Reaction-bonding of aluminum oxide processed by binder jetting

Solis, Daphene Marques; Silva, Antonio V.; Volpato, Neri; Berti, Lucas Freitas

doi:10.1016/j.jmapro.2019.04.008

Cited by 27 publications

(8 citation statements)

References 10 publications

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“…Thus, the addition of coarse powders to the 5 μm powder increases the apparent density by 12.7% (30 μm) and 5.6% (15 μm), improving the tap density by 5.6% (30 μm) and 4.9% (15 μm) [ 13 ]. Moreover, an increase in the density of the sintered material in binder jetting additive manufacturing [ 14 ] has been found when using multimodal, usually bimodal, powders [ 15 , 16 , 17 , 18 , 19 ].…”

Section: Introductionmentioning

confidence: 99%

Preparation of Nano/Micro Bimodal Aluminum Powder by Electrical Explosion of Wires

et al. 2021

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Electrical explosion of aluminum wires has been shown to be a versatile method for the preparation of bimodal nano/micro powders. The energy input into the wire has been found to determine the relative content of fine and coarse particles in bimodal aluminum powders. The use of aluminum bimodal powders has been shown to be promising for the development of high flowability feedstocks for metal injection molding and material extrusion additive manufacturing.

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Section: Introductionmentioning

confidence: 99%

Preparation of Nano/Micro Bimodal Aluminum Powder by Electrical Explosion of Wires

et al. 2021

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“…Generally, the manual granulation method, comprising manual mixing in a crucible, oven drying, Fig. 9 Achieved values of relative green densities and porosities by various special treatment techniques (N stands for no special treatment, G for powder granulation, L for using slurry feedstock, and S for mixing powders of different sizes) [23][24][25]27,37,54,55,57,58,63,64,67,68,73,74,81,82,[86][87][88][89]92,110,156,161] Fig. 10 Achieved values of relative sintered densities and porosities by various special treatment techniques (N stands for no special treatment, C for chemical reaction, G for powder granulation, I for infiltration, L for using slurry feedstock, M for mixing different materials, P for pressing, and S for mixing powders of different sizes) [24,27,37,53,55,[63][64][65][68][69][70][71]77,83,85,86,[88][89]…”

Section: Materials Preparation Techniques For Density Improvementmentioning

confidence: 99%

“…5.2 Chemical Reaction. Chemical reaction is another common method to increase green and sintered densities in ceramic binder jetting, which includes metal oxidation [53,54,79,84], phosphoric acid immersion for calcium phosphate materials [113,117,119,120,122,123,125,126,141,162,163], and pyrolysis of preceramic polymers [83,103]. Metal oxidation uses metal powder as the feedstock material and converts a printed metal part to a ceramic one by oxidation at a high temperature.…”

Section: Mixing Different Materialsmentioning

confidence: 99%

Ceramic Binder Jetting Additive Manufacturing: A Literature Review on Density

Ren

Pei

et al. 2020

Journal of Manufacturing Science and Engineering

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The objective of this review paper is to summarize the current status and identify the knowledge gaps in ceramic binder jetting additive manufacturing, with a particular focus on density. This paper begins with an overview of ceramic binder jetting. Then, it discusses different aspects of density, including various terminologies, measurement methods, and achieved values. Afterward, it reviews two categories of techniques to increase the part density: material preparation techniques (powder granulation, mixing powders of different sizes, using slurry feedstock, and mixing different materials) and postprocessing techniques (sintering, chemical reaction, infiltration, and isostatic pressing). Finally, it presents the knowledge gaps in the literature.

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“…To mitigate these problems, several strategies have been developed, such as the use of powder mixtures [8], the granulation of fine powders with higher surface area [9], the use of slurry feedstocks [10], the use of sintering additives [11], reaction bonding [12], liquid-phase infiltration [13] and isostatic pressing [14] as well as combinations of these [7]. However, powder mixtures can impede powder flowability.…”

Section: Introductionmentioning

confidence: 99%

Improved green and sintered density of alumina parts fabricated by binder jetting and subsequent slurry infiltration

Vogt¹,

Friedrich²,

Stepanyan³

et al. 2021

Prog Addit Manuf

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Additive Manufacturing (AM) of ceramics is a constantly emerging field of interest both in research and in industry. Binder jetting-based AM of ceramics in particular offers the opportunity to produce large ceramic parts with a high wall thickness at a high throughput. One limitation is that it requires flowable powders, which are generally coarse and thus exhibit only limited sintering activity. The resulting low sintered densities impede the commercial binder jetting-based production of dense oxide ceramics. We present an approach to efficiently increase the green density of binder jetted alumina parts by optimized slurry infiltration, which also leads to a significant increase in the sintered density. In a first step, alumina parts were fabricated via binder jetting, using a 20-µm-sized alumina powder, yielding relative green densities of about 47–49%. Initial sintering studies with powder compacts showed that sintering even above 1900 °C is not sufficient to achieve acceptable densification. Therefore, green samples were infiltrated with a highly filled ceramic slurry to fill the remaining pores (about 2–5 µm in size) with smaller particles and thus increase the packing density. Particle volume content (40–50 vol%), particle size (100–180 nm) and the infiltration procedure were adapted for tests on cuboid samples to achieve a high penetration of the green bodies and a high degree of pore filling. In this way, the relative green density could be increased starting from about 47% after binder jetting, to 73.4% after infiltration and drying. After sintering at 1675 °C densities above 90% could be achieved, yielding three-point bending strengths up to 145 MPa. As a conclusion, this approach can be regarded as a promising route for overcoming the drawbacks of the binder jetting process on the way to denser, mechanically more stable sintered alumina parts.

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Reaction-bonding of aluminum oxide processed by binder jetting

Cited by 27 publications

References 10 publications

Preparation of Nano/Micro Bimodal Aluminum Powder by Electrical Explosion of Wires

Preparation of Nano/Micro Bimodal Aluminum Powder by Electrical Explosion of Wires

Ceramic Binder Jetting Additive Manufacturing: A Literature Review on Density

Improved green and sintered density of alumina parts fabricated by binder jetting and subsequent slurry infiltration

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