High-precision green densities of thick films and their correlation with powder, ink, and film properties

A precise geometrical method employing optical profilometry for green density measurements of thick films is presented that provides a typical reproducibility of 0.1–0.2% theoretical density (TD) and a measurement uncertainty of 0.2–0.4% TD for layer thicknesses of around 50 μm. The procedure can be applied for all thick films with a dried thickness of 10 μm or greater. In a case study, the green densities of screen-printed zirconia layers were investigated as a function of the starting powders (grain sizes from 0.1 to 0.4 μm), the solid content, the chain length of ethyl cellulose as binder and its concentration, and two different dispersants and their concentration. Rheological ink properties, surface roughness, drying stresses from deflection measurements, the mechanical properties of green films, and the equivalent compaction pressure were measured and correlated with the green density data. Compressive binder forces and lubrication effects dominated the packing of the particles.