Structure and properties of ZrO2-Al2O3-MgO porous ceramic for biomedical applications

Starch consolidation casting (SCC), which involves pouring starch-containing slurries into an impermeable mould, is a flexible, easy, not harmful, not expensive, and firmly established method for manufacturing ceramic green structures. The procedure depends on the fact that the starch granules, when heated to about 80 °C, start to swell and absorb the water from the ceramic slurries. Following sintering, the starch granules have been completely destroyed by burning, resulting in the formation of porous-structured ceramics. In the current study, porous zirconia-alumina–magnesia (77.5 wt% ZrO2, 2.5 wt% MgO, and 20 wt% Al2O3) ceramic composites have been produced using starch consolidation casting method at different suspension concentration (60, 65, and 70 wt%). Potato or tapioca starches with varying quantities (10, 20, and 30 wt% related to the solid ceramics) were used as a pore and body forming agents. The sintered microstructures were investigated using X-ray diffraction (XRD) and scanning electron microscopy (SEM). Furthermore, the research activity investigates how the apparent density and apparent porosity of the porous ceramic structure that has been produced are affected by the addition of different proportions of starches in different suspension concentrations. The XRD result after sintering reveals monoclinic zirconia, indicating that the tetragonal phase of zirconia is not stabilized by MgO and returns to monoclinic upon cooling. Magnesia does not act as a stabilizer for zirconia, but it is combined with alumina to produce a spinel structure. Maximum apparent porosity value of around 73% were demonstrated for porous-structured ceramics made with (30 wt%) potato starch and (60 wt%) suspension concentration. The SEM analysis of porous-structured ceramics revealed the presence of pore fills in the shape of miniature sintered ceramic shells within the pores. These shells form throughout the drying and burn-out processes, when the starch granules undergo a process that causes them to shrink. For nominal starch quantities of approximately 10 wt%, starch swelling is noticeable, and the pores left behind by sintering are bigger than the starch granules. Swelling is limited for greater amounts of starch by the amount of available space and/or water, and the matrix shrinkage that occurs during sintering more than compensates for the swelling impact, resulting in ceramic pores much smaller than the initial starch granule size. SEM and high-pressure mercury porosimetry results indicated that the prepared porous-structured ceramics have a bimodal pore structure. The maximum compressive strength at around 15.87 MPa for a sample containing 10 wt% tapioca starch and 70 wt% suspension concentration. Compressive strength drastically reduced when starch content increased from 10 to 30 wt% and suspension concentration reduced from 70 to 60 wt%.