Courses - Tape Casting for Research and Manufacturing Innovation
July 11-15, 2011
Engineers, researchers and industrial scientists interested in understanding, and applying ceramic tape casting formulae and techniques. Course includes new techniques for the deterministic compounding of aqueous and solvent-based slurries, effectively broadening the range and domain of ceramic compositions that can be tape cast using laboratory and/or high-volume production scale equipment. Class limit of 15. Reserve early.
This course is intended for engineers, researchers and industrial scientists who are involved in tape casting. It is appropriate for those involved in research using aqueous or solvent-based formulations, because it includes new insights into how to deterministically (rather than empirically) formulate castable tapes. It is appropriate for those using or responsible for high-volume manufacturing of ceramic tapes, because it includes hands-on laboratory work using a high volume tape casting machine in a clean-room environment. It is appropriate for those involved in managing or supervising tape casting operations, because it includes "train the trainer" content on how to create and deliver operator training and development of standard operating procedures. It is also appropriate for training new graduate and post-graduate engineers and scientists who need to learn about and apply tape casting as part of their research or industrial employment.
The course covers raw material selection, slurry preparation, casting, post-processing, and operator training. It also emphasizes safety, clean room protocol, quality control, and data collection. . The mechanisms by which tape casting formulations are determined and processed will be explained, and the information provided by observation of dispersion and rheology will be emphasized. Course activities include a survey of various binder systems, powder and binder characterization, tape casting setup, slurry handling, operation, cleanup, and waste manageemt, as well as post processing including aging and sintering. Emphasis is also placed on safety, clean room protocol for casting electronic and other high-specification substrates, and statistical process control for quality. This is a hands-on course in which the students will have morning lectures covering the topics and afternoon/evening lab sessions in which they will practice what they have learned by casting tapes using manual low-volume and automated high-volume systems.
The first day of the course covers safety, solvents and chemicals, clean room protocol, and personal protection topics important for the safe and effective creation of solvent and aqueous-based tapes. Second day covers raw material selection, including identification and aging of powders, binders, materials characterization, and slurry preparation including batching, mixing and rheology. The third day involves tape casting demonstration and lab work including cleanup, validation, waste handling, and media storage. On the fourth day post-processing of cast tape, including aging, stamping, inspection and sintering along with statistical process control and data collection is the focus. The last day covers operator training, creation of standard procedures for your tape casting facility, and making prototype parts.
Prof. William M. Carty is a Ceramic Engineering Program Chair and Professor of Ceramic Engineering at the New York State College of Ceramics at Alfred University. He received his Ph.D. in Ceramics at University of Washington.
David Dychala is a Philadelphia-based independent materials engineering consultant and process engineer. His specialties include design of experiments, process audits and improvements, program management, bioceramics, fuel cells, inorganic formulations, and high temperature materials processing. He is a Ceramic Engineering graduate of the Pennsylvania State University and holds a Six Sigma Black Belt.
John Olenick has an engineering background in materials, ceramics, and electronics for military and commercial systems. He is a graduate of the Pennsylvania State University in Ceramic Engineering. Recently he has been focused on operations management, business development, marketing, and starting new companies.