Layered extrusion forming of ceramic cores with a nanoceramic suspension as a binder was conducted to explore a novel method to produce complex-shaped ceramic cores. Green bodies were prepared using Al2O3 particles as precursor materials and silica sol combined with aqueous polyvinyl alcohol solution as a binder. Increasing the silica sol content increased the viscosity of the slurry, enhanced the green bending strength, and decreased the green linear shrinkage. The green microstructure showed the nanosized silica particles were deposited on the surface of the Al2O3 particles and among the pores formed by Al2O3 particles irregular packing. In addition, increasing the silica sol content increased the bending strength, however, decreased linear shrinkage and open porosity of the sintered bodies. During sintering, the nanosized silica particles converted to the melting phase and reacted with Al2O3 and the microstructure of sintered bodies indicated the existence of sintering neck with silica sol addition.
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