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Volatile-assisted room-temperature reactive casting of thick-section silicon nitride ceramics with improved debinding stability
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DOI：10.1016/j.jeurceramsoc.2026.118742.png)
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Abstract
En 中文
The fabrication of thick-section silicon nitride (Si3N4) ceramics from organic-rich slurries is limited by debinding-induced cracking. Here, a volatile-assisted room-temperature reactive casting strategy was developed. A 48 vol% Si3N4 slurry derived from photocurable ceramic slurry chemistry was cast into water-soluble poly(vinyl alcohol) molds and bulk-cured using a tert-butyl peroxy-2-ethylhexanoate/N,N-dimethyl-p-toluidine (TBPO/DMPT) redox system, thereby avoiding light-penetration limitations. Volatile nonreactive components were introduced to evaporate before intensive resin decomposition, thereby pre-forming pore-channel-like gas-transport pathways. Increasing terpineol content reduced slurry viscosity, shifted organic removal to lower temperatures, decreased debinding shrinkage, and improved mechanical reliability. A binary terpineol/n-butyl acetate system further regulated staged pore-channel formation, enabling intact 30–40 mm thick solid samples. Dense Si3N4 ceramics with relative densities above 97% and flexural strengths over 830 MPa were obtained, together with complex honeycomb, impeller, tubular, and lattice structures.
Keywords:
Silicon nitride ceramics
Room-temperature reactive casting
Volatile-assisted debinding
Pore-channel formation
Thick-section ceramics
Journal
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6.2
Papers:
1.7W
Citations:
5.1W
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