Analytical Fluid Flow Models for Tape Casting

The details of fluid flow in tape casting of a Newtonian slurry with a parallel blade are analyzed in terms of the relative magnitudes of the driving forces (wall shear and pressure gradient) and the resulting tape thickness. Prior studies are limited to describe the flow under the blade and within the reservoir. Consideration of the flow after the blade exit indicates that the existence of a zero‐shear plane might have a negative effect on particle alignment in the tape. The more common case of a beveled blade is also analyzed using the one‐dimensional flow model, which is shown to be valid for blade angles up to about 45°. The beveled and parallel blades are compared in terms of productivity, minimum thickness, and potential influence on particle alignment.