Hidden correlation between rheological dynamics and crack formation in water-based slurry

Cracks generated in sheet coating of water-based slurries are an increasingly important concern in the development of diverse material science, such as fine ceramics, Pt catalysts, and Li transition metal oxides, from an environmental safety perspective. However, a comprehensive understanding of crack formation remains elusive due to the intricately entangled interplay among various characteristics of slurries. Here, we systematically ascertain the causes at work in crack initiation by analyzing the physical parameters of a series of aqueous alumina slurries using machine learning. The analysis reveals a strong correlation between rheological hysteresis and sheet cracking. As a verification of the correlation, the crack suppression by controlling the rheological hysteresis is experimentally confirmed. Furthermore, we visualize the microstructure in the slurry that induces cracks with a liquid-phase scanning electron microscope, clarifying the rheological dynamics. These results disentangle that rheological hysteresis is a good indicator directly reflecting microstructural durability against drying stress.