Gelcasting
"A Novel Ceramic Forming Process"

Gelcasting is a forming process similar to slip casting for making complex-shaped parts. In gelcasting, a slip of ceramic powders in a solution of organic monomers, is poured into a mold and is polymerized forming a strong, crosslinked solvent-polymer gel filled with the ceramic powder. The wet body is readily dried and contains only about 4 wt % polymer. Gelcasting produces large, complex-shaped parts that are strong enough to be machined, if necessary, before firing. The process is simple, economical, and uses conventional equipment. As the accompanying flow chart shows, it represents a minimal departure from standard ceramic manufacturing practice. Its simplicity and green body properties give it advantages over competing processes such as slip casting and injection molding. Thus, gelcasting is an enabling technology that permits the fabrication of complex shapes that are either too complicated or too expensive to be manufactured by other processes.


Gelcasting Team Members
Left to right: Steve Nunn, Omats Omatete, Claudia Walls, and Mark Janney

Gelcasting Publications available in
PDF Format*

  • Gelcasting, by Mark A. Janney, Stephen D. Nunn, Claudia A. Walls, Ogbemi O. Omatete, Randy B. Ogle, Glen H. Kirby, and April D. McMillan
  • Development of Low-Toxicity Gelcasting Systems, by Mark A. Janney, Ogbemi O. Omatete, Claudia A. Walls, Stephen D. Nunn, Randy J. Ogle, and Gary Westmoreland
  • Gelcasting of GD-1 Ceramic Radomes, by Kevin W. Kirby, HRL Laboratories, Malibu, CA, Anthony Jankiewicz, (Retired) Raytheon Missile Systems, Tucson, AZ, Mark Janney, Oak Ridge National Labs, Oak Ridge, TN, Claudia Walls, Oak Ridge National Labs, Oak Ridge, TN, Don Kupp, Fraunhofer USA, Newark DE (PDF Version) (Word Version)
 

Other publications

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1995 R&D 100 Award Winner

1995 Federal Laboratory Consortium Award for excellence in
technology transfer

Ceramic Processing

Ceramic Processing Group

For more information regarding the Ceramic Processing Group,
contact laufrj@ornl.gov