Recent advancements in low-toxic gelcasting of zircon ceramics have focused on replacing traditional toxic monomers like acrylamide with eco-friendly alternatives such as hydroxyethyl methacrylate (HEMA). A study demonstrated that HEMA-based systems achieved a gelation time of 12.5 minutes at 60°C, with a compressive strength of 120 MPa for green bodies, comparable to acrylamide-based systems. The use of HEMA reduced toxicity by 98%, as measured by LD50 values, while maintaining a high solids loading of 55 vol%. This breakthrough enables safer processing without compromising mechanical properties.
The optimization of dispersants in low-toxic gelcasting has been critical for achieving homogeneous slurry stability. Research revealed that polyacrylic acid (PAA) at a concentration of 0.8 wt% provided the best dispersion efficiency, yielding a viscosity of 0.45 Pa·s at a shear rate of 100 s⁻¹. This resulted in a green density of 3.15 g/cm³ and a sintering density of 6.05 g/cm³, achieving 99.2% of theoretical density. The study also highlighted the role of pH control, with optimal dispersion observed at pH 9.5, ensuring minimal agglomeration and defect-free microstructures.
Innovative crosslinking mechanisms have been explored to enhance the mechanical integrity of green bodies in low-toxic gelcasting systems. A novel approach utilizing calcium alginate as a crosslinker achieved a flexural strength of 25 MPa in green bodies, a 30% improvement over conventional systems. The gelation kinetics were controlled by adjusting Ca²⁺ ion concentration, with an optimal value of 0.1 M yielding a gelation time of 8 minutes. This method also reduced shrinkage during drying to <0.5%, significantly improving dimensional accuracy.
The sintering behavior of zircon ceramics fabricated via low-toxic gelcasting has been extensively studied to optimize thermal properties. A study demonstrated that sintering at 1550°C for 2 hours produced ceramics with a fracture toughness of 6.8 MPa·m¹/² and a Vickers hardness of 13 GPa. The use of nano-sized zirconia powders (d50 = 50 nm) further enhanced densification, achieving a relative density of 99.5%. Thermal cycling tests revealed excellent stability, with less than 0.1% dimensional change after 100 cycles between room temperature and 1200°C.
Environmental and economic assessments have validated the sustainability benefits of low-toxic gelcasting for zircon ceramics. Life cycle analysis (LCA) showed a reduction in carbon footprint by 45% compared to traditional methods, primarily due to the elimination of hazardous waste treatment costs. Economic modeling estimated a production cost reduction of $15 per kilogram, driven by lower material and regulatory compliance expenses. These findings underscore the potential for widespread adoption in industries requiring high-performance ceramics.
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