New processing route for ZrSiO4 by powder injection moulding using an eco-friendly binder system

New processing route has been developed for zircon based on powder injection moulding (PIM). Raw zircon powders, obtained from mineral sands, have been processed using a new water soluble binder system composed of PEG and CAB. Water solvent debinding stage has been studied in depth. On one hand, influence of some debinding parameters (temperature, debinding rate, additives and the use of climate chamber) has been tested. On the other hand, new binder systems were tested and compared with previous studied ones. The full PIM process has been carried out. Mixing, injection molding, solvent and thermal debinding and finally sintering, have been performed with the optimal binder system composition. Homogeneity along the process has been assessed by thermo-gravimetric analysis and by density measurements. After sintering, dimensional variation, density and fracture surface obtained after flexural strength test, have been analyzed. A competitive flexural strength has been achieved for injected zircon samples. (C) 2015 Sociedad Espanola de Ceramica y Vidrio. Published by Elsevier Espana, S.L.U. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).