Processing of Al2O3 sheets by the gel–tape-casting process

Flat ceramic sheets have been produced by a novel method, i.e. the gel–tape-casting process, has been developed. The process makes use of a monomer solution to prepare the ceramic slurry. During casting, a network is formed by the polymerized organic monomers, and the ceramic particles are fixed within the network thus resulting in a green tape. The mechanism of polymerization of ceramic slurry is outlined and the influencing factors on solidification are discussed. Excellent green tapes can be produced by accurately controlling the concentration of the monomer solution, the pH of the slurry, the polymerizing temperature, and the amount of initiator and catalyst.