Conventional versus additive manufacturing in the structural performance of dense alumina-zirconia ceramics: 20 years of research, challenges and future perspectives

Olhero, Susana M.; Torres, Paula M.C.; Mesquita‐Guimarães, J.; Baltazar, Joana; Pinho-da-Cruz, J.; Gouveia, Sónia

doi:10.1016/j.jmapro.2022.02.041

Cited by 65 publications

(14 citation statements)

References 359 publications

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“…Examples of conventional fabrication methods include gel casting [4], direct foaming [5], isostatic pressing [6], slip casting [7], etc. AM methods could perform better in creating ceramic components with complex geometries and designs [8]. Examples of AM processes include stereolithography [9], direct ink writing [10], binder jetting [11], and selective laser sintering [12].…”

Section: Introductionmentioning

confidence: 99%

Next generation of advanced ceramic 3D printers

Choppala¹,

Allam²,

Fang³

et al. 2023

futech

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Ceramic on-demand extrusion (CODE) is a novel slurry-based additive manufacturing (AM) process for technical ceramics. Extensive characterization studies have shown that this process produces dense ceramic specimens with relatively improved mechanical properties such as flexural strength, fracture toughness, hardness, etc. The objective of the current study was to develop the next generation of CODE. The CODE printer created consists of an aluminum extrusion frame, a three-axis gantry system, an extruder, and a heat lamp. The ceramic slurry is fed to an extruder that prints parts onto a bedplate. The green body parts are then subject to postprocessing, including drying, debinding, and sintering. Ceramic composites and functionally graded materials are created using CODE to further study the process. Furthermore, a real-time deep learning defect detection protocol to identify common defects of CODE while printing, as well as a control feedback system to implement corrective action based on the defect detected, is being developed.

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Section: Introductionmentioning

confidence: 99%

Next generation of advanced ceramic 3D printers

Choppala¹,

Allam²,

Fang³

et al. 2023

futech

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“…In order to assess and analyze recent review articles in this area, a Scopus search was conducted in April 2023 for the specific time frame of 2018–2023. This search resulted in 165 review articles on ceramic additive manufacturing or some subset of that topic 1,3–166 . Figure 1 shows a graphical representation of the number of review articles separated into five focus areas.…”

Section: Introductionmentioning

confidence: 99%

Future directions in ceramic additive manufacturing: Fiber reinforcements and artificial intelligence

Rueschhoff,

Baldwin,

Hardin

et al. 2023

J Am Ceram Soc.

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Research in the field of ceramic additive manufacturing (AM) has been rapidly accelerating, resulting in hundreds of publications and review articles in recent years. While strides have been made in forming near‐net and complex‐shaped ceramic components, challenges remain that inhibit more widespread implementation. In this perspective, we provide a meta‐analysis of recent review articles and highlight a deficiency in two areas of promising future directions to address remaining challenges. The first is incorporation of fiber reinforcements in printed parts to overcome the challenges of poor mechanical performance of monolithic ceramics. Recent work in the area has shown promise incorporating discrete fiber reinforcements as an easier use case given existing equipment limitations, but continuous fibers are needed to reach full toughness potential. Here, we overview some options and future directions bases on success in polymer composites. Second, artificial intelligence (AI) approaches, including machine learning (ML), are suggested in order to accelerate feedstock development and process optimization. While there has been very limited work to date in utilizing AI/ML techniques for ceramic AM, again inspiration and lessons learned are drawn from the polymer AM community.

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“…6 These methods are limited in shape complexity and often require specialized tooling and several postprocessing steps; both of which are costly in time and resources. 6,7 Additive Manufacturing (AM) offers a unique approach to producing ceramic near-net and complex-shaped parts, which are not otherwise achievable through conventional means. 8 Additionally, AM allows for rapidly prototyping more conventional designs at a much lower cost since it does not require the expensive tooling that is necessary for traditional ceramic processing such as injection molding.…”

Section: Introductionmentioning

confidence: 99%

“…17,[20][21][22] In order to densify the printed part, the resin is thermally or chemically removed first, often leading to gas/bubble formation, interlayer delamination, and cracking during sintering. 7,23,24 Consequently, DLP is limited by part thickness and offers limited solutions for parts with geometric features greater than ∼10 mm in any direction. 24 It is therefore realized that the thermal debind process is one of the critical processes that can be investigated to help reduce interlayer delamination and cracking of a final component.…”

Section: Introductionmentioning

confidence: 99%

Delamination mitigation in additively manufactured Al₂O₃ via enhanced thermal postprocessing

Lam,

Kassner,

Kemp

et al. 2023

Int J Applied Ceramic Tech

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Manufacturing thick (>10 mm) alumina (Al2O3) parts through the ceramic additive manufacturing technique of digital light processing (DLP) is difficult due to the large amount of polymer that must be removed. Nearly 35–65 vol% of a fugitive UV‐curable polymer is used in commercial ceramic slurries in order to maintain shape through the DLP process. During the thermal debind, gases form and escape quickly due to pressure build‐up, leading to defects in the form of print layer delamination. Here, we analyze the polymer decomposition through thermogravimetric analysis in order to design a less aggressive thermal debind schedule through strategic thermal holds and decreased heating rates. The new schedule led to a 83% reduction in average delaminations per sample (from 6.9 delaminations per sample to 1.2 delaminations per sample) and up to a 100% increase in wall thickness (from nominally 10–20 mm). A complex, Al2O3 turbine rotor (with maximum wall thickness of 5 mm in the center hub section) of a JetCat P400 engine was fabricated to compare the new schedule to the manufacturer provided one. The improved thermal debind schedule produced a turbine rotor with no observable delamination defects.

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Conventional versus additive manufacturing in the structural performance of dense alumina-zirconia ceramics: 20 years of research, challenges and future perspectives

Cited by 65 publications

References 359 publications

Next generation of advanced ceramic 3D printers

Next generation of advanced ceramic 3D printers

Future directions in ceramic additive manufacturing: Fiber reinforcements and artificial intelligence

Delamination mitigation in additively manufactured Al₂O₃ via enhanced thermal postprocessing

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Conventional versus additive manufacturing in the structural performance of dense alumina-zirconia ceramics: 20 years of research, challenges and future perspectives

Cited by 65 publications

References 359 publications

Next generation of advanced ceramic 3D printers

Next generation of advanced ceramic 3D printers

Future directions in ceramic additive manufacturing: Fiber reinforcements and artificial intelligence

Delamination mitigation in additively manufactured Al2O3 via enhanced thermal postprocessing

Contact Info

Product

Resources

About

Delamination mitigation in additively manufactured Al₂O₃ via enhanced thermal postprocessing