Epoxy infiltrated 3D printed ceramics for composite tooling applications

Maravola, Michael; Conner, Brett; Walker, Jason; Cortes, Pedro

doi:10.1016/j.addma.2018.10.036

Cited by 13 publications

(10 citation statements)

References 13 publications

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“…It was found that the CTE of the sintered parts yielded a value of about 24x10 −6 K −1 , which is higher than reported elsewhere. 37 In contrast, the CTE of the transformed parts resulted in an average value of 11.02x10 -6 K -1 , which is two times lower than the aluminum alloy used on current composite tooling molds. These cracks can certainly compromise the mechanical performance of the structure as a composite tooling mold.…”

Section: F I G U R E 8 Compressive Stress-strainmentioning

confidence: 87%

“…A feasible approach to overcome this disadvantage is the incorporation of a coating with high temperature thermoset resins as performed on other 3D printed ceramic systems used for manufacturing composites. 37 In contrast, the CTE of the transformed parts resulted in an average value of 11.02x10 -6 K -1 , which is two times lower than the aluminum alloy used on current composite tooling molds. 36 These IPCs appear to produce robust and stable carbon fiber reinforced epoxy parts as reported by Cortes et al 38 .…”

Section: F I G U R E 8 Compressive Stress-strainmentioning

confidence: 87%

“…They printed carbon-based porous structures followed by a silicon infiltration. 37 A preliminary work performed by Cortes et al 38 showed that composite tooling based on IPCs yielded stable and well consolidated high temperature carbon fiber reinforced epoxy composites. Esposito Corcione et al 31 have also worked on prototyping silica molds for aluminum casting using SLA.…”

Section: Introductionmentioning

confidence: 99%

“…36 Indeed, one critical property that needs to be addressed on the production of fiber reinforced thermoset composites is the dimensionally stability during the curing process. 37 A preliminary work performed by Cortes et al 38 showed that composite tooling based on IPCs yielded stable and well consolidated high temperature carbon fiber reinforced epoxy composites. IPCs are commonly fabricated by immersing a ceramic oxide precursor into a molten metal.…”

Section: Introductionmentioning

confidence: 99%

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The fracture properties of metal‐ceramic composites manufactured via stereolithography

Mummareddy

Maravola

MacDonald

et al. 2019

Int J Applied Ceramic Tech

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In this work, metal-ceramic composite parts based on aluminum and alumina were manufactured in a two-stage process. First, silica was printed using a vat photopolymerization technique, followed by a curing and sintering stage, which resulted in ceramic precursors. Subsequently, these samples were subjected to a metal infiltration process to form interpenetrating metal-ceramic composites (IPCs). These composites have attracted considerable attention in the aerospace and defense sector due to the ductility associated to the metal phase and the strength offered by the ceramics. A novel application with utility includes composite tooling which requires a low coefficient of thermal expansion (CTE) for high temperatures. The investigated specimens were tested for surface quality and shrinkage, followed by a mechanical characterization. It was recorded that the samples presented a 12%-18% of shrinkage after the sintering process. The mechanical testing showed that the hardness, compression, and flexural strength of the composites were superior to the printed and sintered ceramics. A thermal analysis on the composite showed that its CTE is more than two times lower than the common composite tooling materials. It is expected that the present work can provide the foundations for further studies on these systems in the refractory, automotive, and armor-based fields. K E Y W O R D Sceramic-metal systems, fracture, mechanical properties 414 | MUMMAREDDY Et Al.

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Section: F I G U R E 8 Compressive Stress-strainmentioning

confidence: 87%

Section: F I G U R E 8 Compressive Stress-strainmentioning

confidence: 87%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

The fracture properties of metal‐ceramic composites manufactured via stereolithography

Mummareddy

Maravola

MacDonald

et al. 2019

Int J Applied Ceramic Tech

Self Cite

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“…The same research was done in References [ 22 , 23 ] but for orthodontic models. Maravola et al [ 24 ] used an epoxy polymer for infiltrating tooling moulds based on silica sand and zirconia produced via binder jetting. Ayres et al [ 25 ] investigated various infiltrates and different infiltration methods to improve mechanical strength and temperature performance of plaster binder jetting parts.…”

Section: Introductionmentioning

confidence: 99%

Towards Functional Parts by Binder Jetting Calcium-Sulphate with Thermal Treatment Post-Processing

et al. 2020

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The objective of our research is to improve the properties of calcium-sulphate hemihydrate parts printed by binder jetting. In this paper, we show the thermal treatment results when using temperature time ramps on binder-jetted ceramic parts without infiltrating. The results show that the mechanical properties of printed parts are improved substantially. Two different thermal cycles were investigated for their effect on the dehydration process of CaSO4·½H2O using infrared analysis. The thermal-treated samples were compared with respect to porosity, surface roughness, compression strength and dimensional and weight variation. The proposed thermal treatment significantly improves the compression strength in a short time, guaranteeing dimensional stability while providing a good surface. This improvement in mechanical properties offers a great chance for using binder-jetted parts as functional components, for example, in the casting field or the medical sector (scaffolds).

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Additive manufacturing and foundry innovation

et al. 2021

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Additive manufacturing is expected to transform and upgrade the traditional foundry industry to realize the integrated manufacturing and rapid and low-cost development of high-performance components with complex shapes. The additive manufacturing technology commonly applied in casting mold preparation (fusible molds, sand molds/cores and ceramic cores) mainly includes selective laser sintering (SLS) and binder injection threedimensional printing (3DP). In this work, the research status of SLS/3DPcasting processes on material preparation, equipment development, process optimization, simulation and application cases in aerospace, automotive and other fields were elaborated. Finally, the developing trends of the additive manufacturing technology in the future of foundry field are introduced, including multi-material sand molds (metal core included), ceramic core-shell integration and die-casting dies with conformal cooling runners.

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Epoxy infiltrated 3D printed ceramics for composite tooling applications

Cited by 13 publications

References 13 publications

The fracture properties of metal‐ceramic composites manufactured via stereolithography

The fracture properties of metal‐ceramic composites manufactured via stereolithography

Towards Functional Parts by Binder Jetting Calcium-Sulphate with Thermal Treatment Post-Processing

Additive manufacturing and foundry innovation

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