Yttria stabilized zirconia (YSZ) thin wall structures fabricated using laser engineered net shaping (LENS)

Fan, Zhiqi; Zhao, Yitian; Lu, Mingyuan; Huang, Han

doi:10.1007/s00170-019-03322-z

Cited by 27 publications

(8 citation statements)

References 33 publications

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“…Zirconia (ZrO 2 ), often referred to as 'ceramic steel', earns this moniker due to its exceptional mechanical properties such as high strength, wear resistance, and fracture toughness [89]. Its impressive biocompatibility has led to widespread use in biomedical applications, encompassing dental restorations, joint prosthetics, bone repair plates, and orthopedic hip replacements [90,91].…”

Section: Zirconia (Zro 2 )mentioning

confidence: 99%

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Advances and challenges in direct additive manufacturing of dense ceramic oxides

Fan,

Tan,

Kang

et al. 2024

Int. J. Extrem. Manuf.

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Ceramic oxides, renowned for their exceptional combination of mechanical, thermal, and chemical properties, are indispensable in numerous crucial applications across diverse engineering fields. However, conventional manufacturing methods frequently grapple with limitations, such as challenges in shaping intricate geometries, extended processing durations, elevated porosity, and substantial shrinkage deformations. Direct additive manufacturing (dAM) technology stands out as a state-of-the-art solution for ceramic oxides production. It facilitates the one-step fabrication of high-performance, intricately designed components characterized by dense structures. Importantly, dAM eliminates the necessity for post-heat treatments, streamlining the manufacturing process and enhancing overall efficiency. This study undertakes a comprehensive review of recent developments in dAM for ceramic oxides, with a specific emphasis on the laser powder bed fusion and laser directed energy deposition techniques. A thorough investigation is conducted into the shaping quality, microstructure, and properties of diverse ceramic oxides produced through dAM. Critical examination is given to key aspects including feedstock preparation, laser–material coupling, formation and control of defects, in-situ monitoring and simulation. This paper concludes by outlining future trends and potential breakthrough directions, taking into account current gaps in this rapidly evolving field.

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Section: Zirconia (Zro 2 )mentioning

confidence: 99%

“…The later work either incorporated a high energy input or employed absorbing agents for obtaining highly-dense YSZ ceramics in dAM [2,89,93,96,98,99]. Liu et al [96] used an 1 µm fiber laser in L-PBF to fully melt YSZ powder with laser power of 60 W and scanning speeds of 0.01 m•s −1 -0.2 m•s −1 .…”

Section: Zirconia (Zro 2 )mentioning

confidence: 99%

Advances and challenges in direct additive manufacturing of dense ceramic oxides

Fan,

Tan,

Kang

et al. 2024

Int. J. Extrem. Manuf.

Self Cite

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“…With the above advantages being explored, LDED, a material‐structure integration manufacturing technology, has rapidly developed into an emerging MGCs preparation technology. Currently, a variety of high‐performance MGCs, including ZrO 2 , Al 2 O 3 –ZrO 2 , and Al 2 O 3 –YAG–ZrO 2 , and bio ceramics have been successfully prepared using LDED 10,14–16 …”

Section: Introductionmentioning

confidence: 99%

“…Currently, a variety of high-performance MGCs, including ZrO 2 , Al 2 O 3 -ZrO 2 , and Al 2 O 3 -YAG-ZrO 2 , and bio ceramics have been successfully prepared using LDED. 10,[14][15][16] In particular, Al 2 O 3 -based MGCs have become a popular material for LDED process research in view of their excellent comprehensive performance and wide application requirements. 9,[15][16][17] However, the inherent high intrinsic brittleness and thermal expansion coefficient make high-temperature creep resistance become a shortcoming of Al 2 O 3 -based MGCs.…”

Section: Introductionmentioning

confidence: 99%

Cracking mechanism in laser directed energy deposition of melt growth alumina/aluminum titanate ceramics

Huang

et al. 2023

J Am Ceram Soc.

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Thanks to its advantages of high efficiency and near-net shaping, laser directed energy deposition (LDED) is rapidly becoming a remarkable preparation technology for high-purity ceramics. However, the cracking problem in shaping process is always a great challenge for LDED to achieve industrial application. For this purpose, alumina/aluminum titanate melt-growth ceramics (A/AT MGCs) were prepared using LDED system, and the corresponding finite element thermal analysis model was developed. The solidification behavior and cracking mechanism of A/AT MGCs were investigated based on the thermal analysis model, and the influence of process parameters on the cracking characteristics was revealed with experiments. Results show that the crack morphology and distribution are controlled by microstructure and temperature gradient together. The scanning speed of 100-150 mm/min, with better microstructure and lower temperature gradient, is a preferred process window. This study provides theoretical guidance and technical support for the cracking suppression during LDED shaping of ceramics.

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“…After Balla et al 12 used Al 2 O 3 ceramics to verify the feasibility of DLD technology for fabricating melt-grown ceramics, Al 2 O 3 -ZrO 2 ceramics, Al 2 O 3 -YAG eutectic ceramics, zirconate-titanate ceramics, calcium phosphate bioceramics, and ZrO 2 ceramics have also been successfully fabricated in recent years. [13][14][15][16][17] However, with the extremely great thermal stress in DLD process, melt-grown ceramic components are prone to cracking due to its intrinsic brittleness. In recent years, scholars have focused on this issue.…”

Section: Introductionmentioning

confidence: 99%

Effect and mechanism of ZrO₂ doping on the cracking behavior of melt‐grown Al₂O₃ ceramics prepared by directed laser deposition

San

Niu

et al. 2019

Int J Applied Ceramic Tech

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Directed laser deposition (DLD) is a new method for rapidly preparing melt-grown ceramics, but cracking problem greatly limited its application. In this study, cracking behavior of Al 2 O 3 ceramics was suppressed by doping ZrO 2. Crack suppression mechanism of ZrO 2 doping in melt-grown ceramics was also analyzed. Process parameters which are prone to generating cracks were adopted in the experiments, and they contribute to showing the crack clearly. Results show that ZrO 2 doping has remarkable crack suppression effects. It is most obvious when ZrO 2 content is 37 mol%. Compared with those of pure Al 2 O 3 ceramics, crack density reduces by 43.2%, and the number of longitudinal main cracks reduces by 63.2%. Doping of ZrO 2 forms dense composite microstructure with primary α-Al 2 O 3 grains discretely distributing in eutectic continuous matrix. Therefore, initial crack sources are effectively reduced. Morphology of primary Al 2 O 3 grains transforms from cellular to dendritic, which changes crack propagation mode from inter-granular to trans-granular. Mismatch of thermo-physical properties of different phase promotes the arrest, deflection, and bridging phenomena in crack propagation, contributing to crack suppression. On the basis of ZrO 2 doping, we have realized the preparation of crack-free eutectic ceramic (37 mol%ZrO 2) samples through further process optimization. The maximum size of the sample reaches 230 mm.

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Yttria stabilized zirconia (YSZ) thin wall structures fabricated using laser engineered net shaping (LENS)

Cited by 27 publications

References 33 publications

Advances and challenges in direct additive manufacturing of dense ceramic oxides

Advances and challenges in direct additive manufacturing of dense ceramic oxides

Cracking mechanism in laser directed energy deposition of melt growth alumina/aluminum titanate ceramics

Effect and mechanism of ZrO₂ doping on the cracking behavior of melt‐grown Al₂O₃ ceramics prepared by directed laser deposition

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Yttria stabilized zirconia (YSZ) thin wall structures fabricated using laser engineered net shaping (LENS)

Cited by 27 publications

References 33 publications

Advances and challenges in direct additive manufacturing of dense ceramic oxides

Advances and challenges in direct additive manufacturing of dense ceramic oxides

Cracking mechanism in laser directed energy deposition of melt growth alumina/aluminum titanate ceramics

Effect and mechanism of ZrO2 doping on the cracking behavior of melt‐grown Al2O3 ceramics prepared by directed laser deposition

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Effect and mechanism of ZrO₂ doping on the cracking behavior of melt‐grown Al₂O₃ ceramics prepared by directed laser deposition