Elimination of surface spallation of alumina green bodies prepared by acrylamide-based gelcasting via poly(vinylpyrrolidone)

Surface spallation of gelcast alumina green bodies due to the exposure of the surface to air during gelation was successfully eliminated by adding a proper amount of poly(vinylpyrrolidone) (PVP) in aqueous acrylamide premix solution. The influences of PVP on the colloidal characteristics of alumina powder in aqueous solutions, the rheological properties of alumina slurries, the gelation process, and the properties and microstructures of the gelcast green bodies and the sintered samples were systematically investigated. Even though the addition of PVP to premix solution has slightly negative effects on the viscosity of alumina slurries, gelation and strength of green bodies, it has no obvious influence on the final structure and properties of alumina ceramics. Thus, PVP was considered an effective polymer to resolve the problem of the inhibition of gelation due to the presence of oxygen, which usually occurs in gelcasting during the formation of polymer network gel by in situ polymerization (if monomers in air. The mechanism of PVP in eliminating the surface spallation problems of green bodies is also discussed.