Optimization of heating schedules in pyrolytic binder removal from ceramic moldings

A model that finds the maximum permissible heating rate for pyrolysis of ceramic moldings is extended to produce multi-segment temperature–time profiles to minimize the binder removal time. The degradation of the polymer and the diffusion of degradation products in solution to the free surface in a cylinder containing 50 vol% alumina and polyalphamethylstyrene is considered. The theory has previously been validated experimentally for fixed heating rates for cylindrical and flat plate geometries and for overpressure debinding. The extended model, presented here, calculates the vapor pressure of monomer over solution and modifies the heating rate to keep this just below ambient pressure. In this way, the temperature follows the maximum allowable rate at each stage to prevent boiling and hence the incidence of defects.