Preparation of ZrO2 beads by an improved micro-droplet spray forming process

Monodisperse ZrO 2 ceramic beads with size larger than 1 mm have been prepared by an improved micro-droplet spray forming process, through which a compressor and a dispenser were employed to produce droplets continuously. Furthermore, the slurry recipe and drying temperature have been optimized to enhance the sphericity and smoothness of the beads. The sintered ZrO 2 ceramic beads present promising mechanical performance, including a relative density of 84.6%, a crush strength of 256.2 ± 36.6 N as well as a Vickers hardness of 1344.4 ± 58.3 HV. Such procedure reveals great potential in mass production of ceramic beads.