γ-ray CT examination of density gradients in slip cast ceramics: correlation with stress distribution

Abstract Residual stresses caused by processing techniques reduce the safe allowable design life of components. This is especially critical for brittle materials, like ceramics, which do not exhibit plastic deformation. During development of the manufacturing process for an experimental high-precision ceramic component, a characteristic cracking pattern occurred in a series of prototypes, which suggested development of stresses during densification, either during drying or sintering. To examine parameters which may influence the development of these residual stresses, a series of simple geometry specimens were prepared and characterized for density gradients using computed tomography (CT). Using the measured values of density gradients, a model of the sintering process was made and the resultant stress distribution in the parts calculated. Results indicate that the use of nonlinear finite element analysis in conjunction with hypoelastic materials modelling qualitatively represents the sintering stresses.