Preparation of a defect-free alumina cutting tool via additive manufacturing based on stereolithography – Optimization of the drying and debinding processes

Zhou, Maopeng; Liu, Wei; Wu, Haidong; Song, Xuan; Chen, Yong; Cheng, Long; He, Fupo; Chen, Shixi; Wu, Shanghua

doi:10.1016/j.ceramint.2016.04.050

Cited by 172 publications

(78 citation statements)

References 19 publications

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“…Defect‐free alumina parts have also been fabricated by Liu that combined SLA process with water debinding. These properties of Al 2 O 3 parts were similar to those that prepared by the conventional shaping method …”

Section: Introductionsupporting

confidence: 71%

“…These properties of Al 2 O 3 parts were similar to those that prepared by the conventional shaping method. 15 Most of the studies mainly focus on manufacture techniques, slurry preparation, and product properties, whereas the microstructure evolution in the bodies during the sintering process, such as grain growth and pores evolution, has largely neglected. It is well known that ceramic properties are predominantly determined by many factors including manufacturing processes and primary particle.…”

Section: Introductionmentioning

confidence: 99%

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Additive manufacturing and characterization of complex Al₂O₃ parts based on a novel stereolithography method

Xie

et al. 2017

Int J Applied Ceramic Tech

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In this work, we prepared Al2O3 ceramic green parts with complex geometry and architecture using an additive manufacturing process based on stereolithography. The rheological and thermal behavior of Al2O3 slurry was firstly examined and used to establish the conditions for molding and debinding. As opposed to previous researches that only focused on manufacture techniques, the sintering behavior and densification process were systematically investigated. In addition, special attentions were paid to the evolution of microstructure between green bodies and sintered parts. The results showed that debound parts were equipped with uniform particle packing and narrow pore size distribution. The dimensions of the Al2O3 parts changed anisotropically with the different processing steps. The densification process was greatly accelerated by the decrease in pore size and annihilating of interconnected pores in which significant grain growth was observed above 1450°C. The sintered part also had a homogeneous microstructure and no interface between adjacent layers. High densification (relative density of 99.1%) and much desirable Vickers hardness (17.9 GPa) of Al2O3 parts were achieved at the sintering temperature of 1650°C.

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Section: Introductionsupporting

confidence: 71%

Section: Introductionmentioning

confidence: 99%

Additive manufacturing and characterization of complex Al₂O₃ parts based on a novel stereolithography method

Xie

et al. 2017

Int J Applied Ceramic Tech

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“…A two‐step debinding profile was adopted in this work, in which compacts is firstly debound under vacuum to decelerate the pyrolysis rate and then debound in air to guarantee complete removal of the residual carbon.…”

Section: Methodsmentioning

confidence: 99%

3D printing of dense structural ceramic microcomponents with low cost: Tailoring the sintering kinetics and the microstructure evolution

Liu

Tian

et al. 2018

J Am Ceram Soc

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In this study, we have successfully developed a unique 3D printing approach based on mask-image-projection stereolithography (MIP-SL) to fabricate structural ceramics microcomponents with low cost and high efficiency. Ultra-dense submicron crystalline ceramics without fierce grain growth could be obtained via tailoring the sintering kinetics. The ZrO 2 ceramic microcomponents reached the highest relative density (RD) of 99.7% with the average grain size of 0.52 μm upon sintering at 1550°C while the Al 2 O 3 ceramic microcomponents reached its highest RD of 98.31% with the average grain size of 2.6 μm upon sintering at 1600°C.Oxide ceramics microcomponents of fully flexible design can be produced easily without visible defects via the method developed in this study, which demonstrates significant potential in the applications of microelectromechanical systems, micro-optical electronics systems and micro-opto-electro-mechanical systems. The method developed in this study has addressed the problem successfully by healing the interlayer interface defects in densification process via the sintering kinetic window and microstructure evolution. The current work provides a promising opportunity to fabricate structural ceramic microcomponents with complex shape, high precision, and high surface smoothness. K E Y W O R D S

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“…For example, Hagedorn et al [28] reported that SLM of a zirconia toughened alumina (ZTA) ceramic resulted in crack formation that could be avoided by high-temperature preheating below the melting point of the material. In the case of stereolithography manufacturing of alumina, it has been shown [29] that large cracks and delamination between layers could be suppressed using an optimized two-step debinding process. Harrer et al [20] have shown that for Y-TZP zirconia manufactured using the LCM technology, defects could be induced at different steps of the process, especially during the detachment of the green body from the building platform.…”

Section: Introductionmentioning

confidence: 99%

X-ray tomography of additive-manufactured zirconia: Processing defects – Strength relations

Saâdaoui

Khaldoun

Adrien

et al. 2020

Journal of the European Ceramic Society

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Preparation of a defect-free alumina cutting tool via additive manufacturing based on stereolithography – Optimization of the drying and debinding processes

Cited by 172 publications

References 19 publications

Additive manufacturing and characterization of complex Al₂O₃ parts based on a novel stereolithography method

Additive manufacturing and characterization of complex Al₂O₃ parts based on a novel stereolithography method

3D printing of dense structural ceramic microcomponents with low cost: Tailoring the sintering kinetics and the microstructure evolution

X-ray tomography of additive-manufactured zirconia: Processing defects – Strength relations

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Preparation of a defect-free alumina cutting tool via additive manufacturing based on stereolithography – Optimization of the drying and debinding processes

Cited by 172 publications

References 19 publications

Additive manufacturing and characterization of complex Al2O3 parts based on a novel stereolithography method

Additive manufacturing and characterization of complex Al2O3 parts based on a novel stereolithography method

3D printing of dense structural ceramic microcomponents with low cost: Tailoring the sintering kinetics and the microstructure evolution

X-ray tomography of additive-manufactured zirconia: Processing defects – Strength relations

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Additive manufacturing and characterization of complex Al₂O₃ parts based on a novel stereolithography method

Additive manufacturing and characterization of complex Al₂O₃ parts based on a novel stereolithography method