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A novel ceramic near-net shaping method is presented which enables the production of complex-shaped green bodies directly from aqueous suspensions The hydrolysis assisted solidification (HAS) process relies on the time-delayed  in situ  hydrolysis of AlN powder added to concentrated aqueous slurries of the host powder(s), as a reactant. The incubation period before the hydrolysis starts can be controlled by the addition of anions, which adsorb onto the AlN powder’s surface, as well as by temperature. During the hydrolysis reactions part of the water is internally consumed, the aluminum-hydroxide reaction product gels to form a stiff network, whereas the formation of ammonia can be exploited for flocculation. As a result, the viscosity of the host ceramic slurry dramatically increases until its fluid character is lost and a saturated body is formed. Examples of using the HAS process in slurry forming alumina and zirconia bodies are given and the process potential and limitations are discussed.

Hydrolysis Assisted Solidification Process and its Use in Ceramic Wet Forming