Additive manufacturing of advanced ceramic materials

Lakhdar, Yazid; Tuck, Christopher; Binner, Jon; Terry, Anna; Goodridge, Ruth

doi:10.1016/j.pmatsci.2020.100736

Cited by 466 publications

(218 citation statements)

References 274 publications

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“…High melting points, low tolerance to processing defects, limited choice of materials, excessive surface roughness, lumps, internal porosity, and surface micro-and macro-cracks [26] Apart from these techniques, another non-traditional machining techniques such as electro discharge machining (EDM) has also demonstrated its potential as an alternative machining technique for ceramics materials, as it offers several attributes including less tool consumption, no cutting forces, non-contact process, and independency of material hardness. This is an electrothermal process which removes material by melting and vaporization and therefore allows the machining of brittle materials irrespective of the mechanical properties such as wear resistance and hardness [27,28].…”

Section: Electro-chemical Machiningmentioning

confidence: 99%

Understanding Material Removal Mechanism and Effects of Machining Parameters during EDM of Zirconia-Toughened Alumina Ceramic

et al. 2021

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Non-conductive structural ceramics are receiving ever-increasing attention due to their outstanding physical and mechanical properties and their critical applications in aerospace and biomedical industries. However, conventional mechanical machining seems infeasible for the machining of these superior ceramics due to their extreme brittleness and higher hardness. Electro discharge machining (EDM), well known for its machining of electrically conductive materials irrespective of materials hardness, has emerged as a potential machining technique due to its noncontact nature when complemented with an assistive electrode technique. This paper investigates the material removal mechanism and effects of machining parameters on machining speed and dimensional and profile accuracies of features machined on zirconia toughened alumina (ZTA) ceramics using assistive electrode EDM. Our experimental results demonstrate that both increasing peak current and pulse on time improves the MRR, however, it also aids in generating thicker layer on machined surface. In addition, pulse interval time is crucial for the machining of nonconductive ceramics, as larger value might cause the complete removal of intrinsic carbon layer which may lead to non/sparking condition. Higher peak current increases circularity whereas short pulse on and pulse off time aid in increasing circularity due to rough machining. In addition, taperness is found to be regulated by the peak current and pulse on time. Overall, thermal cracking and spalling appear to be a dominating material removal mechanism other than melting and evaporation for the EDM of ZTA.

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Section: Electro-chemical Machiningmentioning

confidence: 99%

Understanding Material Removal Mechanism and Effects of Machining Parameters during EDM of Zirconia-Toughened Alumina Ceramic

et al. 2021

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“…1), and also led to surge increase in article publication in this research area. Several interesting review articles have been published too, in which working principles, advantages, and usefulness of various photopolymerization-based AM techniques are indicated [6,[36][37][38][39]. However, among those review articles, only few unraveled the significance of materialprinting process correlation for achieving defect-free structures with complex geometries and superior mechanical properties.…”

Section: Introduction mentioning

confidence: 99%

Photopolymerization-based additive manufacturing of ceramics: A systematic review

et al. 2021

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Conversion 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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“…Additive processes have been intensively studied in the last years [ 6 , 10 ]. By slurry-based technologies like Vat Polymerization or Inkjet Printing, very fine detailed structures can be realized but the devices are very expensive.…”

Section: Introductionmentioning

confidence: 99%

“…For Inkjet Printing due to small nozzle sizes, submicron powders are essentially [ 6 ]. Powder-based technologies like Direct Laser Sintering or Binder Jetting leads usually to highly porous parts [ 10 ]. Extrusion based technologies like Fused Filament Fabrication (FFF), also known as Fused deposition Modelling (FDM), or Robocasting, use inexpensive devices.…”

Section: Introductionmentioning

confidence: 99%

3D-Printed Hermetic Alumina Housings

et al. 2021

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Ceramics are repeatedly investigated as packaging materials because of their gas tightness, e.g., as hermetic implantable housing. Recent advances also make it possible to print the established aluminum oxide in a Fused Filament Fabrication process, creating new possibilities for manufacturing personalized devices with complex shapes. This study was able to achieve integration of channels with a diameter of 500 µm (pre-sintered) with a nozzle size of 250 µm (layer thickness 100 µm) and even closed hemispheres were printed without support structures. During sintering, the weight-bearing feedstock shrinks by 16.7%, resulting in a relative material density of 96.6%. The well-known challenges of the technology such as surface roughness (Ra = 15–20 µm) and integrated cavities remain. However, it could be shown that the hollow structures in bulk do not represent a mechanical weak point and that the material can be gas-tight (<10−12 mbar s−1). For verification, a volume-free helium leak test device was developed and validated. Finally, platinum coatings with high adhesion examined the functionalization of the ceramic. All the prerequisites for hermetic housings with integrated metal structures are given, with a new level of complexity of ceramic shapes available.

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Additive manufacturing of advanced ceramic materials

Cited by 466 publications

References 274 publications

Understanding Material Removal Mechanism and Effects of Machining Parameters during EDM of Zirconia-Toughened Alumina Ceramic

Understanding Material Removal Mechanism and Effects of Machining Parameters during EDM of Zirconia-Toughened Alumina Ceramic

Photopolymerization-based additive manufacturing of ceramics: A systematic review

3D-Printed Hermetic Alumina Housings

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