The fracture properties of metal‐ceramic composites manufactured via stereolithography

Abstract

In this work, metal-ceramic composite parts based on aluminum and alumina were manufactured in a two-stage process. First, silica was printed using a vat photopolymerization technique, followed by a curing and sintering stage, which resulted in ceramic precursors. Subsequently, these samples were subjected to a metal infiltration process to form interpenetrating metal-ceramic composites (IPCs). These composites have attracted considerable attention in the aerospace and defense sector due to the ductility associated to the metal phase and the strength offered by the ceramics. A novel application with utility includes composite tooling which requires a low coefficient of thermal expansion (CTE) for high temperatures. The investigated specimens were tested for surface quality and shrinkage, followed by a mechanical characterization. It was recorded that the samples presented a 12%-18% of shrinkage after the sintering process. The mechanical testing showed that the hardness, compression, and flexural strength of the composites were superior to the printed and sintered ceramics. A thermal analysis on the composite showed that its CTE is more than two times lower than the common composite tooling materials. It is expected that the present work can provide the foundations for further studies on these systems in the refractory, automotive, and armor-based fields. K E Y W O R D Sceramic-metal systems, fracture, mechanical properties 414 | MUMMAREDDY Et Al.

3D Printed TiO2 Negative Electrodes for Sodium-Ion and Lithium-Ion Batteries Using Vat Photopolymerization

“…These results can be explained by the fusion of the ceramic particles during the sintering stage (Fig. S2) as reported by Mummareddy et al 44 When comparing the stress-strain profiles of the solid electrodes in the green and sintered state (Fig. 5a, it can be observed that the green sample exhibits a relatively higher ductility than the sintered specimen due the influence of the polymer resin.…”

Bio‐Inspired Ceramic–Metal Composites Using Ceramic 3D Printing and Centrifugal Infiltration

“…The properties of 3D printed ceramics can be controlled and potentially be improved by studying the particle concentration and size distribution in photopolymer resin, and the sintering schedule. [ 62 ]…”

“…[27] The approach demonstrated here uses only a calculated amount of metal and produces lesser waste compared to techniques presented in previous studies., [41,43,45,46,61] Second, the infiltration process utilized for this work is time-independent, that is, the amount of infiltration into the ceramic preform is not influenced by the amount of time the molten metal was molten. For ceramic-metal fabrication techniques like pressureless infiltration [27,30,31] and reactive-metal infiltration [24,62,63] the extent of infiltration is directly proportional to the time the molten metal stayed in contact with the preform. [24,30] Third, the control over the design of individual phase morphologies, achieved utilizing the flexibility of ceramic additive manufacturing, provides us with a tool for the development of new architectural designs that can be tailored to suit different applications.…”

“…The properties of 3D printed ceramics can be controlled and potentially be improved by studying the particle concentration and size distribution in photopolymer resin, and the sintering schedule. [62] 5. Conclusions 1) This paper presented a method for the preparation of bioinspired ceramic-metal composites while attempting to bridge the gap between conventional, additive manufacturing, and bio-inspired fabrication methods.…”

Numerical and Experimental Investigation on the Self‐Healing Potential of Interpenetrating Metal–Ceramic Composites

“…[3] Composites with an advanced, interpenetrating (also bi-or co-continuous) microstructure allows for an enhancement of various properties such as stiffness, [4,5] strength, [6] toughness, [7] wear, [8,9] as well as thermal expansion. [4,10] In particular, the possibility to combine and optimize two or more different features simulataneously, e.g., mechanical strength and thermal expansion or thermal/electrical conductivity, [11,12] thus creating multifunctional materials makes interpenetrating composites stand out compared to classical particle or fiber-reinforced MMCs.…”