Optimisation of parameters for aqueous tape-casting of cordierite-based glass ceramics by Taguchi method

Aqueous suspensions of cordierite-based glass ceramics were prepared by using four types of dispersants and binders and different solids loading. The experiments were designed according to the Taguchi method, which shows great advantages in optimising more than two factors that need to be considered in an experimental design. Different parameters such as the type and concentration of the dispersants and the binders, and the solids loading were optimised to obtain homogeneous and crack-free green tapes. Dolapix CE 64 (1.0 wt.%) and Duramax B-1080 or Duramax B-1070 (10 wt.%) with 65 wt.% solids loading represent an optimal selection of the parameters to obtain low viscosity suspension, and crack-free green tapes with the highest green and sintered density. Microstructural differences between crack-free and cracked samples were observed by scanning electron microscopy (SEM). The crack-free green tapes show homogenous microstructures from top to bottom with organic additives uniformly surrounding the powders, whereas cracked samples exhibit heterogeneous microstructures and non-uniform distribution of the organics.