Literature review: Methods for achieving high powder bed densities in ceramic powder bed based additive manufacturing

Diener, Sarah; Zocca, Andrea; Günster, Jens

doi:10.1016/j.oceram.2021.100191

Cited by 21 publications

(17 citation statements)

References 122 publications

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“…For the powder-based process, a vast body of literature is available on the spreading of powder layers 5,6 and on binder-powder interaction, [7][8][9][10][11][12][13][14][15] whereas for the slurry-based process, there is not much literature on the fundamentals. 8,11,16 One key difference between powderbased binder jetting and the LSD-print process is the higher density of the powder bed usually achieved for the slurry-based system, which is due to the capillary forces developed during drying of the layers.…”

Section: Powder-based and Slurry-based Binder Jettingmentioning

confidence: 99%

Influence of the dispersant on the parts quality in slurry‐based binder jetting of SiC ceramics

et al. 2022

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Binder jetting is establishing more and more in the ceramic industry to produce large complex shaped parts. A parameter with a great impact on the quality of the parts is the binder-powder interaction. The use of ceramic slurries as feedstock for this process, such as in the layerwise slurry deposition-print technology, allows a great flexibility in the composition. Such slurries are typically composed of ceramic powder, water, and small amounts of various additives. The understanding of the effect of these components on the printing quality is thus essential for the feedstock development. Four models were developed regarding the impact of additives, such as dispersants on printing. These models were confirmed or rebutted by experiments performed for an SiC slurry system with two different concentrations of a dispersant and a commercial phenolic resin used as a binder. It is shown that for this system the influence of the dispersant on the curing behavior and the clogging of the pores by dispersant can be neglected. The redispersion of the dispersant after the curing of the resin has no or only a minor effect. However, the wetting behavior determined by the surface energies of the system seem to be most crucial. In case the surface energy of the slurry additive is significantly lower than the surface energy of the binder, the strength of the green parts and the printing quality will be low. This was shown by inverse gas chromatography, contact angle measurement, rheological characterization, and mechanical tests with casted samples.

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Section: Powder-based and Slurry-based Binder Jettingmentioning

confidence: 99%

Influence of the dispersant on the parts quality in slurry‐based binder jetting of SiC ceramics

et al. 2022

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“…Because ThO 2 ceramics are prepared from fine powders (<10 μm) of ThO 2 NC-A and -B, the mobility of very small NCs can be hindered by interparticle friction and forces. 40 ThO 2 NC-A has narrower particle-size distribution and larger particle size with better flowability than those of ThO 2 NC-B. 41 As the flowability of the powder is crucial for a homogeneous green and sintered part structure, 42 it is reasonable that the pore size of the ThO 2 ceramics prepared using ThO 2 NC-A is smaller than that of the ThO 2 ceramics prepared using ThO 2 NC-B.…”

Section: Resultsmentioning

confidence: 99%

“…Furthermore, sintering necks were formed among particles, and the fusion of ThO 2 NCs to form large crystals can be observed (1–8 μm). Because ThO 2 ceramics are prepared from fine powders (<10 μm) of ThO 2 NC-A and -B, the mobility of very small NCs can be hindered by interparticle friction and forces . ThO 2 NC-A has narrower particle-size distribution and larger particle size with better flowability than those of ThO 2 NC-B .…”

Section: Resultsmentioning

confidence: 99%

Synthesis of Thorium Dioxide Nanocrystals via Molten Salt Thermal Decomposition for Nuclear Energy-Related Applications

Zhang

Qian

Liu

et al. 2022

ACS Appl. Nano Mater.

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In addition to uranium, thorium is a vital nuclear element that has broad potential for future nuclear energy applications. Herein, we report the synthesis of cubic structured ThO2 nanocrystals (NCs) based on the decomposition of their nitrate salt in air and in a molten salt medium. Both the processes yield pure ThO2 NCs with average sizes of <100 nm. The ThO2 NCs synthesized in the molten salt medium exhibit better crystallinity and a larger average size of ∼75.1 nm with a narrow size distribution owing to the high-temperature liquid growth environment. The ceramic sintered from the salt-derived ThO2 NCs exhibits a considerably higher relative density of 94.6% and similar thermal properties compared with the ceramic fabricated from fine nanopowders (<10 nm) obtained from direct thermolysis of metal nitrate. This study shows that thermal decomposition in a molten salt medium could be an efficient method for producing highly crystalline metal-oxide NCs of thorium-based fuels used in nuclear energy applications.

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“…Moreover, fine particle sizes can be used in the slurry, as opposed to powder bed processes in which usually coarser powders are needed to fulfill certain criteria regarding powder flowability. These advantages, however, come with the disadvantages of needing an extra drying step and of a more complex de‐powdering 10 . Indeed, powder beds produced by LSD are so densely packed that the powder surrounding the printed parts has to be re‐dispersed in water.…”

Section: Introductionmentioning

confidence: 99%

“…These advantages, however, come with the disadvantages of needing an extra drying step and of a more complex de-powdering. 10 Indeed, powder beds produced by LSD are so densely packed that the powder surrounding the printed parts has to be redispersed in water. This consideration implies that certain requirements of the ink and the powder bed are substantially different between powder-based binder jetting and LSD-print.…”

Section: Introductionmentioning

confidence: 99%

Ink development for the additive manufacturing of strong green parts by layerwise slurry deposition (LSD‐print)

et al. 2023

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Obtaining dense fine ceramics by the binder jetting additive manufacturing process is challenging. A slurry‐based binder jetting process, such as the layerwise slurry deposition (LSD‐print) process, can enable the printing of dense ceramic parts. This work describes a procedure to develop and qualify a suitable ink to manufacture silicon carbide green parts by LSD‐print. Not only the printability but also the compatibility of the ink with the powder bed and the effect of the binding agent on the properties of the green parts are considered. Both aspects are important to obtain high green strength, which is necessary for printing large or thin‐walled parts. Characterization methods, such as rheological and surface tension measurements, are applied to optimize three selected inks. The interplay between ink and powder bed is tested by contact angle measurements and by comparing the biaxial strength of cast and additively manufactured specimens. Out of the three binding agents tested, a polyethyleneimine and a phenolic resin have a high potential for their use in the LSD‐print of silicon carbide green bodies, whereas a polyacrylate binding agent did not show the required properties.

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Literature review: Methods for achieving high powder bed densities in ceramic powder bed based additive manufacturing

Cited by 21 publications

References 122 publications

Influence of the dispersant on the parts quality in slurry‐based binder jetting of SiC ceramics

Influence of the dispersant on the parts quality in slurry‐based binder jetting of SiC ceramics

Synthesis of Thorium Dioxide Nanocrystals via Molten Salt Thermal Decomposition for Nuclear Energy-Related Applications

Ink development for the additive manufacturing of strong green parts by layerwise slurry deposition (LSD‐print)

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