• Journal of the Korean Ceramic Society
• /
• v.53 no.5
• /
• pp.557-562
• /
• 2016

Pyrophyllite granule powders for thermal spray coating were successfully prepared through spray drying process. To produce a stable slurry, commercial pyrophyllite powder of $45{\mu}m$ in size was ball-milled for reduction of the size to $2{\sim}3{\mu}m$ and a dispersant was added to control the viscosity. Dense and spherical granules (average granule size : $59{\mu}m$) were prepared under conditions of 12,500 rpm for rotation velocity of the atomizer and 100 cps for slurry viscosity. The granules were then heat treated at $1,200^{\circ}C$ for proper handling strength and flow properties. The final granules had an apparent density of $0.725g/cm^3$ and a flow rate of 2.5 g/sec, which represent excellent properties to be used as the granule powder for thermal spray coatings.

• Journal of the Korean Ceramic Society
• /
• v.33 no.6
• /
• pp.660-664
• /
• 1996

We have studied the test method for strength of spray dried ceramic powder using manual press and UTM. which is one of the important to influence forming process. We could observe the compaction behavior using manual press. However the measurement of granule strength was only possible with UTM capable of providing the condition of a constant pressing rate. The strength of granule can be measured from the slope change of compaction curve and agrees with the value which is obtained from the combination of saturated tap density and compaction curve. So we proposed the accurate method to measure the strength of granule from the results of this study.

• Korean Journal of Materials Research
• /
• v.27 no.12
• /
• pp.716-721
• /
• 2017

SiAlON-based ceramics are some of the most typical ceramic materials used as cutting tools for HRSA(Heat Resistant Super-Alloys). SiAlON can be fabricated using ceramic processing, such as mixing, granulation, compaction, and sintering. Spray drying is a widely-used method for producing a granular powder of controlled morphology and size with flowability. In this study, we report a systematic investigation aimed at optimizing spherical granule morphology by controlling spray-drying parameters such as gas flow and feed rate. Before spray drying, the viscosities of the raw material slurries were also optimized with the amount of dispersant added.

• Korean Journal of Materials Research
• /
• v.30 no.10
• /
• pp.550-557
• /
• 2020

Used in the ceramic tile market as a representative building material, relief ceramic tile is showing increased demand recently. Since ceramic tiles are manufactured through a sintering process at over 1,000 ℃ after uniaxial compression molding by loading granule powders into a mold, it is very important to secure the flowability of granular powders in a mold having a relief pattern. In this study, kaolin, silica, and feldspar are used as starting materials to prepare granule powders by a spray dryer process; the surface of the granule powders is subject to hydrophobic treatment with various concentrations of stearic acid. The effect on the flowability of the granular powder according to the change of stearic acid concentration is confirmed by measuring the angle of repose, tap density, and compressibility, and the occurrence of cracks in the green body produced in the mold with the relief pattern is observed. Then, the green body is sintered by a fast firing process, and the water absorption, flexural strength, and durability are evaluated. The surface treatment of the granule powders with stearic acid improves the flowability of the granule powders, leading to a dense microstructure of the sintered body. Finally, the hydrophobic treatment of the granule powders makes it possible to manufacture relief ceramic tiles having a flexural strength of 292 N/cm, a water absorption of 0.91 %, and excellent mechanical durability.

• Korean Journal of Materials Research
• /
• v.29 no.7
• /
• pp.425-431
• /
• 2019

Generally, ceramic tiles for building construction are manufactured by dry forming process using granular powders prepared by spray drying process after mixing and grinding of mineral raw materials. In recent years, as the demand for large ceramic tiles with natural texture has increased, the development of granule powders with high packing ratio and excellent flowability has become more important. In this study, ceramic tile granule powders are coated with hydrophobically treated silica nanoparticles. The effects of hydrophobic silica coating on the flowability of granule powders and the strength of the green body are investigated in detail. Silica nanoparticles are hydrophobically treated with GPTMS(3-glycidoxypropyl trimethoxy silane), which is an epoxy-based silane coupling agent. As the coating concentration increases, the angle of repose and the compressibility decrease. The tap density and flowability index increase after silica coating treatment. These results indicate that hydrophobic treatment can improve the flowability of the granular powder, and prevent cracking of green body at high pressure molding.

• Journal of the Korean Ceramic Society
• /
• v.32 no.4
• /
• pp.462-470
• /
• 1995

The characteristics of spray-dried granules are important for dry pressing operation since they have great influences on die-filling, compaction ratio, and resulting green microstructure. An attempt was made to control granule morphology and the packing structure of fine Si3N4 particles in granules by adjusting suspension property. Mercury porosimetry was used to characterize the pore structures of both granules and green compacts. Finally, the effects of particle packing structure in granules and green microstructure on sintering behavior were investigated.

• Journal of the Korean Ceramic Society
• /
• v.55 no.4
• /
• pp.337-343
• /
• 2018

The influence of solid loading in the slurry composition on the morphology of 3Y-TZP granules fabricated by two-fluid spray drying was investigated for solid contents varying between 30 wt% and 50 wt%. The resulting 3Y-TZP granules showed a sphere-like shape with diameters of $40-70{\mu}m$. However, a donut-like shape and a few cracks were observed on the granule surfaces fabricated using the slurry with 50 wt% solid content. The green density after cold isostatic pressing at 200 MPa was $2.1-2.2g/cm^3$, and a homogeneous fracture surface was obtained by complete destruction of granules. After sintering at $1500^{\circ}C$ for 2 h, all specimens had relative densities of 96.2 - 98.3%. With increasing solid content, the relative density decreased from 98.3% to 96.2%, but the grain size increased from $0.3{\mu}m$ to $0.6{\mu}m$. Highly sinterable zirconia granule powder could be obtained by controlling the slurry composition.

• Journal of the Korean Ceramic Society
• /
• v.39 no.5
• /
• pp.446-451
• /
• 2002

Zirconia/alumina mixture powder was spray-dried various degree of dispersion, type of dispersants and powder content in the slurry. The quality of the granule was determined by observation of the granule shapes after spray drying and fracture of intergranular boundaries during pressing. Defect-free granules were obtained from the powders that formed weak flocs in the slurry. The granules, spray-dried from the slurry containing 32.5 vol% powder mixture and PVP as binder, were fractured completely during shaping and the sintered specimens showed a density of 99.7% and a flexural strength of 850 MPa.

• Journal of the Korean Ceramic Society
• /
• v.56 no.5
• /
• pp.443-452
• /
• 2019

In this study, TiO₂-polyvinyl alcohol (PVA) composite granules were prepared via spray drying technique. To investigate the effects of solid content and binder/powder ratio in the slurry on the granulation behavior of TiO₂ powders, the feed compositions were designed to vary over a wide range. The morphology, actual densities, and average granule size and size distribution of the TiO₂-PVA composite granules were characterized by using scanning electron microscopy technique, a gas pycnometer, and an image analyzing program (Image-J), respectively. The results indicate that solid content and the amount of PVA in the feedstock slurry are the dominant factors determining the granule morphology, size, and size distribution of TiO₂-PVA composite. Moreover, it was observed that increasing the solid content and the amount of PVA in the slurry improved the granulation process and reduced the granule defects. For the preparation of spherical TiO₂-PVA composite granules with the minimum amount of non-granulated powders, the optimized composition of the feedstock slurry was found to be 35 wt.% solid and 3 wt.% PVA.

• Journal of the Korean Ceramic Society
• /
• v.53 no.3
• /
• pp.332-337
• /
• 2016

As a case study on yttria stabilized zirconia ceramics, the sintering characteristics of submicron powders and the granulation prepared by two-fluid spray drying of submicron particles were investigated. As-received powders of yttria stabilized zirconia particles were reduced to a uniform size of less than about 200 nm by repeated milling. Granulation size obtained by the two-fluid spray drying was affected by the organic matter and the primary particle size. Sintering behavior such as porosity, water absorption ratio, density, and transparency was influenced by processing conditions of the powder, and the discontinuous interfaces in a green body were reduced.