Additive manufacturing is a layer-by-layer strategy enabling the advanced design and fabrication of complex 3D objects and structures, overcoming geometry limitations and reducing waste production compared to conventional technologies. Among various additive manufacturing technologies, digital light processing (DLP), is an additive manufacturing technology used to print photopolymer parts, using a projected light source to cure an entire layer at once. Initially developed for pure resins, recent advances have demonstrated the potential of DLP in the polymerization of ceramic and metal-loaded suspensions, enabling the fabrication of ceramic and metal components after proper debinding and sintering. Such flexibility increases the potential of DLP for different applications, ranging from dental implants and bone scaffolds to smart biomaterials for soft robotics, smart wearables, and microfluidic devices. The review provides an overview of DLP technology and its recent advances; specifically, the review covers the photopolymer properties, the ceramic and metallic feedstock preparation, and the light-matter interaction mechanism underpinning the printing and post-processing steps. Finally, a description of the current application is provided and complemented with future perspectives.
Zirconia–alumina composites couple the high toughness of zirconia with the peculiar properties of alumina, i.e., hardness, wear, and chemical resistance, so they are considered promising materials for orthopedic and dental implants. The design of high performance zirconia composites needs to consider different aspects, such as the type and amount of stabilizer and the sintering process, that affect the mechanics of toughening and, hence, the mechanical properties. In this study, several stabilizers (Y2O3, CuO, Ta2O5, and CeO2) were tested together with different sintering processes to analyze the in situ toughening mechanism induced by the tetragonal–monoclinic (t–m) transformation of zirconia. One of the most important outcomes is the comprehension of the opposite effect played by the grain size and the tetragonality of the zirconia lattice on mechanical properties, such as fracture toughness and bending strength. These results allow for the design of materials with customized properties and open new perspectives for the development of high-performance zirconia composites for orthopedic implants with high hydrothermal resistance. Moreover, a near-net shape forming process based on the additive manufacturing technology of digital light processing (DLP) was also studied to produce ceramic dental implants with a new type of resin–ceramic powder mixture. This represents a new frontier in the development of zirconia composites thanks to the possibility to obtain a customized component with limited consumption of material and reduced machining costs.
This work aims at studying the creep behaviour of 15-15Ti(Si) austenitic steel, under uniaxial stress (range of 300-560 MPa), and its interaction with liquid lead. The steel was tested to verify its sensitivity to Liquid Metal Embrittlement (LME) and to simulate its behaviour in operating thermal and mechanical stress conditions of the IV generation Lead-cooled fast reactor. The experimental results permitted to plot the time-strain creep curve and the characteristic Norton-based curve, simulating the creep behaviour at all stress values. The comparison between the creep curves in air and in lead showed that the LME produces a decrease of creep-rupture time, a reduction of creep strain and then the loss of steel ductility. Moreover, the raw material and fracture surfaces were analyzed by Optical Microscope and Scanning Electron Microscope (SEM). SEM micrographs highlighted that lead changes both the mode and the type of specimen fracture. In addition, it was analyzed the lead action time, as the time after which the corrosion appears with macroscopic effects. Although some tests are still ongoing, it can be assumed that at high stresses, LME takes place after a long time of steel/lead contact while at low stresses, LME tends to prevail on creep effect.
In order to increase the component lifetime of SiC based materials in combustion environments, environmental barrier coatings (EBCs) based on ceramic oxides are used to improve corrosion resistance of SiC, due to their high chemical stability. In this work, mullite and barium-strontium-aluminosilicate (BSAS) coatings were deposited by slurry dip coating on SiC substrates. Slurries were prepared by suspending commercial powders in water or ethanol, using appropriate dispersants. Substrates were dipped into the slurry and subsequently dried and heat treated at high temperature to promote densification. SEM observations were carried out to investigate the microstructure of the obtained coatings and to evaluate crack formation, porosity and adhesion.
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