Direct ink writing of ZrB2-SiC chopped fiber ceramic composites

Kemp, James W.; Diaz, Abel A.; Malek, Elizabeth; Croom, Brendan P.; Apostolov, Zlatomir D.; Kalidindi, Surya R.; Compton, Brett G.; Rueschhoff, Lisa M.

doi:10.1016/j.addma.2021.102049

Cited by 20 publications

(40 citation statements)

References 67 publications

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“…Fortunately, some attempts were carried out on the additive manufacturing of UHTCs, such as by Feilden et al [110], who prepared HfB 2 -based UHTC by a so-called robocasting additive manufacturing technique, as shown in Figure 8a. And Kemp et al [111], who also prepared ZrB 2 -SiC UHTC chopped fiber ceramic composites by a direct ink writing additive manufacturing technique, as shown in Figure 8b. To the best of our knowledge, the key issues involved in the additive manufacturing of UHTCs include the dispersion of a ceramic slurry, the processing of the green part, and the sintering, which are similar to traditional colloidal processing technologies.…”

Section: Prospectsmentioning

confidence: 99%

“…Therefore, it is believed that additive manufacturing techniques will be the most useful methods for fabricating complex-shaped UHTC components in the future. Reproduced with permission from [111].…”

Section: Prospectsmentioning

confidence: 99%

“…Reproduced with permission from [110]. (b) Direct ink writing of ZrB 2 -SiC UHTC chopped fiber ceramic composites, all scale bars were 1 cm.Reproduced with permission from[111].…”

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confidence: 99%

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Colloidal Processing of Complex-Shaped ZrB2-Based Ultra-High-Temperature Ceramics: Progress and Prospects

2022

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Ultra-high-temperature ceramics (UHTCs), such as ZrB2-based ceramics, are the most promising candidates for ultra-high-temperature applications. Due to their strong covalent bonding and low self-diffusion, ZrB2-based UHTCs are always hot-pressed at temperatures above 1800 °C. However, the hot-pressing technique typically produces disks or cylindrical objects limiting to relatively simple geometrical and moderate sizes. Fabrication of complex-shaped ZrB2-based UHTC components requires colloidal techniques. This study reviews the suspension dispersion and colloidal processing of ZrB2-based UHTCs. The most important issues during the colloidal processing of ZrB2-based UHTCs are summarized, and an evaluation of colloidal processing methods of the ZrB2-based UHTCs is provided. Gel-casting, a net or near-net colloidal processing technique, is believed to exhibit a great potential for the large-scale industrialization of ZrB2-based UHTCs. In addition, additive manufacturing, also known as 3D printing, which has been drawing great attention recently, has a great potential in the manufacturing of ZrB2-based UHTC components in the future.

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Section: Prospectsmentioning

confidence: 99%

Section: Prospectsmentioning

confidence: 99%

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Colloidal Processing of Complex-Shaped ZrB2-Based Ultra-High-Temperature Ceramics: Progress and Prospects

2022

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“…Moreover, with the tape casting, only a low amount of fibres (10-15 vol%) can be added [34]. Recently, the inks based on ZrB 2 and short fibres have been prepared by three-dimensional (3D) printing [35,36]. This technique offers the possibility of creating near-net-shaped components with a controlled fibre alignment [37].…”

Section: Introduction mentioning

confidence: 99%

“…However, one major drawback of this process is still represented by a low amount of fibres that can be incorporated, ranging between 5% and 10%. Moreover, another problem of this process is matrix cracking due to the presence of the fibres [36].…”

Section: Introduction mentioning

confidence: 99%

A novel approach for manufacturing of layered, ultra-refractory composites using pliable, short fibre-reinforced ceramic sheets

MOR¹,

Vinci²,

Failla³

et al. 2023

Journal of Advanced Ceramics

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A new additive technique for manufacturing of short fibre-reinforced ultra-refractory ceramics is presented. This technique allows the fabrication of solvent-free, thin (~100 µm), flexible, and easy-to-handle sheets suitable for fabricating homogeneous or layered structures. A large range of compositions, in terms of matrix and fibre volumetric contents, from 0% to 100% is possible. The amount of short carbon fibres incorporated in the sheets ranged from 20 to 50 vol%, whereas the fibre length ranged from 3 to 5 mm. The matrix composition investigated with this technique consisted of ZrB 2 /SiC/Y 2 O 3 . By increasing the fibre amount from 35 to 50 vol%, an improvement of mechanical properties was observed. Four-point flexural strength (σ) ranged from 107 to 140 MPa, depending on the amount of carbon fibres (C f ). The same holds true for the work of fracture, ranging from 108 to 253 J/m 2 . Functionally graded composites were fabricated by overlapping sheets with a fibre gradient (0%-50%).

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Continuous Carbon Fiber Reinforced SiC Ceramic Matrix Composites by Vertical Fiber Laying Combined with Material Extrusion 3D Printing

Li,

Wang,

Gao

et al. 2024

Adv Eng Mater

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3D printing was reported in the fabrication of continuous carbon fiber reinforced silicon carbide ceramic matrix composites (Cf/SiC CMCs), however, there are layer defects in the 3D printed materials, manifested as weak mechanical properties between layers. Therefore, it is essential and urgent to study how to improve the mechanical properties of 3D printed Cf/SiC CMCs at the layers. In this paper, a novel processing technique which combined vertical fiber laying method with material extrusion (ME) 3D printing was proposed to manufacture Cf/SiC CMCs. Firstly, a self‐developed 3D printing fixed‐axis rotating lifting synchronizer was adopted. The vertical fiber laying of continuous carbon fibers (Cf) in Z‐direction was introduced into the X‐Y printing plane. Cf bundles were fixed to a fixed block through a vertical bundle splitter after passing through a rotating transport system. A self‐developed fixed‐axis rotating lifting synchronizer was utilized to achieve the fixed‐axis transportation of Cf. The internal gear drove the link to rotate to avoid the nozzle path, and the bolt was lifted after completing one layer of printing. Five cycles of precursor infiltration and pyrolysis (PIP) were performed to achieve the densification of Cf/SiC CMCs. The effects of Cf bundle numbers on the flexural strength and fracture work of Cf/SiC CMCs were studied. The best performing composite is Cf/SiC CMC with 6 bundles, and the maximum flexural strength and fracture work is 63.84 ± 6.62 MPa and 1291.99 ± 161.39 J/m3, respectively. Compared with pure SiC, the fracture work of Cf/SiC CMC was increased by 2.54 times. This new idea presented in this study lay the future for the preparation of Cf/SiC CMCs.This article is protected by copyright. All rights reserved.

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Direct ink writing of ZrB2-SiC chopped fiber ceramic composites

Cited by 20 publications

References 67 publications

Colloidal Processing of Complex-Shaped ZrB2-Based Ultra-High-Temperature Ceramics: Progress and Prospects

Colloidal Processing of Complex-Shaped ZrB2-Based Ultra-High-Temperature Ceramics: Progress and Prospects

A novel approach for manufacturing of layered, ultra-refractory composites using pliable, short fibre-reinforced ceramic sheets

Continuous Carbon Fiber Reinforced SiC Ceramic Matrix Composites by Vertical Fiber Laying Combined with Material Extrusion 3D Printing

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