Reproducible manufacturing of ceramic components requires understanding and controlling materials and processing. Utilizing characterization and modeling to develop science-based understanding, significant advances have been made to better understand and control ceramic pressing powders, powder compaction, and sintering. This includes identifying some of the critical relationships between powder characteristics/properties, powder compaction behavior, and sintering. Another significant advance includes the development of computer simulation technology for compaction and sintering that provides guidance to improve process reproducibility and control. For powder compaction, a cap-plasticity constitutive model is implemented within a finite element (FE) framework. For sintering, a linear viscous sintering constitutive model is implemented within an FE framework. Both models have been tested and validated by comparing model predictions to experimental observations. The computer modeling technology developed can be used to improve and expand ceramic component designs, to help optimize powder pressing and sintering, and to anticipate and minimize defects during processing. The application of characterization and modeling technology to develop better powders and more robust processes will contribute to more reproducible, efficient, and cost effective manufacturing technology for ceramic components.
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