Additive Manufacturing of Ceramic-based Materials: Process Development, Materials, Process Optimization and Applications: Session I: Extrusion-based AM
Sponsored by: ACerS Engineering Ceramics Division, ACerS Basic Science Division, ACerS Manufacturing Division
Program Organizers: Xuan Song, University of Iowa; Lei Chen, University of Michigan-Dearborn; Xiangyang Dong, Arizona State University; Yiquan Wu, Alfred University; Paolo Colombo, University of Padova; Rajendra Bordia, Clemson University; Long-Qing Chen, The Pennsylvania State University
Monday 8:00 AM
October 18, 2021
Room: A112
Location: Greater Columbus Convention Center
Session Chair: Rajendra Bordia, Clemson University; Xuan Song, University of Iowa
8:00 AM Invited
A Review of Extrusion-based AM via Robocasting: Joe Cesarano1; 1Robocasting Enterprises
A brief perspective of 3-D printing ceramic materials will be presented in general and more specifically for a technique known as robocasting. Robocasting is a specific subset of extrusion-based AM techniques utilizing concentrated fine-particulate pastes carried in a volatile solvent medium. Removal of the solvent transforms the paste into a solid-like state thereby “curing” the particulate assemblage and facilitating the creation of components. Relationships between inter-particle forces and rheology which control robocasting will be discussed. Robocasting is particularly suitable for commercial-scale manufacturing of porous lattice structures for filtration of molten metals, catalyst supports, CO2 sorbent monoliths, and load-bearing bone scaffolds. Custom labware, components with internal structures (e.g., heat exchangers), and multi-material capabilities will be presented. The character and performance of these structures will be reviewed.Considerations for designing parts most amenable to robocasting will be discussed as well as the advantages, disadvantages, limitations, and future challenges.
8:30 AM
Now On-Demand Only - Extrusion-based Additive Manufacturing of Silicon Carbide: Ruoyu Chen1; Adam Bratten1; Joshua Rittenhouse1; Haiming Wen1; 1Missiouri University of Science and Technology
Due to its excellent high-temperature properties and stability, silicon carbide (SiC) is a candidate material for many applications in extreme environments. However, traditional SiC manufacturing techniques are limited in geometric flexibility and accuracy, typically requiring long times and high cost. Additive manufacturing (AM) of SiC is a promising solution to current problems. In this work, an extrusion-based AM technique was used followed by a pressureless field-assisted sintering technique to produce highly dense specimens with no warpage. Microstructure characterization of green and sintered bodies manufactured using this technique was performed by scanning electron microscopy and x-ray diffraction. The effects of rheology of the printing slurry and printing parameters on the final printed specimens were investigated. Finally, a machine learning model was developed to relate printing parameters to the precision of the printed product. Our manufacturing technique is novel and feasible for production of geometrically complex SiC parts.
8:50 AM
Highly Loaded Aqueous Silicon Carbide Suspensions for Direct Ink Writing: Tess Marconie1; Kyle Cox1; Jeffrey Youngblood1; Rodney Trice1; 1Purdue University
Silicon carbide (SiC) is a material of interest for many applications due to its good mechanical properties, oxidation resistance, and high thermal conductivity. Colloidal processing and pressureless sintering can enable forming of complex shaped, dense SiC parts. Direct ink writing (DIW) is a colloidal processing technique where ceramic suspensions are extruded through a nozzle along a path, building up a part layer-by-layer. Ceramic suspensions appropriate for DIW must exhibit shear thinning behavior for extrusion, have a yield stress to retain their shape after extrusion, and have a high particle loading to reduce drying defects. In this work, highly loaded (>50% by volume) aqueous SiC suspensions are developed using small amounts (<5% by volume) of polyethylenimine and polyvinylpyrrolidone additives. The effect of particle loading and polyvinylpyrrolidone amount on the rheological properties and print quality are determined. Density, microstructure, and mechanical properties of direct ink written, pressurelessly sintered SiC will be presented.
9:10 AM
The Influence of Print Layer Orientation on Silicon Carbide Formed via Direct Ink Writing: Kyle Cox1; Tess Marconie1; Jeffrey Youngblood1; Rodney Trice1; 1Purdue University
Silicon carbide is a useful ceramic due to its high melting temperature and high strength. This makes it an attractive material for use in both traditional aircraft and hypersonic vehicles. In this study, additively manufactured silicon carbide, processed via direct ink writing (DIW) of a 53 vol% colloidal suspension, can achieve densities >95% through pressureless sintering. Each part was printed to have a different layer orientation, or to have the angle change between each layer. Four-point bend testing was performed to determine flexural strength of DIW parts. Weibull analysis was performed on each DIW layer configuration to determine the characteristic strength. SEM and optical microscopy were used to analyze the fracture surface.
9:30 AM
Examining the Changes in Micro-mechanical Properties of 3D Printed Cement Paste Using Grid Nanoindentation Coupled with SEM/EDS: Michael Kosson1; Lesa Brown1; Florence Sanchez1; 1Vanderbilt University
Extrusion-based 3D printing using ‘cement inks’ is a promising emerging technology in the construction and infrastructure industries. However, the pressure used to drive extrusion may have dynamic effects on the composition and microstructure of formed filaments. The effects of the extrusion process on microstructural mechanical properties are not well understood. This study employs grid nanoindentation coupled with scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) to examine the changes in mechanical and chemical properties of a cement ink’s heterogeneous microstructure between regions of 3D printed samples corresponding to different stages of the printing process.
9:50 AM Invited
Additive Manufacturing of Ceramics for Aerospace Applications: Lisa Rueschhoff1; William Costakis1; Connor Wyckoff1; Matthew Dickerson1; Michael Cinibulk1; 1Air Force Research Laboratory
The cruise altitudes and speed of flight will be higher than ever before for next generation aerospace applications. While this will enable superior efficiency and reach, it comes at the cost of harsher environments experienced by the component materials. Beyond increased temperature capability, ceramics also offer increased erosion resistance, higher stiffness, lower density, and in some cases, multi-functional properties. Additive manufacturing (AM) of ceramics offers a more agile manufacturing method to create the complex-shaped components needed for next generation component designs. This talk will give an overview of ceramic AM techniques and targeted aerospace applications. Special focus will be given to the technique of direct ink writing of ceramics and composites. Details on selecting and understanding the necessary ink design, rheology, and print parameters will be discussed and be compared between inks with varied solvents (i.e. water and flowable preceramic polymer).
10:20 AM Break
10:40 AM
Now On-Demand Only - Out of the Lab: 3D Printing on Non-ideal Surfaces: Domenic Cipollone1; Javier Mena1; Konstantinos Sierros1; Edward Sabolsky1; 1West Virginia University
3D printing enables in-situ fabrication of printed electronics. However, printing substrates may be rough, highly porous, and feature zones with discrete wetting or surface properties. For a given geometry, the modulation of material processes and property parameters to maintain geometry remains a significant challenge. Therefore, in this work we assess the feasibility of printing on non-ideal surfaces via direct ink writing. Initially, mixture design and sequential learning experiments are used to synthesize and tailor structural and conductive ceramic ink rheology. In order to maintain printing and sensor fidelity, techniques such as surface contouring and laser adjusted feedback are assessed to modulate the nozzle height and printing parameters in real-time. Using the inks, thermistors and strain sensors are deposited on curved and macroporous surfaces. Profilometry and microscopy are used to characterize the deposited geometries and assess system functionality. Ultimately, sensor performance is studied as a function of the processing-properties relationships.