Review Ceramic tape casting: A review of current methods and trends with emphasis on rheological behaviour and flow analysis M. Jabbari a,⇑ , R. Bulatova b , A.I.Y. Tok c , C.R.H. Bahl b , E. Mitsoulis d , J.H. Hattel a a Process Modelling Group, Department of Mechanical Engineering, Technical University of Denmark, Nils Koppels Allé, 2800 Kgs. Lyngby, Denmark b Department of Energy Conversion and Storage, Technical University of Denmark, Frederiksborgvej 399, Building 779, Roskilde, Denmark c School of Materials Science & Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore d School of Mining Engineering and Metallurgy, National Technical University of Athens, Zografou, 15780 Athens, Greece article info Article history: Received 18 February 2016 Received in revised form 3 July 2016 Accepted 26 July 2016 Keywords: Tape casting Fluid flow Rheology Non-Newtonian Modelling abstract Tape casting has been used to produce thin layers of ceramics that can be used as single layers or can be stacked and laminated into multilayered structures. Today, tape casting is the basic fabrication process that provides multilayered capacitors and multilayered ceramic packages. In tape casting the rheological behaviour of the slurry as well as the material flow during casting are of utmost importance since these phenomena to a large extent determine the final properties and hence the quality of the cast product. During the last decades this has led to an increasing number of works in literature within fluid flow anal- ysis of tape casting. In the present paper a review of the development of the tape casting process with particular focus on the rheological classifications as well as modelling the material flow is hence pre- sented and in this context the current status is examined and future potential discussed. Ó 2016 Elsevier B.V. All rights reserved. Contents 1. Introduction .......................................................................................................... 40 1.1. Application examples for tape casting ................................................................................ 42 1.1.1. Substrates ............................................................................................... 42 1.1.2. Multilayered ceramics ..................................................................................... 42 1.1.3. Solid oxide fuel cell (SOFC) ................................................................................. 42 1.1.4. Functionally graded ceramics (FGCs) ......................................................................... 42 1.1.5. Textured ceramics ........................................................................................ 43 1.2. The tape casting process from a materials characterization perspective ..................................................... 43 2. Rheology of fluids...................................................................................................... 43 2.1. Newtonian fluids ................................................................................................. 43 2.2. Non-Newtonian fluids ............................................................................................. 44 2.2.1. Power-law fluid .......................................................................................... 45 2.2.2. Prandtl–Eyring model ...................................................................................... 45 2.2.3. Powell–Eyring model ...................................................................................... 45 2.2.4. Cross model ............................................................................................. 45 2.2.5. Yasuda model ............................................................................................ 46 2.2.6. Bingham material model ................................................................................... 46 2.2.7. Herschel–Bulkley model .................................................................................... 46 2.2.8. Casson model ............................................................................................ 47 2.2.9. Modified visco-plastic models ............................................................................... 47 2.3. Rheological characterization of tape casting slurries .................................................................... 47 3. Modelling approaches .................................................................................................. 48 3.1. Analytical models ................................................................................................ 48 http://dx.doi.org/10.1016/j.mseb.2016.07.011 0921-5107/Ó 2016 Elsevier B.V. All rights reserved. ⇑ Corresponding author. E-mail address: mjab@mek.dtu.dk (M. Jabbari). Materials Science and Engineering B 212 (2016) 39–61 Contents lists available at ScienceDirect Materials Science and Engineering B journal homepage: www.elsevier.com/locate/mseb