Gelcasting as a Novel Processing Route to Fabricate Partially Stabilized Zirconia Ceramic Bodies

Abstract

Bioinert ceramics, like alumina and zirconia are used mainly for replacements of bones, hip joints and for dental implants. Partially stabilized zirconia ceramics (PSZ or TZP with 3 mol.% or 5 wt.% Y₂O₃), appear as perspective bioinert ceramics because of their high strength and corrosion resistance. In order to fabricate complex shapes, it is essential to use a near net shape processing like gelcasting as an uncomplicated method which has appropriate potential of producing special shapes with suitable green and sintered properties (like high mechanical properties and almost full density and machinability of green bodies). Moreover, biocompatibility studies have proved that this processing route is nontoxic. In this experiment, micro-structural observation performed to illustrate the effect of dispersant on homogeneity of gelcast 3Y-TZP bodies. It has been shown that it is possible to achieve uniform microstructure by means of appropriate amount of dispersant and ultrasonic wave. In addition, the machinability of these green bodies has been proven and some complex shaped bodies fabricated, in order to illustrate the capability of the process.