Effect of different sintering additives type on Vat photopolymerization 3D printing of Al2O3 ceramics

Zeng, Yong; Chen, Xingfu; Sun, Lijun; Yao, Haihua; Chen, Jimin

doi:10.1016/j.jmapro.2022.09.022

Cited by 23 publications

(4 citation statements)

References 37 publications

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“…In addition to the stereolithography process parameters, the densification degree of DLP-prepared ceramics is primarily associated with the debinding and sintering process parameters, solid loading of photosensitive suspension, and the incorporation of sintering additives. 51,53 It is well established that moderate solid loading and a certain proportion of sintering aids play a significant role in the density and mechanical performance of 3D-printed ceramics. Upon the results presented here, future experiments will focus on reducing porosity or even achieving full densification to further improve the mechanical performance of textured ceramics based on additive manufacturing technology by the use of appropriate solid loading and sintering additives.…”

Section: Resultsmentioning

confidence: 99%

“…It is worth noting that there is still room for improvement in the mechanical performance of additive‐manufactured Al 2 O 3 ceramics, as full densification has not been achieved. In addition to the stereolithography process parameters, the densification degree of DLP‐prepared ceramics is primarily associated with the debinding and sintering process parameters, solid loading of photosensitive suspension, and the incorporation of sintering additives 51,53 . It is well established that moderate solid loading and a certain proportion of sintering aids play a significant role in the density and mechanical performance of 3D‐printed ceramics.…”

Section: Resultsmentioning

confidence: 99%

See 1 more Smart Citation

Digital light processing‐based additive manufacturing of orientation‐controlled Al₂O₃ ceramics with improved damage tolerance

Wang,

Han,

Zhou

et al. 2024

Int J Applied Ceramic Tech

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Digital light processing (DLP) provides a promising avenue for constructing ceramic parts with high precision and complex shapes, yet the inherent brittleness and strength‐toughness trade‐off hinder their wide applications. Here, according to DLP 3D printing, the textured alumina ceramic components with horizontally aligned textured microstructure were successfully created by adding anisotropically shaped platelets. As a critical process in the preparation of textured ceramics, the alumina platelets were aligned horizontally during printing by using the special shear fields and forming capabilities of DLP technology. The shrinkage, density, microstructure, mechanical performance, and damage‐tolerance behavior of alumina parts with different platelet concentrations were examined, and the toughening mechanisms were investigated. The strength and toughness of ceramics with 5 vol.% platelet addition are increased by 22% and 43%, respectively, as compared with those without platelets. The improved damage tolerance capabilities were primarily ascribed to the collaborative toughening mechanisms stimulated by the platelet addition, including crack branching, crack deflection, uncracked‐ligament bridging, and platelet pull‐out, which increased the crack tortuosity and consumed more fracture energy. The strategy opens up new opportunities to design complex 3D ceramic geometries with bio‐inspired layered or textured architectures, providing optimized damage tolerance.

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Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Digital light processing‐based additive manufacturing of orientation‐controlled Al₂O₃ ceramics with improved damage tolerance

Wang,

Han,

Zhou

et al. 2024

Int J Applied Ceramic Tech

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“…During sintering, the ceramic green body is placed in the muffle furnace at high temperatures, which further reduces the gaps between ceramic particles, resulting in a more robust ceramic structure [24]. Both debinding and sintering require setting appropriate parameters such as time and temperature on the control panel of the muffle furnace [25]. The specific temperature variation curve is shown in Figure 4.…”

Section: Debinding and Sinteringmentioning

confidence: 99%

Vat Photopolymerization of Ceramic Parts: Effects of Carbon Fiber Additives on Microstructure and Mechanical Performance

Wang,

Wu,

Guo

et al. 2024

Materials

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Vat photopolymerization (VPP), as an additive manufacturing (AM) technology, can conveniently produce ceramic parts with high resolution and excellent surface quality. However, due to the inherent brittleness and low toughness of ceramic materials, manufacturing defect-free ceramic parts remains a challenge. Many researchers have attempted to use carbon fibers as additives to enhance the performance of ceramic parts, but these methods are mostly applied in processes like fused deposition modeling and hot pressing. To date, no one has applied them to VPP-based AM technology. This is mainly because the black carbon fibers reduce laser penetration, making it difficult to cure the ceramic slurry and thus challenging to produce qualified ceramic parts. To address this issue, our study has strictly controlled the amount of carbon fibers by incorporating trace amounts of carbon fiber powder into the original ceramic slurry with the aim to investigate the impact of these additions on the performance of ceramic parts. In this study, ceramic slurries with three different carbon fiber contents (0 wt.%, 0.1 wt.%, 0.2 wt.%, and 0.3 wt.%) were used for additive manufacturing. A detailed comparative analysis of the microstructure, physical properties, and mechanical performance of the parts was conducted. The experimental results indicate that the 3D-printed alumina parts with added carbon fibers show varying degrees of improvement in multiple performance parameters. Notably, the samples prepared with 0.2 wt.% carbon fiber content exhibited the most significant performance enhancements.

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“…polymer/inorganic compound), yet fine mixing of the composite powder remains the major barrier of SLS (Chen et al, 2018). Two other prominent AM technologies for ceramics: stereolithography (SLA) and material jetting (MJ) both use UV-curable resin and confer high density and strength to the fabricated final components (Nakai et al, 2021;Willems et al, 2021;Zeng et al, 2022). On the other hand, the drawbacks of using ceramic slurry in SLA and MJ consist in the environmental impact of the toxic photo resin and limited choice of materials (Gibson and Rosen, 2024).…”

Section: Introductionmentioning

confidence: 99%

Material extrusion additive manufacturing of zirconia: from filament characterisation to Weibull statistics

Morfini,

Meng,

Beretta

et al. 2024

RPJ

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Purpose This study aims to investigate the performance of filament-based material extrusion additive manufacturing (MEX), combined with debinding and sintering, as a novel approach to manufacturing ceramic components. Design/methodology/approach A commercial ZrO2 filament was selected and analysed by infra-red (IR) spectroscopy, rheology and thermo-gravimetry. The influence of the print parameters (layer thickness, flow rate multiplier, printing speed) and sintering cycle were investigated to define a suitable printing and sintering strategy. Biaxial flexure tests were applied on sintered discs realised with optimised printing strategies, and the results were analysed via Weibull statistics to evaluate the mechanical properties of printed components. The hardness and thermal conductivity of sintered components were also tested. Findings Layer thickness and flow rate multiplier of the printing process were proved to have significant effect on the density of as-printed parts. Optimised samples display a sintered density >99% of the theoretical density, 20% linear sintering shrinkage, a characteristic flexural strength of 871 MPa with a Weibull modulus of 4.9, a Vickers hardness of 12.90 ± 0.3 GPa and a thermal conductivity of 3.62 W/mK. Gyroids were printed for demonstration purposes. Originality/value To the best of the authors’ knowledge, this work is the first to apply biaxial flexure tests and Weibull statistics to additively manufactured MEX zirconia components, hence providing comparable results to other additive technologies. Moreover, fractography analysis builds the connection between printing defects and the fracture mechanism of bending. This study also provides guidelines for fabricating high-density zirconia components with MEX.

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Effect of different sintering additives type on Vat photopolymerization 3D printing of Al2O3 ceramics

Cited by 23 publications

References 37 publications

Digital light processing‐based additive manufacturing of orientation‐controlled Al₂O₃ ceramics with improved damage tolerance

Digital light processing‐based additive manufacturing of orientation‐controlled Al₂O₃ ceramics with improved damage tolerance

Vat Photopolymerization of Ceramic Parts: Effects of Carbon Fiber Additives on Microstructure and Mechanical Performance

Material extrusion additive manufacturing of zirconia: from filament characterisation to Weibull statistics

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Effect of different sintering additives type on Vat photopolymerization 3D printing of Al2O3 ceramics

Cited by 23 publications

References 37 publications

Digital light processing‐based additive manufacturing of orientation‐controlled Al2O3 ceramics with improved damage tolerance

Digital light processing‐based additive manufacturing of orientation‐controlled Al2O3 ceramics with improved damage tolerance

Vat Photopolymerization of Ceramic Parts: Effects of Carbon Fiber Additives on Microstructure and Mechanical Performance

Material extrusion additive manufacturing of zirconia: from filament characterisation to Weibull statistics

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Product

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Digital light processing‐based additive manufacturing of orientation‐controlled Al₂O₃ ceramics with improved damage tolerance

Digital light processing‐based additive manufacturing of orientation‐controlled Al₂O₃ ceramics with improved damage tolerance