Additive Manufacturing of Ceramics and Ceramic Composites: Materials Properties, Processes, and Modeling: Additive Manufacturing of Ceramics and Ceramic Composites: Materials Properties, Processes, and Modeling
Sponsored by: ACerS Manufacturing Division, TMS: Additive Manufacturing Committee
Program Organizers: Xiangyang Dong, Arizona State University; William Headrick, RHI Magnesita; James Hemrick, Oak Ridge National Laboratory; Eric Faierson, Quad City Manufacturing Laboratory; Keith DeCarlo, Blasch Precision Ceramics
Wednesday 8:00 AM
November 4, 2020
Room: Virtual Meeting Room 7
Location: MS&T Virtual
Session Chair: Xiangyang Dong, Missouri University of Science and Technology
8:00 AM
Additive Manufacturing of Hybrid Silicon Carbide/Carbon Fiber Nano-composites: Saja Al-ajrash; Charles Browning1; 1University of Dayton
A novel route to fabricate a hybrid ceramic matrix composite by utilizing preceramic polymers, chopped carbon nanofiber precursors and subsequent additive manufacturing was introduced in this study. The polycarbosilane was loaded with distinct weight percentages of polyacrylonitrile nanofiber which followed by subsequent 3D printed and pyrolysis. The end objective of the pyrolysis cycle is that the polycarbosilane resin is converted into a silicon carbide matrix, with the PAN converted into reinforcing carbon nanofibers. The impact of the CNF percentages on structural and mechanical properties was investigated using scanning electron microscopy, transmission electron microscopy, and nano-indentation characterization techniques, respectively. The obtained ceramic hybrid composite was fully dense with nearly linear shrinkage and a shiny, smooth surface after pyrolysis. The ceramic matrix composite appeared to have three coexisting phases including silicon carbide, silicon oxycarbide, and turbostratic carbon. The results are promising to fabricate hybrid composites working at high temperatures with complex geometries.
8:20 AM
Additive Manufacturing of Miniaturized RFID Tag Using Electroceramic Materials for High Temperature Wireless Sensing Applications: Kavin Sivaneri Varadharajan Id1; Domenic Cipollone1; Katarzyna Sabolsky1; Edward Sabolsky1; Konstantinos Sierros1; Daryl Reynolds1; 1West Virginia University
The primary objective of this work focused on analyzing the parameters that affect the resolution of direct ink writing of miniaturized RFID tags for wireless temperature sensing at high temperatures. The inks were made by dispersing the electroceramic particles of size < 7 µm in various organic vehicles. Different volume loadings of the electroceramic particles were evaluated to maximize the solid loadings to achieve high density after post-processing. The parameters that affect the process such as viscosity, wettability, print rate, and particle size were evaluated. Several microarchitectures with feature size ranging from 50 – 250 µm were deposited on different substrates including ceramics to demonstrate the capability of the process. The patterned ceramic substrates were sintered at temperatures >1000oC for further characterization. A suite of characterization was performed by particle size analyzer, rheometer, contact angle measurement, SEM, XRD, and impedance spectroscopy.
8:40 AM
Additive Manufacturing of Novel PZT Piezocomposite Structures: Shawn Allan1; Barry Robinson2; Alex Angilella3; Justin Tufariello3; Leslie Riesenhuber3; Brian Pazol2; 1Lithoz America LLC; 2MSI Transducers Corp; 3The MITRE Corporation
Piezoelectric structures were created from soft PZT-5H using lithography-based ceramic manufacturing (LCM). LCM uses digital light projection (DLP) to form green ceramic parts with customizable geometry and high resolution from a photocurable slurry. LCM imparts minimal stress on green parts compared with conventional methods, enabling repeatable creation of periodic structures. Powder preparation and thermal-processing methods were developed to yield sintered LCM parts with density, dielectric constant, and piezoelectric charge coefficient (d33) comparable to conventionally manufactured PZT-5H. An LCM 1-3 piezocomposite resonant at 88 kHz was fabricated into a simple transducer and compared to an equivalent conventional PZT transducer. Modeling and simulation predicted the acoustic performance of the AM and traditional material, laying groundwork to develop novel piezocomposite designs. Feasibility of the creation of novel piezocomposite structures developed through modeling and produced via LCM was demonstrated, with potential to streamline manufacturing processes of piezoelectric ceramics and augment performance in acoustic transducers.
9:00 AM
Effect of Carbon Concentration from Phenolic PIP on the Fabrication and Thermal- Mechanical Properties of SiC Composites by Additive Manufacturing and Reactive Silicon Melt Infiltration: Corson Cramer1; Edgar Lara-Curzio1; Amy Elliott1; Christina Padilla1; Alexis Flores-Betancourt1; Derek Siddel1; Kashif Nawaz1; 1Oak Ridge National Laboratory
Recent advances in additive manufacturing, combined with traditional infiltration processes, have enabled the fabrication of ceramic components with complex shapes, which until recently had not been possible with conventional manufacturing processes. In this presentation, we report results from the characterization and evaluation of silicon carbide composites fabricated by additive manufacturing using binder jet 3D printing followed by phenolic polymer impregnation and pyrolysis (PIP) and reactive silicon melt infiltration (RMI). The ability of increasing the SiC content is demonstrated, and the role of microstructure on thermal, mechanical, and physical properties including thermal conductivity, specific heat, thermal expansion coefficient, and flexural strength is discussed. While these materials have the potential for utilization in a wide range of technologies and applications, the case of heat exchangers for high-temperature applications has been considered and relevant properties have been determined accordingly.
9:20 AM
Fundamental Studies of Tritium Diffusivity in Irradiation Defective LiAlO2 and Li2ZrO3: A Frist Principles Density Function Theory Study: Hari Paudel1; Yuhua Duan1; 1National Energy Technology Laboratory
Li containing ceramics have been in the center of study in Li ion batteries and tritium science and technology as breeding blanket materials for tritium (T) breeding components in the deuterium-tritium (D-T) fusion reactor. The thermal neutron irradiation of lithium isotope (6Li) in tritium (T) -producing burnable absorber rods (TPBARS) of LiAlO2 and Li2ZrO3 crystal produces vacancies, defects of its constituent elements, and several different trapping sites which hinder tritium diffusion process and releasing behavior. Here we investigate the diffusion mechanisms of tritium and OT species in pure and carbon doped LiAlO2 ceramic pellet in order to understand and quantify the effects on diffusion barriers and diffusion coefficients due to the presence of interstitial and substitutional Li defects, hydroxide (O-T) vacancy defect, and the interactions of T with O-vacancies. We also present diffusion of T in pure Li2ZrO3.
9:40 AM
Mechanical Characterization of SLA Printed Silica Lattice Structures: Bhargavi Mummareddy1; Jose Carrillo-Baeza1; Pedro Cortes1; 1Youngstown State University
Advancement in design and manufacturing is giving possibilities to build light-weight durable structural components. In the present work, StereoLithography was used to build lattice structures with silica ceramic resin. An octagon and rhombic dodecahedron unit cells were chosen for evaluation in this work. Print parameters such as point density, print direction and support structures were optimized. Sintering conditions to yield solid structures were investigated. A comparison between densities of bulk specimens and the cellular structure was performed to understand variation along the lattice the structure. Quasi-static and dynamic compressive strength with energy absorption were evaluated. Optical and SEM imaging of the specimen aided in understanding the fracture mechanisms. These light-weight cellular structures can be potentially employed for corrosion resistance, and high temperature applications. Future studies include transformation of the ceramic structures to form interpenetrating phase composites. This could possibly increase the applications into automobile, aerospace, composite tooling and refractory industries.
10:00 AM
Process Development for the Selective Laser Melting of Tungsten Carbide-Nickel Matrix Composites: Edgar Mendoza Jimenez1; Baby Reeja-Jayan1; Jack Beuth1; 1Carnegie Mellon Univ
In this work, laser powder bed fusion (LPBF) is used for the additive manufacturing of composite samples consisting of tungsten carbide particles with a nickel binder. Such process can become a viable low-energy alternative to the conventional production of ceramic-metal composites for applications including tooling, electronics, and wear components. Single track experiments are used to evaluate the melting behavior of the composite material. Samples are then printed with of process parameters that adequately melted the material. The density, microstructure, and functional properties of these samples are measured. Highly dense (>98%) samples are successfully manufactured and analyzed as a function of LPBF parameters. Macro- and microdefects resulting from the laser processing are also discussed. A methodical approach to evaluate an acceptable processing region is presented and used to investigate the feasibility of additively manufacturing tungsten carbide-nickel composites via LPBF.