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In order to achieve high green density of alumina powder compacts of particles with bimodal size distribution, stearic acid and polyethleneglycol were used as forming aids. Burn-out of binder and sintering behavior of these powder compacts were investigated. The forming aids melted at 50°C and concentrated on contact points of particles where large capillary force acts and became difficult to burn out. Therefore, the forming aids in compacts containing a large amount of fine particles tended to burn out at higher temperature. Powder compacts containing 40-100% fine particles expanded prior to burn-out of forming aids and began to contract simultaneously with burn-out of forming aids at 170°C. Powder compacts containing 0-30% fine particles did not expand but began to contract at 300°C. As forming aids burn-out, small pores in compacts shrank, whereas large pores grew. The sintered densities of compacts that were high green density with forming aids were also higher than those of compacts that were low green density without forming aids, until the relative density reached 95%. However, the effect of green density on the densification decreased when the relative density exceeded 95% due to remarkable grain growth.

Burn-out of Binder and Sintering Behavior of Powder Compacts of Bimodally Distributed Alumina Powders with Stearic Acid and Polyethleneglycol