Additive Manufacturing of Ceramic-based Materials: Process Development, Materials, Process Optimization and Applications: Additive Manufacturing of Ceramic-based Materials Process Development, Materials, Process Optimization and Applications I
Sponsored by: ACerS Engineering Ceramics Division, ACerS Basic Science Division, TMS: Additive Manufacturing Committee, TMS: Computational Materials Science and Engineering Committee
Program Organizers: Lei Chen, University of Michigan-Dearborn; Xuan Song, University of Iowa; Nahum Travitzky, University of Erlangen-Nuremberg; Yiquan Wu, Alfred University; Paolo Colombo, University of Padova; Rajendra Bordia, Clemson University; Long-Qing Chen, Pennsylvania State University
Monday 8:00 AM
November 2, 2020
Room: Virtual Meeting Room 6
Location: MS&T Virtual
Session Chair: Lei Chen, University of Michigan-Dearborn
8:00 AM
Introductory Comments: Additive Manufacturing of Ceramic-based Materials: Process Development, Materials, Process Optimization and Applications: Lei Chen1; 1University of Michigan-Dearborn
Introductory Comments
8:05 AM Invited
Ultra-fast, Selective Laser Sintering during Additive Manufacturing of Alumina: Xiao Geng1; Jincheng Lei1; Shenglong Mu1; Hai Xiao1; Jianhua Tong1; Rajendra Bordia1; Fei Peng1; 1Clemson University
Selective laser sintering is an important step for additive manufacturing of dense ceramics. We found an ultra-fast sintering phenomenon of alumina achieved using scanning laser irradiation. Using CO2 laser irradiation, micrometer alumina powder can be sintered to close-to full density within a few seconds. The relative density and grain size of the laser-sintered alumina gradually decreased from the center of the laser beam to the edge. Anisotropy of the grain size was observed along and perpendicular to the scanning direction. The sintering master curve of grain size versus relative density, which reflects the sintering mechanism, was found to be affected by the laser scanning speed. When the laser scanning speed was 0.1mm/s, grain size suppression was found for even at high density. However, at lower scanning speed, there was significant grain growth in the regions where the relative density was greater than 90%.
8:45 AM
Fast Fabrication of Bioceramics Parts by Combining Stereolithography and Microwave Sintering: Anne Leriche1; Hugo Curto1; Florian Jean1; Shaan Chamary1; Anthony Thuault1; Fabrice Petit2; 1Université Polytechnique Hauts-de-France; 2BCRC
The fast fabrication of customized ceramic parts for biomedical applications is one of the today challenge. This work proposes to combine two rapid manufacturing techniques: the micro-stereolithography (SLA) allowing a rapid shaping of complex ceramic parts and the microwave thermal treatment allowing the debinding and the sintering within a very short time. This technology was applied to two bioceramics types: alumina, zirconia and composites materials for dental crowns or implants and hydroxyapatite for scaffolds. For these porous parts, the interest to use the stereolithography technique is an easy achievement of porous objects with a control of pores and pore interconnection sizes and shape to favor the cell invasion. For all the investigated materials, it was shown the coupling SLA and MW sintering leads to similar mechanical properties than those obtained by conventional shaping and sintering and that it allows to obtain customized parts within a few hours.
9:05 AM
Additive Manufacturing of 8 mol % Yttria Stabilized Zirconia Ceramics: John Zaengle1; S.K. Sundaram1; Shawn Allan2; 1Alfred University; 2Lithoz America LLC
We have demonstrated successful 3D printing of 8 mol % yttria stabilized zirconia. YSZ powders of varying sizes were acquired from commercial suppliers. Particle size, surface area, composition, and particle imaging were completed to characterize each powder before slurry preparation. Particles with surface area of 8 m2/g provided ideal solids loading in slurries. Our target was printing with 50% solid loading using CeraFab-8500. Sample disk were printed and sintered. Scanning electron microscopy and energy dispersive spectrometry were used to record microstructure and chemical speciation in these ceramics. Temperature controlled electrical conductivity was measured using appropriate electrode. These results were compared to samples of traditionally pressed ceramics to determine the effects 3D printing has on conductivity and strength of green and sintered ceramics. Areas of focus are the effects layering may have on structure and conductivity as well as the effects the addition of photosensitive polymers has on sintered ceramics density.
9:25 AM
Effects of Printing Parameters on Microstructure and Mechanical Properties of Binder Jet 3D Printed WC-Co: Katerina Kimes1; Pierangeli Rodriguez De Vecchis1; Danielle Brunetta1; Drew Elhassid2; Markus Chmielus1; 1University of Pittsburgh; 2General Carbide Corp.
A cermet material with high toughness and hardness, tungsten carbide-cobalt (WC-Co) is commonly used as a material for tooling. The current production method uses traditional powder processing techniques to shape the powder by pressing, extruding, or molding into parts which are then dewaxed and sintered. These processes result in limitations to part geometry and quantity. Implementing additive manufacturing, specifically binder jet 3D printing, will allow for the production of mass-customized and highly complex shapes in a time- and cost-effective manner. WC-Co powder was provided by General Carbide Corporation and characterized as granules composed of sub-micron- to micron-sized particles. Optimal parameters for powder bed packing and green density were determined using design of experiments methods. After sintering and high isostatic pressing, the resulting highly dense parts show comparable hardness and toughness to traditionally manufactured WC-Co parts.
9:45 AM
Direct Ink Writing of Chopped Fiber Ultra-High Temperature Ceramic Matrix Composites (UHTCMCs): Lisa Rueschhoff1; Zlatomir Apostolov1; James Kemp2; Brett Compton2; Abel Diaz3; Surya Kalidindi3; Brendan Croom1; 1AFRL; 2University of Tennessee-Knoxville; 3Georgia Institute of Technology
Current ultra-high temperature ceramics (UHTCs) are limited in many aerospace applications by low fracture strength and toughness. The use of a reinforcing fiber phase within a UHTC matrix can enhance both strength and damage tolerance while the use of additive manufacturing (AM) will help overcome the challenges in manufacturing complex-shaped components. In this work, the AM technique of direct ink writing (DIW) is used to extrude a preceramic polymer based slurry to build up complex structures of chopped fiber UHTC ceramic composites (UHTCMCs). An additional benefit of the DIW process is the ability to align high aspect ratio reinforcement phase for enhanced mechanical performance. Slurries consist of commercial silicon carbide preceramic polymer highly loaded (>40 vol.%) with ZrB2 powder and chopped SiC fiber (up to 10 vol.%). Pyrolysis experiments have been carried out at 1200 and 1600 oC with fiber distribution and orientation explored through microscopy and x-ray CT analysis.
10:15 AM
Laser-based Additive Manufacturing of Bi-metallic & Tri-metallic Oxide Layers: Yi Lu1; Michael Hurst2; Subramaniam Velumani3; Mathew Kuttolamadom4; Homero Castaneda1; Olivia Esmacher5; 1Department of Materials Science and Engineering, Texas A&M University; 2Department of Engineering Technology & Industrial Distribution Texas A&M University; 3Departamento de Ingeniería Eléctrica (SEES), Centro de Investigación y de Estudios Avanzados del Instituto Politécnico Nacional (CINVESTAV-IPN), Av. Instituto Politécnico Nacional 2508, Col. San Pedro Zacatenco, Ciudad de México, México, CP 07360; 4Department of Engineering Technology & Industrial Distribution, Texas A&M University; 5Texas A&M University
The motivation of this work is to gain the ability to fabricate material layers that impart corrosion-resistance, self-cleaning and antibacterial properties, leading to an integration of multifunctional characteristics for various applications. Three naturally non-combinable powered metallic oxides namely zinc oxide, zirconium dioxide and titanium oxide were mixed and exposed to a high-energy laser to form solidified layers. The properties of the layers “coated” onto substrates were evaluated by microscopy (SEM), spectroscopy (EDS), diffraction (XRD), hardness, and electrochemical impedance spectroscopy (EIS). The XRD pattern indicates the formation of a tri-metallic oxide and some other bimetallic compositions which are known to exhibit certain of the above-mentioned beneficial properties. Zinc dominated in atomic fraction when compared to titanium and zirconium. Higher energy densities imparted via the laser resulted in the steel substrate mixing with the powder layers, leading to more of a surface alloying action as compared to surface coating.
10:35 AM
Fused Filament Fabrication of Metal Matrix Composites (MMC): Nancy Bhardwaj1; Hani Henein1; Tonya Wolfe2; 1University of Alberta; 2InnoTech Alberta
Fused Filament Fabrication (FFF) has been widely used for the Additive Manufacturing of polymer-based components. Due to the versatility of equipment used in FFF, the feasibility to incorporate other classes of materials within the polymer filament, such as metallic and ceramic powders, is an attractive option. When metallic powders are incorporated into the polymer, FFF provides the opportunity to retain the fine structure of the rapidly solidified powder. This work will discuss the random loose porosity for mixtures of metal matrix composite (MMC) powders containing Nickel alloy, Titanium and Tungsten carbides. The packing of fine and non-spherical particles for these powder mixtures will provide a datum for determining the maximum packing achievable to increase carbide content, and for predicting the flow characteristics of composite filaments containing polymer and MMC fillers for use in FFF. The printability of the composite filaments in relation to particle packing will also be discussed.
10:55 AM
Geometry Limitations of Indirect Laser Sintering of Alumina: Doug Sassaman1; Joseph Beaman1; Desiderio Kovar1; Matthew Ide2; 1Univ of Texas Austin; 2ExxonMobil Research and Development Company
There are increasing applications for additive manufacturing of ceramics in applications that rely on structures engineered at the macro- and mesoscale (e.g. catalyst supports). Design guidelines for the successful manufacture of ceramics with such complex architectures is currently lacking. This study is aimed developing a methodology for predicting the design limitations in additively manufactured ceramics with complex architectures. We utilize indirect Selective Laser Sintering (SLS) of alumina components that contain hollow channels as a testbed. Simple geometries, such as thin walls and holes, were produced and measured with conventional metrology tools. External surface roughness was measured with optical profilometry. Complex geometries, such as internal helices and cellular structures, were then produced and imaged with x-ray computed tomography (XCT) to determine internal feature accuracy. The results were used to map the design-space, which elucidates the output limitations (e.g. minimum hole size) based on inputs (e.g. material composition, laser parameters).