Processing and properties of SiC composites made via binder jet 3D printing and infiltration and pyrolysis of preceramic polymer

Cramer, Corson L.; Armstrong, Herb; Flores‐Betancourt, Alexis; Han, Lu; Elliott, Amy M.; Saito, Tomonori; Nawaz, Kashif

doi:10.1002/ces2.10070

Cited by 21 publications

(11 citation statements)

References 35 publications

(63 reference statements)

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“…Permeability tests were performed on flat disk-shaped specimens according to the procedure outlined in Ref. [23], which quantify the amount of air that permeates through the material when subjected to a pressure differential across the thickness of the disk.…”

Section: Characterization and Mechanical Propertiesmentioning

confidence: 99%

“…The effect of the number of phenolic resin impregnation and pyrolysis (IP) cycles on microstructure, physical, thermal, and mechanical properties is reported. To date, none of the publications on the fabrication of siliconized SiC composites by the reactive melt infiltration of BJ3DP preforms has reported values of gas permeability of the final product, except for objects manufactured by BJ3DP of SiC powder followed by preceramic PIP, 23 which despite being dense, were permeable to air. Here, we demonstrate that it is possible to obtain air impermeable materials with thermal and mechanical properties comparable to traditionally manufactured SiC monoliths but with significantly more design flexibility because of the use of BJ3DP.…”

Section: Introductionmentioning

confidence: 99%

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Properties of SiC‐Si made via binder jet 3D printing of SiC powder, carbon addition, and silicon melt infiltration

et al. 2021

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We report the physical and mechanical properties of ceramic composite materials fabricated by binder jet 3D printing (BJ3DP) with silicon carbide (SiC) powders, followed by phenolic resin infiltration and pyrolysis (IP) to generate carbon, and a final reactive silicon melt infiltration step. After two phenolic resin infiltration and pyrolysis cycles; porosity was less than 2%, Young's modulus was close to 300 GPa, and the flexural strength was 517.6 ± 24.8 MPa. However, diminishing returns were obtained after more than two phenolic resin infiltration and pyrolysis cycles as surface pores in carbon were closed upon the formation of SiC, resulting in reaction choking and residual-free carbon and porosity. The instantaneous coefficient of thermal expansion of the composite was found to be independent of the number of phenolic IP cycles and had values of between 4.2 and 5.0 ppm/°C between 300 and 1000℃, whereas the thermal conductivity was found to have a weak dependence on the number of phenolic IP cycles. While the manufacturing procedures described here yielded highly dense, gas impermeable, siliconized SiC composites with properties comparable to those of bulk siliconized silicon carbide processed according to conventional techniques, BJ3DP enables the manufacture of objects with complex shape, unlike conventional techniques. K E Y W O R D Sbinder jet 3D printing, phenolic impregnation and pyrolysis, reactive melt infiltration, SiC This manuscript has been authored by UT-Battelle LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downl oads/doe-publi c-acces s-plan).

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Section: Characterization and Mechanical Propertiesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Properties of SiC‐Si made via binder jet 3D printing of SiC powder, carbon addition, and silicon melt infiltration

et al. 2021

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“…The thermal behavior of preceramic polymers is important in many manufacturing processes. 18,19,37 The four major reactions that occur during the thermal crosslinking of polysilazanes include hydrosilylation, vinyl polymerization, transamination, and dehydrocoupling (dehydrogenation). 32 The hydrosilylation reaction is rather fast, and its rate can be remarkably increased using a catalyst.…”

Section: Resultsmentioning

confidence: 99%

Processing and 3D printing of SiCN polymer‐derived ceramics

Mahmoudi

Kim

Arifuzzaman

et al. 2021

Int J Applied Ceramic Tech

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Preceramic polymer resins are attractive for the 3D printing of net-shaped ceramic components. Recently various processes have been demonstrated for 3D printing of polymer-derived ceramics (PDCs). Ultimately in these processes, the process outcomes strongly depend on the process parameters. In particular, for PDCs the ceramic density, and ceramic yield are affected by the catalyst concentration and cross-linking duration. Here, we use thermal analysis and FTIR to quantify the interrelation of the process parameters on the process outcome for polysilazanes and demonstrate 3D printing of PDC components based on the best-identified process parameters. The results of this work can be used as guidelines for future additive manufacturing of PDCs.

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“…Specimen processing information is based on previously reported work with more details reported previously. 7 SiC powder with an average diameter of ∼20 μm was binder jet 3D printed on an ExOne Innovent (The ExOne Company, North Huntingdon, PA). The resulting preform was ∼45% dense.…”

Section: Methodsmentioning

confidence: 99%

“…6 Of the various additive manufacturing (AM) approaches available, binder jet 3D printing stands out as a high-throughput method for complex component development. 7 The reason that this method stands out is the relative simplicity of the process. 5 A powder layer is deposited first, then a binding agent (polymer) is printed in as 2D layer, and the process repeated.…”

Section: Introductionmentioning

confidence: 99%

Oxidation performance and limitations of additively manufactured SiC/Si─O─C composites at elevated temperatures

Ridley,

Lance,

Aguirre

et al. 2023

J Am Ceram Soc.

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SiC preforms were infiltrated with polycarbosiloxane preceramic polymer to create low‐cost SiC – SixOyCz matrix composites for possible high temperature application. The effect of specimen annealing conditions on the steam and air oxidation resistance were analyzed. Air exposures from 900–1500°C showed stability of the SixOyCz matrix phase with moderate oxidation resistance. After 900°C exposures, oxidation of the composite is primarily limited to the matrix phase, and only at 1200°C and 1500°C was SiC consumption visualized. Steam cycle exposures at 1200°C resulted in rapid linear oxidation of the composites with induced specimen swelling from volume expansion associated with internal oxidation. Specimens annealed in argon were found to be the most oxidation resistant due to increased matrix crystallinity and carbon retention. The results of this work were used to develop clear strategies for improving the high‐temperature properties of SiC – SixOyCz composites.This article is protected by copyright. All rights reserved

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Processing and properties of SiC composites made via binder jet 3D printing and infiltration and pyrolysis of preceramic polymer

Cited by 21 publications

References 35 publications

Properties of SiC‐Si made via binder jet 3D printing of SiC powder, carbon addition, and silicon melt infiltration

Properties of SiC‐Si made via binder jet 3D printing of SiC powder, carbon addition, and silicon melt infiltration

Processing and 3D printing of SiCN polymer‐derived ceramics

Oxidation performance and limitations of additively manufactured SiC/Si─O─C composites at elevated temperatures

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