Effect of polyethyleneimine-fatty acid complex type dispersant structure on the overall processing chain of Si3N4 ceramics using multicomponent non-aqueous slurries

The effect of fatty acid structure of polyethyleneimine (PEI)-fatty acid complex, which was designed as a polymer dispersant for multi-component non-aqueous slurries, on the overall processing chain of Si₃N₄ ceramics involving slurry stabilization, spray drying, compaction, and liquid sintering was investigated using PEI-oleic acid (PEI-OA) and PEI-isostearic (PEI-ISA) complexes. Si₃N₄-Y₂O₃-Al₂O₃-AlN-TiO₂/toluene slurries were selected as a real model for Si₃N₄-based multicomponent slurries. It was observed that both PEI-OA and PEI-ISA can stabilize Si₃N₄-Y₂O₃-Al₂O₃-AlN-TiO₂/toluene slurries; however, the PEI-ISA system tended to have slightly higher slurry viscosity, which was suspected to be due to the interactions between protruded PEI segments among short ISA chains. The spray-dried granules from PEI-ISA-stabilized slurry were observed to have filled structures with higher surface roughness whereas those prepared from PEI-OA-stabilized slurry were observed to have hollow-structured granules. The granules prepared from PEI-OA slurry had improved flow and compaction properties with higher relative density of green compacts compared with those prepared from PEI-ISA-stabilized slurry, whereas the relative density and microstructural homogeneity of S₃N₄ ceramics sintered at 1600?°C for 2?h were observed to be higher for the PEI-ISA system. It is suspected that PEI-OA effectively improved the dispersion stability of multicomponent slurries and flow/compaction properties of granules; however, the inhomogeneous microstructures of green compacts induced by the hollow-structured granules had an adverse effect on the sintering of Si₃N₄ ceramics.