Preparation of alumina-toughened zirconia via 3D printing and liquid precursor infiltration: manipulation of the microstructure, the mechanical properties and the low temperature aging behavior

Wu, Haidong; Liu, Wei; Lin, Lu; Lian, Li; Li, Yanhui; Tian, Zhiling; Zhao, Zhe; Ji, Xuanrong; Xie, Zhipeng; Wu, Shanghua

doi:10.1007/s10853-019-03432-9

Cited by 25 publications

(11 citation statements)

References 28 publications

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“…2c shows that the shell is amorphous; and Fig. 2d presents the lattice fringes of Al2O3 (2)(3)(4)(5)(6)(7)(8)(9)(10)(11)(12)(13) and (-114) planes with interplanar spacing of about 0.201 nm and 0.259 nm, respectively, indicating that the core is Al2O3 crystalline. This result verifies that a uniform amorphous deposition was formed on the surface of the Al2O3 particle.…”

Section: Characterization Of Cp Processed Al 2 O 3 Powdermentioning

confidence: 98%

“…The power density in modern electronic systems is now increasing at an unprecedented speed, thus it is urgent to fabricate the fin-type Al2O3 ceramic heat sinks and microchannel substrates with complex shapes, in order to dissipate heat quickly and protect valuable electronic components effectively. However, the high hardness and low toughness of structural ceramics make it difficult to shape and machine complex-shaped ceramic parts [4].…”

Section: Introductionmentioning

confidence: 99%

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Microstructure refinement - homogenization and flexural strength improvement of Al2O3 ceramics fabricated by DLP-stereolithography integrated with chemical precipitation coating process

Nie

Sheng

et al. 2020

Preprint

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In this study, the chemical precipitation coating (CP) process was creatively integrated with DLP-stereolithography based 3D printing for refining and homogenizing the microstructure of 3D printed Al2O3 ceramic. Based on this novel approach, Al2O3 powder was coated with a homogeneous layer of amorphous Y2O3; with the coated Al2O3 powder found to make the microstructure of 3D printed Al2O3 ceramic more uniform and refined, as compared with the conventional mechanical mixing (MM) of Al2O3 and Y2O3 powders. The grain size of Al2O3 in Sample CP is 64.44% and 51.43% lower than those in the monolithic Al2O3 ceramic (AL) and Sample MM, respectively. Sample CP has the highest flexural strength of 455.37±32.17 MPa, which is 14.85% and 25.45% higher than those of Samples MM and AL, respectively; also Sample CP has the highest Weibull modulus of 16.88 among the three kinds of samples. Moreover, the fine grained Sample CP has a close thermal conductivity to the coarse grained Sample MM because of the changes in morphology of Y3Al5O12 phase from semi-connected (Sample MM) to isolated (Sample CP). Finally, specially designed fin-type Al2O3 ceramic heat sinks were successfully fabricated via the novel integrated process, which has been proven to be an effective method for fabricating complex-shaped Al2O3 ceramic components with enhanced flexural strength and reliability.

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Section: Characterization Of Cp Processed Al 2 O 3 Powdermentioning

confidence: 98%

Section: Introductionmentioning

confidence: 99%

Microstructure refinement - homogenization and flexural strength improvement of Al2O3 ceramics fabricated by DLP-stereolithography integrated with chemical precipitation coating process

Nie

Sheng

et al. 2020

Preprint

Self Cite

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“…In addition to the economical evaluation, we should also consider the important aspects related to the realization of parts with completely new designs and positive impacts on environmental sustainability due to the limited production of wastes and the sustainable use of raw materials. Finally, zirconia-based composites represent a new class of materials for applications with 3D printing technologies [38][39][40][41][42]: the need for the complex or customized shapes required in the field of biomaterials could be more easily satisfied by AM techniques. Additional studies are, however, required in order to demonstrate that AM can be conveniently applied to zirconia-alumina composites to produce reliable components.…”

Section: Introductionmentioning

confidence: 99%

New Perspectives on Zirconia Composites as Biomaterials

et al. 2021

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Zirconia–alumina composites couple the high toughness of zirconia with the peculiar properties of alumina, i.e., hardness, wear, and chemical resistance, so they are considered promising materials for orthopedic and dental implants. The design of high performance zirconia composites needs to consider different aspects, such as the type and amount of stabilizer and the sintering process, that affect the mechanics of toughening and, hence, the mechanical properties. In this study, several stabilizers (Y2O3, CuO, Ta2O5, and CeO2) were tested together with different sintering processes to analyze the in situ toughening mechanism induced by the tetragonal–monoclinic (t–m) transformation of zirconia. One of the most important outcomes is the comprehension of the opposite effect played by the grain size and the tetragonality of the zirconia lattice on mechanical properties, such as fracture toughness and bending strength. These results allow for the design of materials with customized properties and open new perspectives for the development of high-performance zirconia composites for orthopedic implants with high hydrothermal resistance. Moreover, a near-net shape forming process based on the additive manufacturing technology of digital light processing (DLP) was also studied to produce ceramic dental implants with a new type of resin–ceramic powder mixture. This represents a new frontier in the development of zirconia composites thanks to the possibility to obtain a customized component with limited consumption of material and reduced machining costs.

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“…Alumina (Al 2 O 3 ) ceramic has been widely used in thermal management applications, such as substrates, heat sinks, and packaging materials for integrated and low toughness of structural ceramics make it difficult to shape and machine complex-shaped ceramic parts [4]. The conventional ceramic-shaping methods, such as dry pressing, isostatic pressing, gel casting, injection molding, etc.…”

Section: Introduction mentioning

confidence: 99%

Microstructure refinement-homogenization and flexural strength improvement of Al2O3 ceramics fabricated by DLP-stereolithography integrated with chemical precipitation coating process

Nie

Sheng

et al. 2021

J Adv Ceram

Self Cite

View full text Add to dashboard Cite

In this study, the chemical precipitation coating (CP) process was creatively integrated with DLP-stereolithography based 3D printing for refining and homogenizing the microstructure of 3D printed Al2O3 ceramic. Based on this novel approach, Al2O3 powder was coated with a homogeneous layer of amorphous Y2O3, with the coated Al2O3 powder found to make the microstructure of 3D printed Al2O3 ceramic more uniform and refined, as compared with the conventional mechanical mixing (MM) of Al2O3 and Y2O3 powders. The grain size of Al2O3 in Sample CP is 64.44% and 51.43% lower than those in the monolithic Al2O3 ceramic and Sample MM, respectively. Sample CP has the highest flexural strength of 455.37±32.17 MPa, which is 14.85% and 25.45% higher than those of Samples MM and AL, respectively; also Sample CP has the highest Weibull modulus of 16.88 among the three kinds of samples. Moreover, the fine grained Sample CP has a close thermal conductivity to the coarse grained Sample MM because of the changes in morphology of Y3Al5O12 phase from semi-connected (Sample MM) to isolated (Sample CP). Finally, specially designed fin-type Al2O3 ceramic heat sinks were successfully fabricated via the novel integrated process, which has been proven to be an effective method for fabricating complex-shaped Al2O3 ceramic components with enhanced flexural strength and reliability.

show abstract

Preparation of alumina-toughened zirconia via 3D printing and liquid precursor infiltration: manipulation of the microstructure, the mechanical properties and the low temperature aging behavior

Cited by 25 publications

References 28 publications

Microstructure refinement - homogenization and flexural strength improvement of Al2O3 ceramics fabricated by DLP-stereolithography integrated with chemical precipitation coating process

Microstructure refinement - homogenization and flexural strength improvement of Al2O3 ceramics fabricated by DLP-stereolithography integrated with chemical precipitation coating process

New Perspectives on Zirconia Composites as Biomaterials

Microstructure refinement-homogenization and flexural strength improvement of Al2O3 ceramics fabricated by DLP-stereolithography integrated with chemical precipitation coating process

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