GRADED CASTING OF MATERIALS WITH CONTINUOUS GRADIENTS

A process is introduced for producing continuously graded materials by slip casting with a continuous flow of slip of changing composition. The approach has been tested using alumina and zirconia slips to produce alumina/zirconia composites with a graded composition. Observation of the microstructure has shown that the phases are relatively well dispersed. Compositional analysis revealed a relatively smooth transition in composition through the thickness of sintered bodies. Results have also indicated that for flow rates up to approximately 60 cm/min, the highest linear flow rate tested, the casting rate of alumina slips containing 38.6 vol% solids was not affected.