development and retention in tape-cast ceramic layers.