Yttria-stabilized tetragonal zirconia (YTZP) ceramics with high densification and superior mechanical properties were obtained using gel casting technology and a two-stage sintering process. Well-dispersed Nano-sized (94 nm) zirconia slurry with high solid content (45vol%) was prepared for gel casting using Dolapix CE64 as the dispersant. As the dispersed slurry was added epoxy monomer (EGDGE) and polymerization initiator (DPTA), Dolapix CE64 promoted gelling, leading to an abrupt increase in the slurry viscosity. As Dolapix CE64 was added into the slurry, its functional carboxyl groups reacted with EGDGE, resulting in a decrease in gelling incubation time and an increase in viscosity, hence, leading to gel casting failure. The addition of hydroquinone (HQ) into the slurry can be used to delay the polymerization and extend the gel casting working time. After gel casting, the temperature was raised to above 60o C to promote the polymerization, leading to an increase in the green strength.A two-stage sintering process was used to control the grain growth. The first stage sintering temperature was chosen at 1300oC, where the relative density reached 83%. In the second sintering stage, the temperature was lowered to 1240°C and soaked for 24 h to inhibit grain growth (mean grain size of 195 nm) and continue densification to a relative density of above 99%. Vickers hardness of 15.2GPa, fracture toughness of 7.8MPa.m1/2, and flexural strength of 771MPa can be obtained for the sample prepared using gel casting technology with a two-stage sintering process.

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