Journal articles: 'Ceramic Additive Manufacturing'

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He, Rujie, Niping Zhou, Keqiang Zhang, Xueqin Zhang, Lu Zhang, Wenqing Wang, and Daining Fang. "Progress and challenges towards additive manufacturing of SiC ceramic." Journal of Advanced Ceramics 10, no. 4 (July 18, 2021): 637–74. http://dx.doi.org/10.1007/s40145-021-0484-z.

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AbstractSilicon carbide (SiC) ceramic and related materials are widely used in various military and engineering fields. The emergence of additive manufacturing (AM) technologies provides a new approach for the fabrication of SiC ceramic products. This article systematically reviews the additive manufacturing technologies of SiC ceramic developed in recent years, including Indirect Additive Manufacturing (Indirect AM) and Direct Additive Manufacturing (Direct AM) technologies. This review also summarizes the key scientific and technological challenges for the additive manufacturing of SiC ceramic, and also forecasts its possible future opportunities. This paper aims to provide a helpful guidance for the additive manufacturing of SiC ceramic and other structural ceramics.

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Halloran, John W. "Ceramic Stereolithography: Additive Manufacturing for Ceramics by Photopolymerization." Annual Review of Materials Research 46, no. 1 (July 2016): 19–40. http://dx.doi.org/10.1146/annurev-matsci-070115-031841.

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Nevarez-Saenz, David, Ted Adler, Wei Wei, and Bhisham Sharma. "Additive manufacturing of ceramic porous structures for acoustical applications." INTER-NOISE and NOISE-CON Congress and Conference Proceedings 264, no. 1 (June 24, 2022): 560–66. http://dx.doi.org/10.3397/nc-2022-773.

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Ceramics offer the unique ability to withstand extreme temperatures and pressures without mechanical degradation-characteristics that make them ideal for acoustic applications in extreme environments. While ceramic forming is now a mature technology, traditional forming methods only allow two-dimensional design freedom, cannot create internal features, and often require expensive dies. Here, we propose the use of additive manufacturing (AM) to fabricate porous structures with complex pore geometries suitable for noise reduction applications. We fabricate cylindrical impedance tube test coupons of various pore geometries using a robocasting method that relies on clay extrusion. The printed green bodies are fired and sintered in an automated kiln to obtain the final ceramic sample. In this paper, we present the preliminary results from our wok on characterizing the relationships between the ceramic AM process parameters and the final ceramic part quality and dimensional accuracy. Finally, we investigate the acoustic absorption characteristics of the printed coupons using the normal incidence two microphone impedance tube method. Our results show that ceramics AM provides an attractive route to fabricate complex acoustic structures suitable for high temperature environments.

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Hassanin, Hany, Khamis Essa, Amr Elshaer, Mohamed Imbaby, Heba H. El-Mongy, and Tamer A. El-Sayed. "Micro-fabrication of ceramics: Additive manufacturing and conventional technologies." Journal of Advanced Ceramics 10, no. 1 (January 18, 2021): 1–27. http://dx.doi.org/10.1007/s40145-020-0422-5.

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AbstractCeramic materials are increasingly used in micro-electro-mechanical systems (MEMS) as they offer many advantages such as high-temperature resistance, high wear resistance, low density, and favourable mechanical and chemical properties at elevated temperature. However, with the emerging of additive manufacturing, the use of ceramics for functional and structural MEMS raises new opportunities and challenges. This paper provides an extensive review of the manufacturing processes used for ceramic-based MEMS, including additive and conventional manufacturing technologies. The review covers the micro-fabrication techniques of ceramics with the focus on their operating principles, main features, and processed materials. Challenges that need to be addressed in applying additive technologies in MEMS include ceramic printing on wafers, post-processing at the micro-level, resolution, and quality control. The paper also sheds light on the new possibilities of ceramic additive micro-fabrication and their potential applications, which indicates a promising future.

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Chugunov, Svyatoslav, Nikolaus A. Adams, and Iskander Akhatov. "Evolution of SLA-Based Al2O3 Microstructure During Additive Manufacturing Process." Materials 13, no. 18 (September 5, 2020): 3928. http://dx.doi.org/10.3390/ma13183928.

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Evolution of additively manufactured (AM) ceramics’ microstructure between manufacturing stages is a hardly explored topic. These data are of high demand for advanced numerical modeling. In this work, 3D microstructural models of Al2O3 greenbody, brownbody and sintered material are presented and analyzed, for ceramic samples manufactured with SLA-based AM workflow, using a commercially available ceramic paste and 3D printer. The novel data, acquired at the micro- and mesoscale, using Computed Tomography (CT), Scanning Electron Microscopy (SEM) and Focused Ion-Beam SEM (FIB/SEM) techniques, allowed a deep insight into additive ceramics characteristics. We demonstrated the spatial 3D distribution of ceramic particles, an organic binder and pores at every stage of AM workflow. The porosity of greenbody samples (1.6%), brownbody samples (37.3%) and sintered material (4.9%) are analyzed. Pore distribution and possible originating mechanisms are discussed. The location and shape of pores and ceramic particles are indicative of specific physical processes driving the ceramics manufacturing. We will use the presented microstructural 3D models as input and verification data for advanced numerical simulations developed in the project.

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OHJI, Tatsuki. "Additive manufacturing of ceramic components." Synthesiology 11, no. 2 (2018): 81–93. http://dx.doi.org/10.5571/synth.11.2_81.

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OHJI, Tatsuki. "Additive manufacturing of ceramic components." Synthesiology English edition 11, no. 2 (2019): 81–92. http://dx.doi.org/10.5571/syntheng.11.2_81.

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Nefedovaa, L. A., V. I. Ivkov, M. M. Sychov, S. V. Diachenko, and M. V. Gravit. "Additive manufacturing of ceramic insulators." Materials Today: Proceedings 30 (2020): 520–22. http://dx.doi.org/10.1016/j.matpr.2020.01.040.

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Schönherr, Julia Anna, Sonja Baumgartner, Malte Hartmann, and Jürgen Stampfl. "Stereolithographic Additive Manufacturing of High Precision Glass Ceramic Parts." Materials 13, no. 7 (March 25, 2020): 1492. http://dx.doi.org/10.3390/ma13071492.

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Lithography based additive manufacturing (AM) is one of the most established and widely used 3D-printing processes. It has enabled the processing of many different materials from thermoplast-like polymers to ceramics that have outstanding feature resolutions and surface quality, with comparable properties of traditional materials. This work focuses on the processing of glass ceramics, which have high optical demands, precision and mechanical properties specifically suitable for dental replacements, such as crowns. Lithography-based ceramic manufacturing (LCM) has been chosen as the optimal manufacturing process where a light source with a defined wavelength is used to cure and structure ceramic filled photosensitive resins. In the case of glass ceramic powders, plastic flow during thermal processing might reduce the precision, as well as the commonly observed sintering shrinkage associated with the utilized temperature program. To reduce this problem, particular sinter structures have been developed to optimize the precision of 3D-printed glass ceramic crowns. To evaluate the precision of the final part, testing using digitizing methods from optical to tactile systems were utilized with the best results were obtained from micro computed tomography (CT) scanning. These methods resulted in an optimized process allowing for possible production of high precision molar crowns with dimensional accuracy and high reproducibility.

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Nawrot, Witold, and Karol Malecha. "Additive manufacturing revolution in ceramic microsystems." Microelectronics International 37, no. 2 (March 28, 2020): 79–85. http://dx.doi.org/10.1108/mi-11-2019-0073.

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Purpose The purpose of this paper is to review possibilities of implementing ceramic additive manufacturing (AM) into electronic device production, which can enable great new possibilities. Design/methodology/approach A short introduction into additive techniques is included, as well as primary characterization of structuring capabilities, dielectric performance and applicability in the electronic manufacturing process. Findings Ceramic stereolithography (SLA) is suitable for microchannel manufacturing, even using a relatively inexpensive system. This method is suitable for implementation into the electronic manufacturing process; however, a search for better materials is desired, especially for improved dielectric parameters, lowered sintering temperature and decreased porosity. Practical implications Relatively inexpensive ceramic SLA, which is now available, could make ceramic electronics, currently restricted to specific applications, more available. Originality/value Ceramic AM is in the beginning phase of implementation in electronic technology, and only a few reports are currently available, the most significant of which is mentioned in this paper.

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Lakhdar, Y., C. Tuck, J. Binner, A. Terry, and R. Goodridge. "Additive manufacturing of advanced ceramic materials." Progress in Materials Science 116 (February 2021): 100736. http://dx.doi.org/10.1016/j.pmatsci.2020.100736.

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Travitzky, Nahum, Alexander Bonet, Benjamin Dermeik, Tobias Fey, Ina Filbert-Demut, Lorenz Schlier, Tobias Schlordt, and Peter Greil. "Additive Manufacturing of Ceramic-Based Materials." Advanced Engineering Materials 16, no. 6 (April 8, 2014): 729–54. http://dx.doi.org/10.1002/adem.201400097.

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Schwentenwein, Martin, Peter Schneider, and Johannes Homa. "Lithography-Based Ceramic Manufacturing: A Novel Technique for Additive Manufacturing of High-Performance Ceramics." Advances in Science and Technology 88 (October 2014): 60–64. http://dx.doi.org/10.4028/www.scientific.net/ast.88.60.

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Albeit widely established in plastic and metal industry, additive manufacturing technologies are still a rare sight in the field of ceramic manufacturing. This is mainly due to the requirements for high performance ceramic parts, which no additive manufacturing process was able to meet to date.The Lithography-based Ceramic Manufacturing (LCM)-technology which enables the production of dense and precise ceramic parts by using a photocurable ceramic suspension that is hardened via a photolithographic process. This new technology not only provides very high accuracy, it also reaches high densities for the sintered parts. In the case of alumina a relative density of over 99.4 % and a 4-point-bending strength of almost 430 MPa were realized. Thus, the achievable properties are similar to conventional manufacturing methods, making the LCM-technology an interesting complement for the ceramic industry.

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Bae, Chang-Jun, Arathi Ramachandran, Kyeongwoon Chung, and Sujin Park. "Ceramic Stereolithography: Additive Manufacturing for 3D Complex Ceramic Structures." Journal of the Korean Ceramic Society 54, no. 6 (November 30, 2017): 470–77. http://dx.doi.org/10.4191/kcers.2017.54.6.12.

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Mahmood, Muhammad, Alexandra Bănică, Carmen Ristoscu, Nicu Becherescu, and Ion Mihăilescu. "Laser Coatings via State-of-the-Art Additive Manufacturing: A Review." Coatings 11, no. 3 (March 4, 2021): 296. http://dx.doi.org/10.3390/coatings11030296.

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Ceramics and ceramic-reinforced metal matrix composites (CMMCs) demonstrate high wear resistance, excellent chemical inertness, and exceptional properties at elevated temperatures. These characteristics are suitable for their utilization in biomedical, aerospace, electronics, and other high-end engineering industries. The aforementioned performances make them difficult to fabricate via conventional manufacturing methods, requiring high costs and energy consumption. To overcome these issues, laser additive manufacturing (LAM) techniques, with high-power laser beams, were developed and extensively employed for processing ceramics and ceramic-reinforced CMMCs-based coatings. In respect to other LAM processes, laser melting deposition (LMD) excels in several aspects, such as high coating efficiency and lower labor cost. Nevertheless, difficulties such as poor bonding between coating and substrate, cracking, and reduced toughness are still encountered in some LMD coatings. In this article, we review recent developments in the LMD of ceramics and CMMCs-based coatings. Issues and solutions, along with development trends, are discussed and summarized in support of implementing this technology for current industrial use.

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Castro e Costa, Eduardo, José Pinto Duarte, and Paulo Bártolo. "A review of additive manufacturing for ceramic production." Rapid Prototyping Journal 23, no. 5 (August 22, 2017): 954–63. http://dx.doi.org/10.1108/rpj-09-2015-0128.

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Purpose In this paper, the authors aim to address the potential of mass personalization for ceramic tableware objects. They argue that additive manufacturing (AM) is the most adequate approach to the production of such objects. Design/methodology/approach The authors review the manufacturing of ceramic tableware objects, both traditional techniques and AM processes, and assess which available AM technologies are suitable for the research purpose. Findings The authors consider binder jetting and material extrusion as the most suitable processes for the production of ceramic objects to be integrated into a mass personalization system of ceramic tableware. Originality/value This paper provides an original overview of traditional and innovative techniques in ceramic manufacturing, exposing not only its differences but also its commonalities. Such overview supports the conceptual design of original equipment.

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de Camargo, Italo, João Fiore Parreira Lovo, Rogério Erbereli, Eduardo Bock, and Carlos Fortulan. "Fabrication of ceramics using photosensitive slurries: A comparison between UV-casting replication and vat photopolymerization 3D printing." Processing and Application of Ceramics 16, no. 2 (2022): 153–59. http://dx.doi.org/10.2298/pac2202153c.

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The development of photosensitive ceramic slurries for vat photopolymerization (stereolithography or digital light processing) has received much effort in recent years. However, many of these ceramic suspensions have high viscosity and they are suitable for use only on equipment, specialized in ceramic additive manufacturing. In this work, ceramic manufacturing using photocurable slurries was tested in a low-cost vat photopolymerization printer and in silicone moulds for UV-casting replication, with the latter approach still scarcely explored in the literature. Both processes were able to produce ceramic parts. The UV-casting replication was able to work with more viscous photocurable ceramic slurries and proved more suitable for the manufacturing of ceramic parts with larger cross-sections, providing pieces with improved flexural strength to those produced by additive manufacturing. This work presents the possibility of UV-casting photosensitive slurries to manufacture ceramics, an approach that could be easily adopted without high equipment costs.

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Tufariello, Justin, Shawn Allan, Barry Robinson, Brian Pazol, Leslie Riesenhuber, Alex Angilella, and Casey Corrado. "Ceramic additive manufacturing for enhanced piezocomposite transducers." Journal of the Acoustical Society of America 149, no. 4 (April 2021): A44. http://dx.doi.org/10.1121/10.0004469.

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Lee, Hyo Jun, Young Tae Cho, and Seok Kim. "Unconventional Additive Manufacturing for Multiscale Ceramic Structures." Journal of the Korean Society for Precision Engineering 38, no. 9 (September 1, 2021): 639–50. http://dx.doi.org/10.7736/jkspe.021.072.

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Sabin, Jenny E., Martin Miller, Nicholas Cassab, and Andrew Lucia. "PolyBrick: Variegated Additive Ceramic Component Manufacturing (ACCM)." 3D Printing and Additive Manufacturing 1, no. 2 (June 2014): 78–84. http://dx.doi.org/10.1089/3dp.2014.0012.

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Hinton, Jack, Dejan Basu, Maria Mirgkizoudi, David Flynn, Russell Harris, and Robert Kay. "Hybrid additive manufacturing of precision engineered ceramic components." Rapid Prototyping Journal 25, no. 6 (July 8, 2019): 1061–68. http://dx.doi.org/10.1108/rpj-01-2019-0025.

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Purpose The purpose of this paper is to develop a hybrid additive/subtractive manufacturing platform for the production of high density ceramic components. Design/methodology/approach Fabrication of near-net shape components is achieved using 96 per cent Al3O2 ceramic paste extrusion and a planarizing machining operations. Sacrificial polymer support can be used to aid the creation of overhanging or internal features. Post-processing using a variety of machining operations improves tolerances and fidelity between the component and CAD model while reducing defects. Findings This resultant three-dimensional monolithic ceramic components demonstrated post sintering tolerances of ±100 µm, surface roughness’s of ∼1 µm Ra, densities in excess of 99.7 per cent and three-point bending strength of 221 MPa. Originality/value This method represents a novel approach for the digital fabrication of ceramic components, which provides improved manufacturing tolerances, part quality and capability over existing additive manufacturing approaches.

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Weigold, Matthias, Timo Scherer, Eric Schmidt, Martin Schwentenwein, and Thomas Prochaska. "Additive Fertigung keramischer Schneidstoffe/Additive manufacturing of ceramic cutting materials. Production of indexable inserts for turning using the LCM process." wt Werkstattstechnik online 110, no. 01-02 (2020): 2–6. http://dx.doi.org/10.37544/1436-4980-2020-01-02-4.

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Die additive Fertigung von Schneidstoffen hat das Potenzial, leistungsfähigere Zerspanungswerkzeuge zu ermöglichen. Das Lithography-based Ceramic-Manufacturing-(LCM)-Verfahren erlaubt die Fertigung hochbelastbarer Bauteile aus Keramik. Dieser Beitrag stellt zum einen das LCM-Verfahren und zum anderen die Entwicklung additiv herstellbarer Wendeschneidplatten vor. Zuletzt erfolgt die Überprüfung der Funktionstauglichkeit von additiv hergestellten keramischen Wendeschneidplatten in Außenlängsdrehversuchen mit vermicularem Gusseisen (GJV-450).   The additive manufacturing of cutting materials has the potential to enable more efficient cutting tools. The Lithography-based Ceramic Manufacturing (LCM) process allows for the production of high-performance ceramic components. This article presents the LCM process as well as the development of indexable inserts that can be produced additively. Finally, the results of external longitudinal turning tests in Compacted Graphite Iron (CGI-450) are presented.

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Hildebrand, Gerhard, Johanna C. Sänger, Uwe Schirmer, Willi Mantei, Yannick Dupuis, Ruth Houbertz, and Klaus Liefeith. "Process Development for Additive Manufacturing of Alumina Toughened Zirconia for 3D Structures by Means of Two-Photon Absorption Technique." Ceramics 4, no. 2 (May 17, 2021): 224–39. http://dx.doi.org/10.3390/ceramics4020017.

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Additive manufacturing is well established for plastics and metals, and it gets more and more implemented in a variety of industrial processes. Beside these well-established material platforms, additive manufacturing processes are highly interesting for ceramics, especially regarding resource conservation and for the production of complex three-dimensional shapes and structures with specific feature sizes in the µm and mm range with high accuracy. The usage of ceramics in 3D printing is, however, just at the beginning of a technical implementation in a continuously and fast rising field of research and development. The flexible fabrication of highly complex and precise 3D structures by means of light-induced photopolymerization that are difficult to realize using traditional ceramic fabrication methods such as casting and machining is of high importance. Generally, slurry-based ceramic 3D printing technologies involve liquid or semi-liquid polymeric systems dispersed with ceramic particles as feedstock (inks or pastes), depending on the solid loading and viscosity of the system. This paper includes all types of photo-curable polymer-ceramic-mixtures (feedstock), while demonstrating our own work on 3D printed alumina toughened zirconia based ceramic slurries with light induced polymerization on the basis of two-photon absorption (TPA) for the first time. As a proven exemplary on cuboids with varying edge length and double pyramids in the µm-range we state that real 3D micro-stereolithographic fabrication of ceramic products will be generally possible in the near future by means of TPA. This technology enables the fabrication of 3D structures with high accuracy in comparison to ceramic technologies that apply single-photon excitation. In sum, our work is intended to contribute to the fundamental development of this technology for the representation of oxide-ceramic components (proof-of-principle) and helps to exploit the high potential of additive processes in the field of bio-ceramics in the medium to long-term future.

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Rasaki, Sefiu Abolaji, Dingyu Xiong, Shufeng Xiong, Fang Su, Muhammad Idrees, and Zhangwei Chen. "Photopolymerization-based additive manufacturing of ceramics: A systematic review." Journal of Advanced Ceramics 10, no. 3 (March 27, 2021): 442–71. http://dx.doi.org/10.1007/s40145-021-0468-z.

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AbstractConversion of inorganic-organic frameworks (ceramic precursors and ceramic-polymer mixtures) into solid mass ceramic structures based on photopolymerization process is currently receiving plentiful attention in the field of additive manufacturing (3D printing). Various techniques (e.g., stereolithography, digital light processing, and two-photon polymerization) that are compatible with this strategy have so far been widely investigated. This is due to their cost-viability, flexibility, and ability to design and manufacture complex geometric structures. Different platforms related to these techniques have been developed too, in order to meet up with modern technology demand. Most relevant to this review are the challenges faced by the researchers in using these 3D printing techniques for the fabrication of ceramic structures. These challenges often range from shape shrinkage, mass loss, poor densification, cracking, weak mechanical performance to undesirable surface roughness of the final ceramic structures. This is due to the brittle nature of ceramic materials. Based on the summary and discussion on the current progress of material-technique correlation available, here we show the significance of material composition and printing processes in addressing these challenges. The use of appropriate solid loading, solvent, and preceramic polymers in forming slurries is suggested as steps in the right direction. Techniques are indicated as another factor playing vital roles and their selection and development are suggested as plausible ways to remove these barriers.

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Stoll, Thomas, Aarief Syed-Khaja, and Joerg Franke. "Prototyping and Production of High-temperature Power Electronic Substrates through Additive Manufacturing Processes." International Symposium on Microelectronics 2017, no. 1 (October 1, 2017): 000761–67. http://dx.doi.org/10.4071/isom-2017-thp51_10.

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Abstract This paper reveals a study on Selective Laser Melting (SLM) as an alternative technology for producing power electronic substrates, and shows the possibility of producing a stable interface between alumina and copper through SLM technique. Additive Manufacturing (AM) has not yet been established in the manufacturing of electronic devices. The prevalent benefits of the generative manufacturing sector such as material efficiency, product customization/–flexibility, elimination of the usage of tools, constructional freedom and less process steps in contrast to the conventional fabrication methods of ceramic substrates for power electronic applications like DBC or AMB, are pointed out. Moreover, AM reduces energy costs due to the elimination of the necessary firing, etching and washing processes. The realized study focuses on the examination of adhesion strengths of copper structures, melted on different Al2O3 ceramics with and without pre-copper and -glass paste coating. The melting process was categorized for different laser parameters (1–3) based on the same energy input. Maximum shear values of the substrate probes reached were at about 30 N/mm2 for copper coated ceramic, and at 20 N/mm2 for conventional and glass paste coated substrates. All results were determined in a full factorial design of experiment (DoE) with 54 combinations and a sample size of six samples per parameter combination. Furthermore, several cross sections of the probes produced were illustrated to better understand the melting and joining behavior of the copper powder applied on the ceramic substrates. For improved mechanical adhesion, the ceramic substrates were roughened by laser radiation, with roughness values measured, and the cracking behavior of the exposed ceramics explained.

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Kovacev, Nikolina, Sheng Li, Weining Li, Soheil Zeraati-Rezaei, Athanasios Tsolakis, and Khamis Essa. "Additive Manufacturing of Novel Hybrid Monolithic Ceramic Substrates." Aerospace 9, no. 5 (May 7, 2022): 255. http://dx.doi.org/10.3390/aerospace9050255.

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Additive manufacturing (AM) can revolutionise engineering by taking advantage of unconstrained design and overcoming the limitations of traditional manufacturing capabilities. A promising application of AM is in catalyst substrate manufacturing, aimed at the enhancement of the catalytic efficiency and reduction in the volume and weight of the catalytic reactors in the exhaust gas aftertreatment systems. This work addresses the design and fabrication of innovative, hybrid monolithic ceramic substrates using AM technology based on Digital Light Processing (DLP). The designs are based on two individual substrates integrated into a single, dual-substrate monolith by various interlocking systems. These novel dual-substrate monoliths lay the foundation for the potential reduction in the complexity and expense of the aftertreatment system. Several examples of interlocking systems for dual substrates were designed, manufactured and thermally post-processed to illustrate the viability and versatility of the DLP manufacturing process. Based on the findings, the sintered parts displayed anisotropic sintering shrinkage of approximately 14% in the X–Y direction and 19% in the Z direction, with a sintered density of 97.88 ± 0.01%. Finally, mechanical tests revealed the mechanical integrity of the designed interlocks. U-lock and Thread configurations were found to sustain more load until complete failure.

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Wolf, Alexander, Philipp Laurens Rosendahl, and Ulrich Knaack. "Additive manufacturing of clay and ceramic building components." Automation in Construction 133 (January 2022): 103956. http://dx.doi.org/10.1016/j.autcon.2021.103956.

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O'Masta, Mark R., Ekaterina Stonkevitch, Kayleigh A. Porter, Phuong P. Bui, Zak C. Eckel, and Tobias A. Schaedler. "Additive manufacturing of polymer‐derived ceramic matrix composites." Journal of the American Ceramic Society 103, no. 12 (June 18, 2020): 6712–23. http://dx.doi.org/10.1111/jace.17275.

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Felzmann, Ruth, Simon Gruber, Gerald Mitteramskogler, Passakorn Tesavibul, Aldo R. Boccaccini, Robert Liska, and Jürgen Stampfl. "Lithography-Based Additive Manufacturing of Cellular Ceramic Structures." Advanced Engineering Materials 14, no. 12 (May 23, 2012): 1052–58. http://dx.doi.org/10.1002/adem.201200010.

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Grigoriev, Sergei, Tatiana Tarasova, Andrey Gusarov, Roman Khmyrov, and Sergei Egorov. "Possibilities of Manufacturing Products from Cermet Compositions Using Nanoscale Powders by Additive Manufacturing Methods." Materials 12, no. 20 (October 19, 2019): 3425. http://dx.doi.org/10.3390/ma12203425.

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Complicated wear-resistant parts made by selective laser melting (SLM) of powder material based on compositions of metal and ceramics can be widely used in mining, oil engineering, and other precision engineering industries. Ceramic–metal compositions were made using nanoscale powders by powder metallurgy methods. Optimal regimes were found for the SLM method. Chemical and phase composition, fracture toughness, and wear resistance of the obtained materials were determined. The wear rate of samples from 94 wt% tungsten carbide (WC) and 6 wt% cobalt (Co) was 1.3 times lower than that of a sample from BK6 obtained by the conventional methods. The hardness of obtained samples 2500 HV was 1.6 times higher than that of a sample from BK6 obtained by the traditional method (1550 HV).

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Lian, Qin, Wenquan Sui, Xiangquan Wu, Fei Yang, and Shaopeng Yang. "Additive manufacturing of ZrO2 ceramic dental bridges by stereolithography." Rapid Prototyping Journal 24, no. 1 (January 2, 2018): 114–19. http://dx.doi.org/10.1108/rpj-09-2016-0144.

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Purpose This paper aims to develop an additive manufacturing technique for complex zirconia ceramic dental bridges. Design/methodology/approach To carry out this study, a dental bridge model was obtained by three-dimensional reverse engineering, and a light-curable zirconia ceramic suspension was formulated. Zirconia bridges were manufactured by stereolithography and then treated by vacuum freeze drying, vacuum infiltration and sintering. The optimal scanning speed was determined according to the shape precision comparison. Then, characteristics of the sintered ceramic parts were tested as size shrinkage, relative density, surface Vickers hardness, surface roughness and microstructure. Findings The method for preparation of light-curable zirconia suspension (40 volume per cent solid loading) with a viscosity value of 127 mPa·s was proposed. The optimal laser scanning speed for zirconia bridge fabrication was 1200 mm/s. A relative density of 98.58 per cent was achieved; the obtained surface Vickers hardness and surface roughness were 1,398 HV and 2.06 µm, respectively. Originality/value This paper provides a potential technical method for manufacturing complex zirconia dental bridges and other small complex-shaped ceramic components which are difficult to be made by other manufacturing techniques.

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Wätjen, Anja Mareike, Philipp Gingter, Michael Kramer, and Rainer Telle. "Novel Prospects and Possibilities in Additive Manufacturing of Ceramics by means of Direct Inkjet Printing." Advances in Mechanical Engineering 6 (January 1, 2014): 141346. http://dx.doi.org/10.1155/2014/141346.

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Direct inkjet printing is a versatile additive manufacturing technology to produce complex three-dimensional components from ceramic suspensions. By successive printing of cross-sections, the sample is built up layer by layer. The aim of this paper is to show the different possibilities of direct inkjet printing of ceramic suspensions, like printing of oxide (3Y-TZP, Al2O3, and ZTA) or nonoxide (Si3N4, MoSi2) ceramics, featuring microstructures, laminates, three-dimensional specimens, and dispersion ceramics. A modified thermal inkjet printer was used and the ink replaced by aqueous ceramic suspensions of high solids content. The suspensions were processed in an attrition mill or agitator bead mill to reduce the grain size <1 μm to avoid clogging of printhead nozzles. Further significant parameters are rheological properties (viscosity and surface tension) and solids content which were adjusted to the requirements of the printheads. The printed and sintered samples were analysed by SEM. Mechanical properties of 3Y-TZP samples were examined as well by use of the ball-on-three-balls test. The biaxial flexural strength of 3Y-TZP specimens was up to 1393 MPa with a Weibull modulus of 10.4 for small specimens (3 × 4×0.3 mm3).

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Kumar, Penumuru, Arumugam Mahamani, and B. Durga Prasad. "Additive Manufacturing - A Literature Review." Materials Science Forum 979 (March 2020): 74–83. http://dx.doi.org/10.4028/www.scientific.net/msf.979.74.

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In the present scenario, the industries are looking for creating the model quickly and making the prototype. Additive manufacturing (AM) is a rising technology for a hefty choice of applications. This route has plenty of advantages such as the availability of a wide range of materials, fabrication speed and resolution of the final components. The current paper deals with the review of the recent developments in additive manufacturing methods and their applications. Further, the discussion has been made about the various materials used for additive manufacturing such as ceramic, polymer, composites and biomaterials. The survey denotes that fused deposition modeling has received the widespread attention of the researchers. Finally, some of the gaps in the research are found and reported.

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Dimitriadis, Konstantinos, and Simeon Agathopoulos. "Selective Laser Melting-Sintering Technology: From Dental Co-Cr Alloys to Dental Ceramic Materials." Solid State Phenomena 339 (December 19, 2022): 115–22. http://dx.doi.org/10.4028/p-03fhb7.

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The general term of CAD/CAM technology (i.e., Computer-Aided Design/Compute-Aided Manufacturing) comprises several aspects, such as subtractive manufacturing processes, like milling (soft and hard milling), and additive manufacturing processes, like Selective Laser Melting (SLM), which refers to metallic materials, or Selective Laser Sintering (SLS), which refers to glasses/glass-ceramics/ceramic, or polymeric, or related composite materials produced via powder metallurgy technique. In biomaterials fabrications, the first step in SLM or SLS technology is the digital design of the prosthetic restoration, whereby the patient's individual anatomical and morphological features are precisely described. Afterwards laser-aided melting or sintering is repeated (layer-by-layer) until the complete restoration item is fabricated. A wide range of dental materials can be produced by SLM or SLS technology, e.g., metals and alloys, thermoplastic polymers, glasses/ceramics, waxes, and thermoplastic composites. Thus, it is a promising technology for producing a variety of dental restorations, such as metal-ceramic restorations, all-ceramic restorations, maxillofacial prostheses, functional skeletons, individual scaffolds for tissue engineering, etc. SLM technology is already widely applied for fabricating metal objects for dental (e.g., Co-Cr alloy) and orthopedic prostheses. As a subsequence, in the last decade, researchers' interest has been shifted to SLS of ceramic powders, such as SiO2, Al2O3, SiO2/Al2O3, and ZrO2/Y2O3. This article comprehensively reviews the SLS process and its prospects for producing glasses/glass-ceramic/ceramic materials for biomedical/dental applications. The experimental results clearly show that this very modern additive manufacturing technology does not jeopardize the properties of the ceramic biomaterials' properties.

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Wang, Ying Ying, Ling Li, Zai Yi Wang, Fu Tian Liu, Jia Hui Zhao, Ping Ping Zhang, and Chun Lu. "Fabrication of Dense Silica Ceramics through a Stereo Lithography-Based Additive Manufacturing." Solid State Phenomena 281 (August 2018): 456–62. http://dx.doi.org/10.4028/www.scientific.net/ssp.281.456.

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Silica ceramics were fabricated via an additive manufacturing process based on stereolithography. Ceramic suspension with low viscosity and high solid loading is of importance to stereolithography based UV-curable. In this work, to meet the requirements of stereolithography, effects of temperature, additive content and ball-milling time on the viscosity of silica slurry were investigated, and properties of silica ceramics sintered at different temperature were also researched.The results show that increasing temperatures strongly decrease the viscosity unless when the temperature is above 70°C. The minimum of viscosity was observed for an appropriate addition of dispersant, which is corresponding to the best dispersion state of silica particles in the photopolymerizable monomer. And optimizing ball-milling time showed the lowest viscosity suitable for the stereolithography process. The appropriate temperature, additive content and ball-milling time facilitating stereolithography was 70°C, 2% and 60min respectively. The prepared ceramics sintered at 1220°C showed a density and flexural strength of 1.57g/cm3 and 13.31MPa respectively.

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Scheithauer, Uwe, Eric Schwarzer, Tassilo Moritz, and Alexander Michaelis. "Additive Manufacturing of Ceramic Heat Exchanger: Opportunities and Limits of the Lithography-Based Ceramic Manufacturing (LCM)." Journal of Materials Engineering and Performance 27, no. 1 (August 1, 2017): 14–20. http://dx.doi.org/10.1007/s11665-017-2843-z.

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Weigold, Matthias, Timo Scherer, Eric Schmidt, Martin Schwentenwein, and Thomas Prochaska. "Additive Fertigung keramischer Schneidstoffe." VDI-Z 162, no. 07-08 (2020): 38–41. http://dx.doi.org/10.37544/0042-1766-2020-07-08-38.

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Die additive Fertigung von Schneidstoffen bietet die Chance, leistungsfähigere Zerspanungswerkzeuge herzustellen. Vorgestellt wird zum einen das Lithography-based Ceramic-Manufacturing-(LCM)-Verfahren und zum anderen die Entwicklung damit gefertigter Wendeschneidplatten (WSP). Die Funktionstauglichkeit dieser keramischen WSP wird in Außenlängsdrehversuchen an vermicularem Gusseisen untersucht.

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Mihailescu, Cristian N., Mihai Oane, Bogdan A. Sava, Andrei C. Popescu, Mihail Elisa, Muhammad Arif Mahmood, Natalia Mihailescu, et al. "Laser Additive Manufacturing of Bulk Silicon Nitride Ceramic: Modeling versus Integral Transform Technique with Experimental Correlation." Crystals 12, no. 8 (August 16, 2022): 1155. http://dx.doi.org/10.3390/cryst12081155.

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A semi-analytical-numerical solution is theorized to describe the laser additive manufacturing via laser-bulk ceramic interaction modeling. The Fourier heat equation was used to infer the thermal distribution within the ceramic sample. Appropriate boundary conditions, including convection and radiation, were applied to the bulk sample. It was irradiated with a Gaussian spatial continuous mode fiber laser (λ = 1.075 µm) while a Lambert-Beer law was assumed to describe the laser beam absorption. A close correlation between computational predictions versus experimental results was validated in the case of laser additive manufacturing of silicon nitride bulk ceramics. The thermal field value rises but stays confined within the irradiated zone due to heat propagation with an infinite speed, a characteristic of the Fourier heat equation. An inverse correlation was observed between the laser beam scanning speed and thermal distribution intensity. Whenever the laser scanning speed increases, photons interact with and transfer less energy to the sample, resulting in a lower thermal distribution intensity. This model could prove useful for the description and monitoring of low-intensity laser beam-ceramic processing.

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Kirihara, Soshu. "Systematic Compounding of Ceramic Pastes in Stereolithographic Additive Manufacturing." Materials 14, no. 22 (November 22, 2021): 7090. http://dx.doi.org/10.3390/ma14227090.

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In this paper, stereolithographic additive manufacturing of ceramic dental crowns is discussed and reviewed. The accuracy of parts in ceramic processing were optimized through smart computer-aided design, manufacturing, and evaluation. Then, viscous acrylic resin, including alumina particles, were successfully compounded. The closed packing of alumina particles in acrylic pastes was virtually simulated using the distinct element method. Multimodal distributions of particle diameters were systematically optimized at an 80% volume fraction, and an ultraviolet laser beam was scanned sterically. Fine spots were continuously joined by photochemical polymerization. The optical intensity distributions from focal spots were spatially simulated using the ray tracing method. Consequently, the lithographic conditions of the curing depths and dimensional tolerances were experimentally measured and effectively improved, where solid objects were freely processed by layer stacking and interlayer bonding. The composite precursors were dewaxed and sintered along effective heat treatment patterns. The results show that linear shrinkages were reduced as the particle volume fractions were increased. Anisotropic deformations in the horizontal and vertical directions were recursively resolved along numerical feedback for graphical design. Accordingly, dense microstructures without microcracks or pores were obtained. The mechanical properties were measured as practical levels for dental applications.

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Kirihara, Soshu. "Fabrication of Bio-ceramic Implants by Stereolithographic Additive Manufacturing." Materia Japan 57, no. 4 (2018): 155–58. http://dx.doi.org/10.2320/materia.57.155.

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Kirihara, Soshu. "Additive manufacturing of ceramic components using laser scanning stereolithography." Welding in the World 60, no. 4 (March 24, 2016): 697–702. http://dx.doi.org/10.1007/s40194-016-0331-y.

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Jang, Seongwan, Sujin Park, and Chang-jun Bae. "Development of ceramic additive manufacturing: process and materials technology." Biomedical Engineering Letters 10, no. 4 (October 10, 2020): 493–503. http://dx.doi.org/10.1007/s13534-020-00175-4.

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Hensen, Tucker J., Trevor G. Aguirre, Corson L. Cramer, Austin S. Wand, Kaka Ma, David A. Prawel, John D. Williams, and Troy B. Holland. "Additive manufacturing of ceramic nanopowder by direct coagulation printing." Additive Manufacturing 23 (October 2018): 140–50. http://dx.doi.org/10.1016/j.addma.2018.07.010.

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Zhabin, A. N., and A. N. Nyafkin. "MANUFACTURING OF METAL-MATRIX COMPOSITE MATERIALS USING ADDITIVE TECHNOLOGIES (review)." Proceedings of VIAM, no. 2 (2022): 64–74. http://dx.doi.org/10.18577/2307-6046-2022-0-2-64-74.

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A review of scientific and technical literature in the field of obtaining metal-matrix composite materials (MMCM) reinforced with ceramic particles using additive technologies is presented. The structure, basic physical and mechanical properties and morphology of MMCM are briefly described. The structure and properties of MMCM reinforced with micro- and nano-sized ceramic particles are briefly described. The use of additive technologies for the manufacture of MMKM will make it possible to manufacture parts of a more complex shape, providing high adhesion between powder layers.

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Lei, Jincheng, Qiurui Zhang, Yihao Wang, and Haobo Zhang. "Direct laser melting of Al2O3 ceramic paste for application in ceramic additive manufacturing." Ceramics International 48, no. 10 (May 2022): 14273–80. http://dx.doi.org/10.1016/j.ceramint.2022.01.315.

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Zhang, Lei, Teng Wang, Jinxing Sun, Xiaoteng Chen, Xing Hong, Peng Zhou, and Jiaming Bai. "A study of lead-free (K0.5N0.5)NbO3 piezoelectric ceramics processed by additive manufacturing." Journal of Micromechanics and Molecular Physics 05, no. 04 (December 2020): 2050011. http://dx.doi.org/10.1142/s2424913020500113.

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Lead-free (K[Formula: see text]N[Formula: see text]NbO3 piezoelectric ceramics have drawn wide attention due to its environment-friendly and excellent piezoelectric performance. Since the difficulty of post-processing of ceramics limit its further development and practical application, three-dimensional (3D) printing technology has been developed in this work. A homogeneous piezoelectric ceramic suspension with 40 vol% modified (K[Formula: see text]N[Formula: see text]NbO3 nanoparticles can be 3D printed well based on a stereolithography process. In addition, by the post heat treatment under different sintering temperature, a density value of 4.31[Formula: see text]g[Formula: see text]cm[Formula: see text] with the relative density of about 96% was obtained in the sample sintered at 1120[Formula: see text]C, which results in the larger dielectric constant and lower dielectric loss in this sample. These printed ceramics exhibit two successive phase transitions and reduce with increase of sintering temperature at measured temperature range.

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Shulunov, Vyacheslav R. "A Roll Powder Sintering Additive Manufacturing Technology." Applied Mechanics and Materials 789-790 (September 2015): 1212–16. http://dx.doi.org/10.4028/www.scientific.net/amm.789-790.1212.

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This paper describes the roll powder sintering (RPS) technology providing breakthrough advantages for dominant rapid prototyping and manufacturing (RP&M) processes that are currently on the market. The RPS based on ribbon perforation where a powder needs to be poured, while it is being rewound. When the whole component roll is rewound, it is ready for a sintering plant. This technology has increased reliability, higher precision up to 77000 dpi, lower cost and power consumption. Processing time of plastic, ceramic, metal and other objects 1 m3 (or more) in volume directly from a 3D CAD model with a layer thickness of 30 μm is about 1 hour.

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Liu, Qiu, Shen, Jiao, Ye, Xie, Wang, Xiao, and Zhao. "Additive Manufacturing of Monolithic Microwave Dielectric Ceramic Filters via Digital Light Processing." Electronics 8, no. 10 (September 20, 2019): 1067. http://dx.doi.org/10.3390/electronics8101067.

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Microwave dielectric ceramics are employed in filters as electromagnetic wave propagation media. Based on additive manufacturing (AM) techniques, microwave dielectric ceramic filters with complex and precise structures can be fabricated to satisfy filtering requirements. Digital light processing (DLP) is a promising AM technique that is capable of producing filters with high accuracy and efficiency. In this paper, monolithic filters made from Al2O3 and TiO2, with a molar ratio of9:1 (0.9 Al2O3-0.1 TiO2), were fabricated by DLP. The difference in the dielectric properties between the as-sintered and post-annealed samples at different temperatures was studied. The experimental results showed that when sintered at 1550 °C for 2 h and post annealed at 1000 °C for 5 h, 0.9 Al2O3-0.1 TiO2 exhibited excellent dielectric properties: εr = 12.4, Q × f = 111,000 GHz, τf = + 1.2 ppm/°C. After comparing the measured results with the simulated ones in the passband from 6.5 to 9 GHz, it was concluded that the insertion loss (IL) and return loss (RL) of the filter meet the design requirements.

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Kirihara, Soshu. "Stereolithographic Additive Manufacturing of Ceramic Components by Using Nanoparticle Paste Feeding." Materials Science Forum 879 (November 2016): 2485–88. http://dx.doi.org/10.4028/www.scientific.net/msf.879.2485.

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Titania and alumina photonic crystals were fabricated by using stereolithographic additive manufacturing to control electromagnetic waves in terahertz frequency. Micro ceramic patterns were designed spatially by graphic software. Photosensitive liquid resin with ceramic particles were spread onto a grass substrate by mechanical knife edge, and two dimensional (2D) images were drawn using fine pattern exposing to create a cross sectional solid layer. After stacking these layers, the obtained three dimensional (3D) structures of composite precursors are dewaxed and sintered.

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Scheithauer, Uwe, Florian Kerber, Alexander Füssel, Stefan Holtzhausen, Wieland Beckert, Eric Schwarzer, Steven Weingarten, and Alexander Michaelis. "Alternative Process Routes to Manufacture Porous Ceramics—Opportunities and Challenges." Materials 12, no. 4 (February 22, 2019): 663. http://dx.doi.org/10.3390/ma12040663.

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Porous ceramics can be realized by different methods and are used for various applications such as cross-flow membranes or wall-flow filters, porous burners, solar receivers, structural design elements, or catalytic supports. Within this paper, three different alternative process routes are presented, which can be used to manufacture porous ceramic components with different properties or even graded porosity. The first process route is based on additive manufacturing (AM) of macro porous ceramic components. The second route is based on AM of a polymeric template, which is used to realize porous ceramic components via replica technique. The third process route is based on an AM technology, which allows the manufacturing of multimaterial or multiproperty ceramic components, like components with dense and porous volumes in one complex-shaped component.

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Journal articles on the topic 'Ceramic Additive Manufacturing'

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