A Review on Surface Finishing Techniques for Difficult-to-Machine Ceramics by Non-Conventional Finishing Processes

Heng, Lida; Kim, Jeong Su; Song, Jun; Mun, Sang Don

doi:10.3390/ma15031227

Cited by 9 publications

(3 citation statements)

References 104 publications

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“…Serving as armor protective materials, alumina ceramics with a light weight counteract high-speed ammunition by virtue of their high hardness and high strength [8,9]. However, special shapes are generally required for armor protection systems, and armor protection ceramics with a high strength and hardness must be processed using diamond grinding tools [10,11], and the expensive price of machining processing reaches about 80% of the total cost [12]. In addition, there are some complex shapes in armor protection systems which cannot be manufactured using available manufacturing technologies, and new manufacturing technology is desired.…”

Section: Introductionmentioning

confidence: 99%

Alumina Ceramics for Armor Protection via 3D Printing Using Different Monomers

Zhang,

Liang,

Chen

et al. 2024

Materials

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Alumina ceramic is an ideal candidate for armor protection, but it is limited by the difficult molding or machining process. Three-dimensional printing imparts a superior geometric flexibility and shows good potential in the preparation of ceramics for armor protection. In this work, alumina ceramics were manufactured via 3D printing, and the effects of different monomers on the photosensitive slurry and sintered ceramics were investigated. The photosensitive slurries using dipropylene glycol diacrylate (DPGDA) as a monomer displayed the optimal curing performance, with a low viscosity, small volume shrinkage and low critical exposure energy, and each of the above properties was conducive to a good curing performance in 3D printing, making it a suitable formula for 3D-printed ceramic materials. In the 3D-printed ceramics with DPGDA as a monomer, a dense and uniform microstructure was exhibited after sintering. In comparison, the sample with trimethylolpropane triacrylate (TMPTA) showed an anisotropic microstructure with interlayer gaps and a porosity of about 9.8%. Attributed to the dense uniform microstructure, the sample with DPGDA exhibited superior properties, including a relative density of 97.5 ± 0.5%, a Vickers hardness of 19.4 ± 0.8 GPa, a fracture toughness of 2.6 ± 0.27 MPa·m1/2, a bending strength of 690 ± 54 MPa, and a dynamic strength of 3.7 ± 0.6 GPa at a strain rate of 1200 s−1.

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Section: Introductionmentioning

confidence: 99%

Alumina Ceramics for Armor Protection via 3D Printing Using Different Monomers

Zhang,

Liang,

Chen

et al. 2024

Materials

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“…Tungsten carbide (WC) is one of the most important materials used for scientific research, industrial molds and products, and precision tools [ 1 , 2 , 3 ], owing to its high hardness, high strength, corrosion resistance [ 4 , 5 , 6 ], wide range of wear resistance and good fracture toughness [ 7 , 8 , 9 ]. Among the different kinds of WC, binder-less tungsten carbide (termed ‘WC-0Co’) is mainly used for the manufacture of precision molds in the fields of optics and aerospace [ 10 ].…”

Section: Introductionmentioning

confidence: 99%

Effect of the Binder during Ultra-Precision Polishing of Tungsten Carbide Using a Semirigid Bonnet Tool

et al. 2022

Materials

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Tungsten carbide (WC) has the characteristics of high hardness, high strength, corrosion resistance, wear resistance and excellent fracture toughness. Accordingly, it has been commonly used as the material for cutting tools and molds in glass-forming techniques. To obtain ultra-smooth surfaces, fine polishing of WC is indispensable. However, the efficiency of WC polishing is low using the existing polishing methods, and the mechanism behind the polishing process requires further investigation. Specifically, the effect of the binder in WC polishing is not clear since there are different kinds of WC with various weight percentages of the binder. In this paper, we present the findings of a study on the polishing performance of two kinds of WC material, with and without the binder, using a semi-rigid (SR) bonnet polishing tool. A series of experiments were performed on a 6-DOF robotic polishing instrument to investigate the material-removal characteristics, surface integrity and sub-surface damage after polishing. The results demonstrate that the SR bonnet polishing tool successfully reduced the surface roughness of WC with and without the binder to the nanometric level, though the lowest surface roughness was obtained on binder-less WC. No obvious sub-surface damage was observed under SEM inspection, while the processing efficiency was greatly improved owing to the high material removal rate of the tool. Based on our analysis of key polishing parameters and corresponding surface integrities, the effect of the binder on the polishing performance is explained, which offers excellent guidance for WC polishing.

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“…Rakesh Chaudhari et al [ 11 ] experimentally investigated the effect of alumina (Al2O3) nano-powder on the electrical discharge machining (EDM) process of a Nitinol shape memory alloy (SMA), and the related parameters were optimized via ANOVA analysis. Lida Heng et al [ 12 ] summarized the recent advances in non-conventional finishing processes for difficult-to-machine ceramics.…”

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confidence: 99%