Processing of porous yttria-stabilized zirconia tapes: Influence of starch content and sintering temperature

The tape-casting process was used to produce porous yttria-stabilized zirconia (YSZ) substrates with volume fractions of porosity ranging from 28.9 to 53 vol.% by using starch as a fugitive additive. Concentrated aqueous YSZ slips with different amounts of starch and an acrylic latex binder were prepared. The influence of the volume fraction of starch and sintering temperature on the sintering behavior and final microstructure were investigated. The microstructure consisted of large pores created by the starch particles with lengths between 15 and 80 μm and smaller pores in the matrix with lengths between 0.6 and 3.8 μm. The pores in the matrix reduced the sinterability of the YSZ leading to the retention of closed porosity in the sintered tapes. The porosities were above those predicted for each of the starch contents. However, larger deviations from the predicted porosity were found as more starch was added. The open to total porosity ratio in the sintered tapes could be controlled by the volume fraction of added starch as well as by the sintering temperature. As the volume fraction of starch increased from 17.6 to 37.8 vol.% there was a gradual increase in the interconnectivity of the pore structure. The sintering shrinkage of the tapes at a given temperature could be directly related to the YSZ packing density in the matrix.