• Journal of the Korean Ceramic Society
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• v.43 no.12 s.295
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• pp.859-864
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• 2006

For the pressure compaction process of the ceramic powder, the green density is very different with both the ceramic body shape and the processing conditions. The density difference cause non-uniform shrinkages and deformations, and make cracks in the sintered ceramics. In this paper, Material properties of the alumina powder mixed with binder and the friction coefficient between the powder and the tool set were determined through the simple compaction experiments: Also the powder flow characteristics were simulated and the green density was analyzed during the powder compaction process with Finite Element Method (FEM). The results show that the density distributions of the green body were improved at the optimized processing condition and both the possibility of the farming crack generation and rho deformation of the sintered Alumina body were reduced.

• Journal of the Korean Ceramic Society
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• v.31 no.12
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• pp.1467-1474
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• 1994

The effects of the dispersion, drying, and binder burning-out on the green-microstructures of gelcasted alumina were studied. The slip consisting of 55 vol% alumina powder and 5 wt% organic materials was well-dispersed by adding 0.28 wt% polyelectrolyte polymer. Green bodies were dried at >85% relative humidity at room temperature. Green-microstructures were observed to be depended on the heating rate during binder burnout. Constant drying rate was not observed in drying process of gelcasted alumina. Sintered body showed its relative density higher than 99% when it was sintered at 1$600^{\circ}C$ for 2 hours.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.926-931
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• 2002

Although ceramic plates with many micro-hales are used as MCP (Micro-channel plate) for electron amplification, catalytic converters, filters, electrical insulators and thermal conductors in integrated circuits, the drilling of micro-hales in the ceramics is difficult because of their low thermal conductivity, high hardness and brittleness. Therefore, in this work, the machining of ceramic green body fellowed by sintering of green body was employed fur fabricating ceramic plates with many micro-holes. The micro-drilling of alumina green body was performed with diamond abrasive WC drills, and the cutting force w.r.t. drilling times was measured for the determination of toot life. From the investigation of the wear of micro-drill tip w.r.t. drilling times, the wear mechanism of tip during micro-drilling of ceramic green body was suggested.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.10a
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• pp.923-928
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• 1997

An MCP (Microchannel Plate) is a secondary electron multiplier to detect and amplify electrons. An MCP has many rnicrochannels whose diameters range from 10 to 100pm and whose lengths range from 40 to 100times of the diameter. Each microchannel of the MCP amplifies electrons over IOOOtimes by the secondary electron emission. Even though MCPs have high performance for electron amplification, the application of MCPs is limited to high performance electronic equipments because of their high fabricating cost and the limit of increasing their size due to the conventional fabrication process. Therefore, in this work, microchannels of the MCP are manufactured by micro-drilling to reduce the cost of the MCP and to increase their size. Alumina green body with epoxy binder was machined for fabricating microchannels using a high speed air turbine spindle and micro-drills with diamond grinding abrasives. Then alumina MCP was fabricated through the sintering of the machined alumina green body.

• Journal of the Korean Ceramic Society
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• v.32 no.2
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• pp.217-226
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• 1995

Alumina powders were dispersed using crosslinkable organic molecules by electrosteric stabilization and then consolidated by crosslinking of organic molecules. The effect of processing variables such as the physicochemical properties of both solvent media and organic molecules, the proportions of mixed organic media, etc. were studied. FT-IR was used todeduce the mechanism of organic molecules adsorption on the alumina particle surfaces. The adsorption characteristics and the electrokinetic behavior of alumina suspensions were correlated with the stability of particle in alumina suspension using rheological measurements. The green body of alumina consolidated by the chemical crosslinking of the adsorbed organic molecules after the alumina suspension had been stabilized was tough enough for green machining and the sintered alumina fabricated by this proposed process also showed a high bending strength and a homogeneous microstructure.

• Journal of the Korean Ceramic Society
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• v.31 no.1
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• pp.31-38
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• 1994

To overcome the demerit of conventional forming method, new forming method, pressureless powder packing forming method, was investigated. This technique is performed by powder packing followed by the infiltration of binder solution. Various alumina powders were used as starting materials and the powders showing good packing condition through powder packing experiment were chosen. The green densities prepared by this new forming method with these powders were lower than those of specimens by pressing method, but, nearly same density was obtained in case of green body prepared with the powders having high packing density. The distribution of binder in a green body was homogeneous and it was possible to a complex shape form by this forming method.

• Journal of the Korean Ceramic Society
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• v.36 no.7
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• pp.718-724
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• 1999

Densification and grain growth behavior of bimodal size distributed alumina powder mixtures were investigated as a function of amount of coarse alumina powder. The specimens which contained coarse alumina powder for 60to 80wt% showed the highest green density. The amount of shrinkage of sintered specimen lineraly decreased with the increase of coarse alumina powder up to the content that showed the highest green density and then further addition of coarse alumina powder led to drastic decrease of shrinkage of specimen. Especially crack-like void were concurrently revealed in the sintered body with addition of coarse alumina powder above 60wt% When the sintering temperature increased up to 1650$^{\circ}C$ the amount of shrinkage of specimen linearly decreased and the grain growth were also retarded with increase of coarse lauminia powder.

• Journal of the Korean Ceramic Society
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• v.44 no.4 s.299
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• pp.235-239
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• 2007

For the pressure compaction process of the ceramic powder, the density distribution is very important for the uniform shrinkages at the sintered body. In this paper, we fabricated alumina green body using compaction process and simulated about same condition. Then comparison of simulation and experimental result confirmed that accuracy of simulation. On the average density of top and lower part was each $2.41g/cm^3,\;2.27g/cm^3$ and deviation at final step was calculated with 0.06 in simulation. Also, experiments show that total density of top and lower part was each $2.59g/cm^3,\;2.36g/cm^3$, and deviation was 0.09. Conclusion, that was not a difference to the simulation and experimental result. The application using the finite element simulation method is possible optimization of the compressing process, predict generated part of cracks and there is a possibility of getting result of more fast, more accurate then existing experience method.

• Journal of the Korean Ceramic Society
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• v.46 no.3
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• pp.306-312
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• 2009

The size of various alumina ceramics used in semiconductor and display industry is also required to increase with increase in wafer and panel size. In this research, large alumina ceramics was fabricated by filter pressing of alumina slurry using commercial powder and thereafter sintering at $1600^{\circ}C$ in gas furnace. The characteristics of large alumina ceramics thereby were compared to those of small alumina ceramics prepared by pressure forming such as uniaxial pressing and CIP. Careful control of properties of alumina slurry and filter pressing made the fabrication of large alumina ceramics possible, and its characteristics were equivalent to those of small alumina ceramics. The large alumina ceramics, prepared by sintering the green body of 63% relative density at $1600^{\circ}C$, exhibited both dense microstructure corresponding to 98.5% of relative density and 99.8% of high purity as in starting powder.

• Journal of the Korean Ceramic Society
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• v.48 no.2
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• pp.152-159
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• 2011

The green and hard machining characteristics of dental ceramics are of great interest to dental industry. The green bodies of TZP/$Al_2O_3$ composites were prepared by the cold isostatic pressing, and machined on the CNC lathe using PCD (polycrystalline diamond) insert under various machining conditions. With increasing nose radius of PCD insert, surface roughness initially increased due to increased cutting resistance, but decreased by the onset of sliding fracture. The lowest surface roughness was obtained at spindle speed of 1,300 rpm and lowest feed rate. Hard bodies were prepared by pressureless sintering the machined green bodies at several temperatures. The grinding test for sintered hard body was conducted using electroplated diamond bur with different grit sizes. During grinding, grain pull out in the composite was occurred due to thermal expansion mismatch between the alumina and zirconia. The strength of the composite decreased with alumina contents, due to increased surface roughness and high monoclinic phase transformed during grinding process. The final polished samples represented high strength by the elimination of a phase transformation layer.