Gel injection molding of silicon carbide ceramics

Gel system selection

Gel system is the core component of gel injection molding technology, and its selection directly affects the performance of the final product. Commonly used gel systems include organic gel, inorganic gel and composite gel. When selecting a gel system, it is necessary to consider its stability, viscosity, curing speed, and adaptability to the specific material.

1. Crosslinking agent: The crosslinking agent is an important part of the gel system, which can make the solution cross-linked under specific conditions to form a three-dimensional network structure. The selection of a suitable crosslinker needs to consider its compatibility with the solvent, reaction speed and the stability of the formed network.

2. Solvent: The choice of solvent directly affects the viscosity of the gel system, the curing speed and the performance of the final product. Solvents with good compatibility, low viscosity and good stability should be selected. At the same time, it is also necessary to consider the volatility, toxicity and environmental friendliness of the solvent.

3. Additives: Additives can fine-tune the gel system to improve its performance and processing characteristics. For example, adding a leveling agent can improve the leveling of the gel system, making it easier to fill the mold. According to the need to choose different types of additives, such as dispersants, thickeners, pigments, etc.

4. Cost: Cost is an important factor to consider when choosing a gel system. On the premise of meeting the performance requirements, the gel system with lower cost should be selected to reduce the production cost.

5. Environmental protection requirements: With the emphasis on environmental protection, the choice of environmentally friendly gel systems has become an inevitable trend. Non-toxic or low toxic solvents and additives should be selected to reduce the burden on the environment.

Injection mold process parameters

The parameters of injection molding have important influence on the quality of billet and the control of molding process. These parameters include injection mold temperature, injection mold pressure, injection mold speed, etc. The proper casting parameters can improve the compactness of the body, reduce bubbles and cracks, and thus improve the performance of the product.

Gel curing

Gel curing is an important part of gel injection molding technology, which determines the structure and strength of the body. In the process of gel curing, the temperature and time should be controlled to ensure that the billet is fully cured and the structure is stable. At the same time, attention should be paid to preventing deformation and cracking of the billet.

1. Temperature: Temperature is a key factor affecting gel curing. By controlling the temperature, the organic monomer can be induced to undergo a polymerization reaction, so that the gel system can be changed from liquid to solid. The appropriate temperature should be slightly higher than the curing temperature of the gel system to ensure that the body can be completely cured during the injection process.

2. Time: In the process of gel curing, it is necessary to control the time. Too short time may lead to incomplete curing of the gel system and affect the structure and strength of the billet. If the time is too long, it may cause cracking or deformation of the body. Therefore, it is necessary to choose the appropriate curing time according to the characteristics of the gel system and production conditions.

3. Catalyst: Catalyst can accelerate the gel curing reaction. Choosing the right catalyst can improve the speed and efficiency of gel curing and shorten the production cycle. At the same time, it is also necessary to pay attention to the amount of catalyst to avoid excessive catalysis resulting in a decline in the performance of the billet.

4. Environmental factors: Environmental factors such as humidity and oxygen content will also have an impact on gel curing. During the curing process, environmental factors should be well controlled to avoid adverse effects on gel curing.

Body stripping

Demoulding is the key step of gel injection molding technology, it is necessary to adopt appropriate demoulding methods, such as mechanical vibration demoulding, thermal demoulding, etc., in order to reduce the demoulding force and avoid the damage of the body. In the process of demoulding, it is also necessary to carry out the necessary treatment of the billet, such as surface cleaning and drying.

Sintered Mass

Sintering is the process of improving the density of the body, and it is also an important step to optimize the performance of the product. In the sintering process, the sintering temperature and atmosphere should be controlled to ensure that the billet is fully sintered and the performance is up to standard. At the same time, attention should also be paid to preventing deformation and cracking during the sintering process.

Product performance testing

Product performance testing is an important means to evaluate the application effect of gel injection molding technology. The mechanical properties, thermal properties and chemical stability of the product are tested comprehensively by means of physical properties testing, chemical properties testing and microstructure observation. This helps to understand the practical application value of the product and provides a basis for further optimization of the technology.

Defect analysis and improvement

On the basis of product performance testing, the defects in the product should be analyzed to find out the causes of defects, and take appropriate measures to improve. This includes adjusting gel system, optimizing injection process parameters, improving curing and sintering conditions, etc. Through the analysis and improvement of defects, the quality and stability of gel injection molding technology are continuously improved.

Technology application and development trend

With the continuous development of materials science and the increasing maturity of gel injection molding technology, its application in many fields is more and more extensive. For example, in the preparation of ceramic materials, metal materials, composite materials, etc., gel injection molding technology has shown unique advantages. In the future, with the improvement of environmental protection requirements and the further improvement of material properties, gel injection molding technology will develop in the direction of green, efficient and intelligent. At the same time, the development of new gel systems and composite molding processes will also become the focus of research. It is believed that in the near future, gel injection molding technology will be widely used and breakthroughs in more fields.

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