High-strength porous YSZ ceramics fabricated by TBA-based gelcasting with high solid loading slurry

Porous yttria-stabilized zirconia (YSZ) ceramics were fabricated by tert-butyl alcohol (TBA)-based gelcasting method using high solid loading slurry. Micron pores were generated by using low-cost carbon powder as the pore-forming agent. The TBA-based slurries of 50% solid loading appropriate for gelcasting were successfully prepared by using commercial dispersant BYK-163. The rheological behavior of the slurries were measured and discussed. The porosity, microstructure, compressive strength and thermal conductivity of the porous ceramics were tested and analyzed. The results show that this low-cost technology is significant for fabricating porous ceramics with both high compressive strength and low thermal conductivity.