About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Advanced Materials for Reusable Rocket Engines
|
| Presentation Title |
Disruption of Oxide Barriers in Reaction Bonded, 3D Printed Ceramics via Surface-Applied In–Ga Eutectic |
| Author(s) |
Zachary A. Chase, Audrey Chyung, Fernando Milach Teixeira, Katherine T. Faber |
| On-Site Speaker (Planned) |
Zachary A. Chase |
| Abstract Scope |
We present a hybrid laser powder bed fusion and reaction bonding process to fabricate Al–Al₂O₃–YSZ ceramics without polymeric binders or compaction. During sintering in air to 1600°C, Al transforms to α-Al₂O₃, producing a ~30% volumetric expansion. Passivating oxide shells, however, limit Al wetting and subsequent densification. A surface-applied indium–gallium eutectic chemically disrupts these shells—without the need for alloying or nitridation—enabling uniform Al infiltration and preventing confined melt pool formation. Treated specimens reach ~85% density and exhibit reduced microcracking, stable cubic ZrO₂, and suppressed YSZ grain growth. Scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, and electron probe microanalysis confirm selective incorporation of Ga into Al₂O₃ and In into YSZ lattices without secondary phases. By simplifying oxide shell disruption, this method removes longstanding barriers to rapid, binder-free ceramic additive manufacturing—offering a pathway toward oxidation-tolerant components for high-temperature aerospace and space propulsion environments. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Ceramics, High-Temperature Materials |