Advances in crack formation mechanism and inhibition strategy for ceramic additive manufacturing

Liu, Zhiwen; Ma, Chaoqun; Chang, Zhengxu; Pei, Yan; Li, Fazhi

doi:10.1016/j.jeurceramsoc.2023.05.008

Cited by 22 publications

(5 citation statements)

References 134 publications

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“…Pore characteristics, such as porosity, pore size, and pore shape, are important factors affecting the mechanical properties of the sintered samples, which typically exhibit incomplete densification [ 36 , 39 , 40 , 41 ]. And the pores are potential areas for localized stress concentration and also play an important role in representing the potential sites of the first cracks forming [ 37 , 40 , 42 ].…”

Section: Resultsmentioning

confidence: 99%

Investigation on the Attainment of High-Density 316L Stainless Steel with Selective Laser Sintering

Zhu,

He,

Guan

et al. 2023

Materials

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Due to the low density of the green part produced by selective laser sintering (SLS), previous reports mainly improve the sample’s density through the infiltration of low-melting metals or using isostatic pressing technology. In this study, the feasibility of preparing high-density 316L stainless steel using 316L and epoxy resin E-12 as raw materials for SLS combined with debinding and sintering was investigated. The results indicated that in an argon atmosphere, high carbon and oxygen contents, along with the uneven distribution of oxygen, led to the formation of impurity phases such as metal oxides, including Cr2O3 and FeO, preventing the effective densification of the sintered samples. Hydrogen-sintered samples can achieve a high relative density exceeding 98% without losing their original design shape. This can be attributed to hydrogen’s strong reducibility (effectively reducing the carbon and oxygen contents in the samples, improving their distribution uniformity, and eliminating impurity phases) and hydrogen’s higher thermal conductivity (about 10 times that of argon, reducing temperature gradients in the sintered samples and promoting better sintering). The microstructure of the hydrogen-sintered samples consisted of equiaxed austenite and ferrite phases. The samples exhibited the highest values of tensile strength, yield strength, and elongation at 1440 °C, reaching 513.5 MPa, 187.4 MPa, and 76.1%, respectively.

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Section: Resultsmentioning

confidence: 99%

Investigation on the Attainment of High-Density 316L Stainless Steel with Selective Laser Sintering

Zhu,

He,

Guan

et al. 2023

Materials

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“…Cracking stands out as the predominant and detrimental defect in dAMed ceramic oxides. It significantly constrains the mechanical performance of as-printed components, rendering them unreliable and susceptible to premature failure [179]. The ceramic oxides are particularly vulnerable to cracking in laser processing, which arises from the interplay of inherent material properties, characterized by high melting point, low thermal shock resistance and the brittleness, and the dAM procedure itself, which features rapid cooling, steep thermal gradients, and complex thermal cycling.…”

Section: Cracks Formation Mechanismmentioning

confidence: 99%

Advances and challenges in direct additive manufacturing of dense ceramic oxides

Fan,

Tan,

Kang

et al. 2024

Int. J. Extrem. Manuf.

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Ceramic oxides, renowned for their exceptional combination of mechanical, thermal, and chemical properties, are indispensable in numerous crucial applications across diverse engineering fields. However, conventional manufacturing methods frequently grapple with limitations, such as challenges in shaping intricate geometries, extended processing durations, elevated porosity, and substantial shrinkage deformations. Direct additive manufacturing (dAM) technology stands out as a state-of-the-art solution for ceramic oxides production. It facilitates the one-step fabrication of high-performance, intricately designed components characterized by dense structures. Importantly, dAM eliminates the necessity for post-heat treatments, streamlining the manufacturing process and enhancing overall efficiency. This study undertakes a comprehensive review of recent developments in dAM for ceramic oxides, with a specific emphasis on the laser powder bed fusion and laser directed energy deposition techniques. A thorough investigation is conducted into the shaping quality, microstructure, and properties of diverse ceramic oxides produced through dAM. Critical examination is given to key aspects including feedstock preparation, laser–material coupling, formation and control of defects, in-situ monitoring and simulation. This paper concludes by outlining future trends and potential breakthrough directions, taking into account current gaps in this rapidly evolving field.

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Section: Types and Mechanisms Of Residual Stress In Ammentioning

confidence: 99%

“…Similarly, constraint stress is developed due to the displacement constraints in the solidified region. In indirect additive manufacturing processes such as SLA, thermal stress is developed due to the temperature gradient, and contraction stress is developed due to solidification and cooling [34]. Mercelis et al [24] explained the formation mechanism of residual stress with the help of a temperature gradient mechanism (TGM) model and cool-down phase model.…”

Section: Types and Mechanisms Of Residual Stress In Ammentioning

confidence: 99%

A Review of the Residual Stress Generation in Metal Additive Manufacturing: Analysis of Cause, Measurement, Effects, and Prevention

Bastola,

Jahan,

Rangasamy

et al. 2023

Micromachines

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Metal additive manufacturing (AM) is capable of producing complex parts, using a wide range of functional metals that are otherwise very difficult to make and involve multiple manufacturing processes. However, because of the involvement of thermal energy in the fabrication of metallic AM parts, residual stress remains one of the major concerns in metal AM. This residual stress has negative effects on part quality, dimensional accuracy, and part performance. This study aims to carry out a comprehensive review and analysis of different aspects of residual stress, including the causes and mechanisms behind the generation of residual stress during metal AM, the state-of-the-art measurement techniques for measuring residual stress, various factors influencing residual stress, its effect on part quality and performance, and ways of minimizing or overcoming residual stress in metal AM parts. Residual stress formation mechanisms vary, based on the layer-by-layer deposition mechanism of the 3D printing process. For example, the residual stress formation for wire-arc additive manufacturing is different from that of selective laser sintering, direct energy deposition, and powder bed fusion processes. Residual stress formation mechanisms also vary based on the scale (i.e., macro, micro, etc.) at which the printing is performed. In addition, there are correlations between printing parameters and the formation of residual stress. For example, the printing direction, layer thickness, internal structure, etc., influence both the formation mechanism and quantitative values of residual stress. The major effect residual stress has on the quality of a printed part is in the distortion of the part. In addition, the dimensional accuracy, surface finish, and fatigue performance of printed parts are influenced by residual stress. This review paper provides a qualitative and quantitative analysis of the formation, distribution, and evolution of residual stress for different metal AM processes. This paper also discusses and analyzes both in situ and ex situ measurement techniques for measuring residual stress. Microstructural evolution and its effect on the formation of residual stress are analyzed. Various pre- and post-processing techniques used to countermeasure residual stress are discussed in detail. Finally, this study aims to present both a qualitative and quantitative analysis of the existing data and techniques in the literature related to residual stress, as well as to provide a critical analysis and guidelines for future research directions, to prevent or overcome residual stress formation in metal AM processes.

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Advances in crack formation mechanism and inhibition strategy for ceramic additive manufacturing

Cited by 22 publications

References 134 publications

Investigation on the Attainment of High-Density 316L Stainless Steel with Selective Laser Sintering

Investigation on the Attainment of High-Density 316L Stainless Steel with Selective Laser Sintering

Advances and challenges in direct additive manufacturing of dense ceramic oxides

A Review of the Residual Stress Generation in Metal Additive Manufacturing: Analysis of Cause, Measurement, Effects, and Prevention

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