Fabrication of semi-conductive ceramics by combination of gelcasting and reduction sintering

In this study, we propose a new process to fabricate electrically semi-conductive alumina by the combination of gelcasting and reduction sintering. The process is similar to the conventional gelcasting method except for varying amounts of methacrylamide monomer dosages at 2.83, 5.50, and 8.04 wt% relative to the mass of the slurry. Correspondingly, the rheological evaluation of aqueous slurry was conducted. The resulting fluidity exhibited that monomer dosage until 8.04 wt% yielded slurry viscosity of 1628 MPA·s at shear rate of 20 s⁻¹, which was feasible for gelcasting without noticeable casting defects. The freshly gelled bodies were demolded, carefully dried, and then sintered at different schedules in nitrogen atmosphere. The reduction-sintered samples were re-sintered in air for comparative evaluation of physical property. The sintered alumina body was characterized by electrical resistance, X-ray diffraction, and scanning electron microscopy. The results showed that monomer additions and sintering schedule significantly affect in lowering electrical resistivity. The obtained lowest value was 3.6 × 10⁶ Ω-cm with 8.04 wt% monomer dosage and sintering at 1550°C with 2 h holding time. The resulting material is classified as semi-conductive, which is potential for electrostatic shielding applications. The effect of physical property and microstructure on electrical conductivity and the corresponding reaction mechanism were discussed in details.