Influence of the aging time of yttria stabilized zirconia slips on the cracking behavior during drying and green properties of cast tapes

Tape-casting process was used to produce yttria stabilized zirconia (YSZ) substrates in an aqueous system using a low amount of an acrylic latex binder. Concentrated suspensions with different aging times were cast, and the influence of the slip aging time on the drying kinetics and cracking behavior of the tapes were studied. In addition, the effect of the slip aging time on the properties of the resultant green tapes was investigated. The latex particles consolidated by coalescence during the aging time of the slips and resulted in an increase in the smaller pore size of the cast tapes. The pore radius increased with increasing the slip aging time up to 14 days thereby decreasing the capillary pressure in the liquid. Aging times over 14 days did not change the pore radius and consequently the capillary pressure. The capillary tension drove the consolidation; the tapes produced from slips with lower aging times which had higher capillary pressure shrank more, had lower pore volume and consequently higher green density. Cracking was found in tapes prepared from slips with aging times shorter than 14 days; the crack area decreased with increasing the slip aging time. For slip aging time ≥14 days cracking was not observed. Aging before casting up to 14 days reduced cracking in tapes prepared with low amounts of latex; however, the lower capillary pressure resulted in low green density of the cast tapes.