Computer-Aided Modeling and Additive Manufacturing of Promising Protective Layer Materials for Catalytic Reactors

Nikulshin, P.A.; Dorokhov, V. S.; Ovsienko, O. L.; Rogozina, M. V.; Anikeev, N. A.; Sidel’nikov, I. V.; Chugunov, Svyatoslav

doi:10.1134/s0965544121110098

Cited by 3 publications

(2 citation statements)

References 10 publications

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“…catalytic applications [88][89][90][91][92], ceramic core for investment casting [93][94][95][96][97], dental restoration [6,7,98,99], solid oxide fuel [3,4,100,101], heat exchanger [75,[102][103][104], among others. Figure 5 illustrates some of these potential applications published in related articles.…”

Section: Ceramics By Vat Photopolymerizationmentioning

confidence: 99%

“…In addition to atmospheric air, different atmospheres can be used as vacuum [37,106,181], nitrogen [64,76,92,151,158,224,225], and argon [226][227][228][229][230]. Such atmospheres avoid oxidation (exothermic decomposition) [106,158,231] promoting decreased volatilization/pyrolysis rate of organics, which may reduce deformation in this step [230].…”

Section: Post-processingmentioning

confidence: 99%

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Additive manufacturing of advanced ceramics by digital light processing: equipment, slurry, and 3D printing

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Additive manufacturing (AM) or 3D printing is a set of technologies that fabricate parts by successively adding layers. This technique is already applied in all classes of materials. In ceramic manufacturing, AM allows the fabrication of small series components with greater geometric freedom, lower cost, and reduced delivery time. Among the AM technologies, vat photopolymerization (VP) stands out for its ability to produce ceramic pieces with excellent dimensional accuracy and surface finish. However, there is a shortage of VP commercial equipment dedicated to producing ceramics at an affordable price, given the challenges of dealing with raw material with high particle loading. In this work, which approaches the fabrication of advanced ceramics by digital light processing VP, the feasibility of using a topdown 3D printer prototype and an ordinary commercial bottom-up printer (usually applied in polymer 3D printing) in the processing of ceramic materials was tested. For this, a 3D printer prototype was designed and built, creating an innovative recoating system (patent pending), composed of two blades with distinct and sequential functions. This system aims to overcome the challenge of creating layers for ceramic suspensions, which usually have high viscosity. In addition, photosensitive suspensions were developed seeking to meet process requirements related to high ceramic loading, rheological behavior, photosensitive parameters, and stability.The ceramic powders were selected to evaluate the process using distinct groups of advanced ceramics: nanometric powders (3Y-TZP) and submicrometric powders (electrofused mullite).Furthermore, a combination of natural raw material (zircon) with alumina was used to investigate the in-situ formation of mullite-zirconia composites in 3D printed parts. Thus, photosensitive ceramic suspensions based on a nanometric zirconia powder (3Y-TZP) were developed and characterized, selecting the appropriate components (monomer, photoinitiator, and dispersant). In this way, a ceramic slurry was obtained capable of validating the developed prototype and manufacturing green ceramic bodies. Nonetheless, the same formulation was not suitable for the commercial 3D printer, due to its rheological behavior not being compatible with the equipment. On the other hand, the submicrometric mullite powder allowed the preparation of formulations with high solid loading (up to 50 vol%). These new formulations were successfully used in both pieces of equipment tested. Furthermore, the formulation based on the mixture of ceramic powders (zircon and alumina) showed that the technique can be combined with reactive sintering to create in-situ mullite and zirconia composites. After analysis of the thermal decomposition, a protocol for the thermal treatment was created and the printed bodies were submitted to burning of the organic components and sintering. Both 3D printers tested proved capable of creating dense ceramic pieces (>95%) and with geometries that would be unfeasible or even impossible by other man...

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Section: Ceramics By Vat Photopolymerizationmentioning

confidence: 99%

Section: Post-processingmentioning

confidence: 99%

Additive manufacturing of advanced ceramics by digital light processing: equipment, slurry, and 3D printing

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Filtration Performance of 3D-Printed Ceramic Pellets: Investigation Using CFD and Computed Tomography

et al. 2023

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Filtration Performance of 3D-Printed Ceramic Pellets: Investigation Using CFD and Computed Tomography

Dorokhov,

Ovsienko,

Chugunov

et al. 2023

Neftehimiâ

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This study demonstrates the potential for computer-aided engineering and additive manufacturing techniques to fabricate protective layer materials with a novel design of filtration channels. Using computational fluid dynamics (CFD) simulation for channels of various geometries, potential locations of the capture of solid dust particles in ceramic filter pellets were identified. The filter pellets were fabricated from ceramic material using laser stereolithography. The printed samples were subjected to a filtration test. The CFD simulation of the pellet channels to identify potential filtration locations, followed by a comparative assessment of the simulation results and the post-test X-ray computed tomography (CT) scan of the 3D-printed pellets, demonstrated the feasibility of CFD models for the design of filter materials. The study findings are intended for the development of innovative protective materials with filtering capabilities to be implemented in specific industrial refining applications

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Computer-Aided Modeling and Additive Manufacturing of Promising Protective Layer Materials for Catalytic Reactors

Cited by 3 publications

References 10 publications

Additive manufacturing of advanced ceramics by digital light processing: equipment, slurry, and 3D printing

Additive manufacturing of advanced ceramics by digital light processing: equipment, slurry, and 3D printing

Filtration Performance of 3D-Printed Ceramic Pellets: Investigation Using CFD and Computed Tomography

Filtration Performance of 3D-Printed Ceramic Pellets: Investigation Using CFD and Computed Tomography

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