A comprehensive simulation scheme for tape casting: From flow behavior to anisotropy development

A new simulation scheme for tape casting is presented and applied. The model allows considering both the macroscopic flow behavior and the orientation of individual particles inside the ceramic slurry. It is based on the smoothed particle hydrodynamics method, a particle-based computational fluid dynamics solver, and Jeffery's equations of particle motion, which describe the rotation of rigid, ellipsoidal particles in a fluid. It is shown how different process parameters and the rheological behavior of the slurry influence its flow behavior, which in turn affects the orientation of nonspherical particles inside the slurry. The simulations predict that a preferred, anisotropic particle orientation develops in the green tapes, whose extent depends mainly on the powder properties. All simulations are performed with real tape-casting data concerning geometry of casting unit, casting parameters, slurry rheology, and powder properties. The anisotropy results are confirmed by experimental analysis of cross sections of tape-cast films made from different powders.