Modares Mechanical Engineering

Modares Mechanical Engineering

Optimization Challenges in Manufacturing SiC-Al2O3-YSZ Composite Green Parts via Ceramic-Feedstock Warm Pressing Process

Document Type : Original Article

Authors
Mohammad Keshavarzi
عسل حسینی منزه
Faculty of Mechanical and Energy Engineering, Shahid Beheshti University, Tehran, Iran
10.48311/mme.2026.119836.82997
Abstract
This research presents an investigation into the optimization of ceramic-feedstock warm-pressing for the fabrication of SiC-based composites. The process integrates uniaxial warm-pressing with injection molding, employing SiC, Al2O3, YSZ, and a polymer binder. Critical challenges encountered during green body production were meticulously identified, leading to the proposal of effective solutions. Significant process advancements involved designing a mold with guide screws, implementing a dual-stage coating technique, and utilizing a pulverizer for feedstock powder preparation. Through Design of Experiments (DOE), the optimal warm-pressing parameters were determined, revealing that temperature is the primary factor controlling the binder’s rheological behavior and facilitating particle rearrangement. Hardness test data indicated that the optimal conditions for warm-pressing were 120°C, 185 bar, and 27 minutes. Microstructural examination corroborated the uniform distribution of reinforcements and the cohesive strength imparted by the binder. Furthermore, particle size analysis (distribution range: 1.37 μm; distribution slope: 3.96) indicates the suitability of this powder for the molding process.
Keywords
Silicon Carbide Feedstock
Ceramic Composite
Uniaxial Warm-Pressing
Molding
Design of Experiments (DOE)
Subjects
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Modares Mechanical Engineering
Volume 27, Issue 1
January 2027
Pages 29-47