Pressure slip casting for advanced oxide ceramics: Processing dynamics, green-state integrity, and sintered performance.
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| Title: | Pressure slip casting for advanced oxide ceramics: Processing dynamics, green-state integrity, and sintered performance. |
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| Authors: | Raju, P1,2 (AUTHOR) praju.ra@gmail.com |
| Source: | Bulletin of Materials Science. Sep2026, Vol. 49 Issue 3, p1-17. 17p. |
| Subjects: | Slip casting, Oxide ceramics, Manufacturing processes, Ceramic engineering |
| Abstract: | Pressure slip casting (PSC) has emerged as a promising forming technique for advanced ceramics, offering superior shape precision, green strength, and densification compared to conventional processing methods. However, its application to oxide-based ceramics remains relatively underexplored. This article presents a critical evaluation of the processing parameters, structure–property relationships, representative case studies, and overall performance of PSC for advanced oxide ceramics, using alumina (Al2O3) as a model system. A comprehensive comparison of PSC, conventional slip casting (CSC), and cold isostatic pressing (CIP) is provided based on published literature and selected case studies. Under optimized conditions, PSC at 35 bar has been shown to achieve green densities of approximately 65% of theoretical density (TD), comparable to those obtained by CIP (approximately 66% TD at 1200 bar) and significantly higher than those achieved by CSC (approximately 50% TD). PSC-processed alumina can attain densification levels of up to 98.6% TD after sintering at 1600°C, compared with approximately 97% TD for CSC under similar conditions. Furthermore, PSC yields improved flexural strength and fracture toughness owing to enhanced particle packing and superior microstructural homogeneity. This review examines the influence of slurry rheology, bimodal particle-size distribution (7 μm and 1.43 μm at a 65:35 ratio), mold permeability, and pressure-controlled filtration kinetics on green-body integrity and the performance of sintered components. The feasibility of fabricating large, dense alumina components, such as 60 mm diameter spheres, for structural and grinding applications is also evaluated. Finally, current challenges, including defect control, mold durability, and process scale-up, are discussed, and future research directions are proposed to further establish PSC as a scalable, high-performance manufacturing route for oxide ceramic fabrication. [ABSTRACT FROM AUTHOR] |
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| Database: | Engineering Source |
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| Abstract: | Pressure slip casting (PSC) has emerged as a promising forming technique for advanced ceramics, offering superior shape precision, green strength, and densification compared to conventional processing methods. However, its application to oxide-based ceramics remains relatively underexplored. This article presents a critical evaluation of the processing parameters, structure–property relationships, representative case studies, and overall performance of PSC for advanced oxide ceramics, using alumina (Al2O3) as a model system. A comprehensive comparison of PSC, conventional slip casting (CSC), and cold isostatic pressing (CIP) is provided based on published literature and selected case studies. Under optimized conditions, PSC at 35 bar has been shown to achieve green densities of approximately 65% of theoretical density (TD), comparable to those obtained by CIP (approximately 66% TD at 1200 bar) and significantly higher than those achieved by CSC (approximately 50% TD). PSC-processed alumina can attain densification levels of up to 98.6% TD after sintering at 1600°C, compared with approximately 97% TD for CSC under similar conditions. Furthermore, PSC yields improved flexural strength and fracture toughness owing to enhanced particle packing and superior microstructural homogeneity. This review examines the influence of slurry rheology, bimodal particle-size distribution (7 μm and 1.43 μm at a 65:35 ratio), mold permeability, and pressure-controlled filtration kinetics on green-body integrity and the performance of sintered components. The feasibility of fabricating large, dense alumina components, such as 60 mm diameter spheres, for structural and grinding applications is also evaluated. Finally, current challenges, including defect control, mold durability, and process scale-up, are discussed, and future research directions are proposed to further establish PSC as a scalable, high-performance manufacturing route for oxide ceramic fabrication. [ABSTRACT FROM AUTHOR] |
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| ISSN: | 02504707 |
| DOI: | 10.1007/s12034-026-03668-7 |
