Tape casting of alumina in water with an acrylic latex binder

Aqueous tape casting of alumina with an acrylic latex binder has been studied in a continuous tape casting machine. The aim of the study was to evaluate this type of system in the different processing steps. Four slurry compositions were used in the experiments with varied binder level and solids content. The rheological properties of the slips were measured with a controlled stress rheometer and related to the casting behaviour. The critical cracking thickness, i.e. the thickness when spontaneous cracking during drying occurs, was also studied. Casting rates of 2 cm/s resulting in a total drying time of 3.1 min could be used for slips with a high solids content at a blade gap of 300 mu m. All slurries gave good quality tapes with smooth surfaces. The tapes were possible to laminate at room temperature. A bending strength of 536 MPa and a Weibull modulus of 17 were reached for a material laminated from 200 mu m green tapes. (C) 1996 Elsevier Science Limited.