Additive Manufacturing of Ceramic-based Materials: Process Development, Materials, Process Optimization and Applications: Additive Manufacturing of Ceramics-based Materials II
Sponsored by: ACerS Basic Science Division, ACerS Engineering Ceramics Division, ACerS Manufacturing Division
Program Organizers: Lei Chen, University of Michigan-Dearborn; Xuan Song, University of Iowa; 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 2:00 PM
October 10, 2022
Room: 307
Location: David L. Lawrence Convention Center
Session Chair: Doug Sassaman, University of Texas Austin; Jung-Ting Tsai, Argonne National Laboratory
2:00 PM Invited
Additive Manufacturing of Mullite Ceramic by Digital Light Processing: Jung-Ting Tsai1; Dileep Singh1; 1Argonne National Laboratory
A novel UV curable Mullite (SiO2-Al2O3) precursor is 3D printed via DLP (digital light process). The UV cured Mullite material is debinded and sintered (plain atmosphere) for achieving high material strength, thermal shock resistance, and structural stability, which can be a suitable candidate for high-temperature structural and thermal applications. The PDC (polymer-derived ceramic) process reaches 95% densification without compromising design flexibility and material performance. In addition, large-scale prototypes are printed concurrently with fine-resolution (25 um) for intricate design on the parts. The material's flexural strength, hardness, and thermal conductivity are obtained while materials characterization is investigated for determining the printed materials' structure-property relationships. This research allows manufacturers to advance their design with time-efficient and cost-effectiveness.
2:30 PM
Fabrication of Powder Components with Cooling Channels by Spark Plasma Sintering and Additive Manufacturing: Elisa Torresani1; Maricruz Carrillo1; Chris Haines2; Darold Martin3; Eugene Olevsky1; 1San Diego State University; 2US Army DEVCOM - Army Research Laboratory; 3US Army DEVCOM – Armaments Center, Picatinny Arsenal
A novel method of producing complex ceramic and metallic parts with designed internal channels is developed. The method utilizes a combination of the additive manufacturing technique of solvent jetting and spark plasma sintering (SPS.) The developed manufacturing approach brings benefits in producing complex shape with internal channels. Along with geometric customization of the 3D printed mold, a major advantage of this method is the removal of the need for a long debinding process, usually necessary with other 3D printing methods, by using the SPS. High density ceramic and metallic complex parts with internal channels were successfully produced with close to theoretical densities. The conducted studies include the development of a model that can predict the evolution and/or distortions of the complex-shaped powder assembly during the sintering process. The model is based on the continuum theory of sintering formulations embedded in a finite element code.
2:50 PM
Mass Customization, Moving Forwards with Additive Manufacturing: Cindy Schick1; Richard Gaignon1; Rouslan Svintsitski1; 13DCERAM-SINTO
Thus far, ceramic additive manufacturing is mostly associated to only prototyping, but thanks to the recent developments achieved by 3DCERAM and revealed in this presentation, this technology can now meet industrial needs by offering a wide range of quality ceramic materials and large-scale processes. Indeed, since more than a decade, 3DCERAM has worked with the C900 printer which is designed with high viscosity slurries. Nevertheless, 2 years ago, we started to focus on the development of lower viscosity and higher reactivity materials with the same high loading content. The use of low viscosity slurries improves the automatization of the process and the reduction of the printing time. Moreover, the high loading content ensures high quality sintered parts (microstructure, density and accuracy). 3DCERAM has also developed 2 new printers compatible with these low viscosity slurries: the C100 to develop skills and designs, and the C3600 for the industrial scale.
3:10 PM
Multi-material Printing of Reaction Bonded Carbides by Robocasting: Larissa Wahl1; Michelle Weichelt1; Nahum Travitzky1; 1Friedrich-Alexander Universität Erlangen-Nürnberg
Reaction bonded boron carbide (RBBC) and reaction bonded silicon carbide (BRSC) composites were fabricated using multi-material robocasting followed by liquid silicon infiltration (LSI). Multi-material robocasting offers the possibility to combine materials and thus their properties, as demonstrated in this work with silicon carbide (SiC) and boron carbide (B4C). The feasibility of combining RBSC and RBBC was demonstrated by printing multilayer bending bars. The microstructure of the samples was investigated and, in particular, the interfaces at each processing step were studied. After LSI, cracks were observed in the B4C layers due to differences in thermal expansion, but the interfaces showed no delamination and good interfacial bonding between the layers was evident. Residual stresses in the layers, which were theoretically calculated and further investigated by Raman measurements, could explain the cracking. By adjusting the paste composition, the stresses could be influenced and the crack formation prevented.
3:30 PM Break
3:50 PM Invited
Bonding Mechanisms in Indirect Selective Laser Sintering: Doug Sassaman1; Matthew Ide2; Joseph Beaman1; Desiderio Kovar1; 1University of Texas Austin; 2ExxonMobil Research and Engineering Company
Ceramics with intricate geometries can be produced by indirect selective laser sintering (SLS) where a polymer is added to bind the ceramic particles together during laser heating. We use observations from video images captured under realistic SLS processing conditions to propose a mechanistic model. We then use the model to predict the operating conditions required to achieve particle bonding during indirect SLS. The physical basis for the model is that particle bonding occurs when molten polymer binder permeates through the porous ceramic shell that surrounds the polymer particles and forms solid bridges when the polymer solidifies. The model predictions are tested by building parts using a wide range of laser powers and scan speeds to determine experimentally if particle bonding has occurred. The results show that a permeation-based model is an accurate descriptor of binding mechanisms in indirect SLS of mixed polymer/ceramic powders.
4:20 PM
Exploration of the Underlying Space in Microscopic Images via Deep Learning for Additively Manufactured Piezoceramics: Wenhua Yang1; Zhuo Wang2; Tiannan Yang3; Li He4; Xuan Song5; Yucheng Liu6; Lei Chen1; 1University of Michigan-Dearborn; 2University of Michigan; 3Pennsylvania State University; 4The University of Iowa; 5University of Iowa; 6South Dakota State University
Existing DL-based methods are generally limited in generating (1) microstructures with high resolution, (2) microstructures with high variability, (3) microstructures with guaranteed periodicity, and (4) highly controllable microstructures. In this study, a DL approach based on a stacked generative adversarial network (StackGAN-v2) is proposed to overcome these shortcomings. The presented modeling approach can reconstruct high-fidelity microstructures of additively manufactured piezoceramic, which are statistically equivalent to original microstructures either experimentally observed or numerically predicted. Advantages of the proposed modeling approach are also illustrated in terms of its capability in controlling the probability density function (PDF) of grain size, grain orientation, and micropore in a large space, which would have significant benefits in exploring the effects of these microstructure features on the piezoelectricity of piezoceramics. Therefore, this DL approach can significantly accelerate the process of designing optimal microstructures when integrating with computational methods to achieve desired piezoelectric properties.