Investigation of nanosized alumina-binder feedstock rheology for ceramics injection molding (CIM) and survey spark plasma sintering of output green body to obtain transparent alumina

The purpose of this work is to optimize the feed containing alumina-binder nanoparticles for ceramics injection molding to create transparent alumina parts. In this research, two Alumina with and without MgO as sintering aid fabricated via the spark plasma sintering method. Feed fluidity, fracture toughness, density, IR, and visible transmission of SPSed bodies of the sintered pieces were measured. Furthermore, a pin on the disc test was used on the disk to examine the alumina friction coefficient. The results of feed rheology showed that the sample prepared at 90°C had the best conditions as a pseudoplastic fluid for the ceramic injection molding (CIM) method. The results showed that a combination of CIM and spark plasma sintering (SPS) methods cause more visible transmission than conventional SPS of alumina nanopowder. Also, the fracture toughness and hardness of as-obtained transparent alumina were in the range of 3.6 MPa m^0.5 and 20.1 MPa, respectively. The wear rate of the as-obtained transparent sample (4.5 × 10⁻⁷ mm³/N m) was proportional to the alumina grain size (1–4 μm).