Direct Laser Additive Manufacturing of Ceramics by Powder Deposition

Abstract

In this study, LMD-CLAD® process (Direct Laser Additive manufacturing) is developed for alumina and Al2O3-Y2O3-ZrO2ternary eutectic compositions. Powder flowability, laser-material interaction and thermal gradient control have been investigated. Powder granules of aforementioned compositions have been designed by spray-drying. Particle size distribution, Hall funnel test and SEM observations have been performed. Flowability has been improved by 20% in order to match with the LMD-CLAD® process by adjusting their density, size and surface quality. Otherwise, optical absorption of the ceramics has been increased up to 90% thanks to the addition of doping ions. With such a flowability improvement, laser powder deposition tests were successful and enabled us to investigate the effect of laser parameters and thermal environment on deposited beads state.

Effect of Laser Power on the Deposition of Alloy 718 Powder on Alumina Substrate Using Laser Directed Energy Deposition: A Single-Track Study

“…However, the quality of the produced materials mainly depends on the optimal process parameters, and interaction between metals and ceramics in the melt pool [6]. Moreover, the low thermal conductivity and low thermal shock resistance make ceramics sensitive to sudden temperature rise [8,9]. This makes studying the effect of process parameters on FGM deposition and its properties crucial.…”