Fabrication of fine-grained alumina ceramics by a novel process integrating stereolithography and liquid precursor infiltration processing

Liu, Wei; Wu, Haidong; Zhou, Maopeng; He, Rongxuan; Jiang, Qiangguo; Wu, Ziwei; Cheng, Yong; Song, Xuan; Chen, Yong; Wu, Shanghua

doi:10.1016/j.ceramint.2016.08.099

Cited by 33 publications

(12 citation statements)

References 22 publications

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“…As for the conventional shaping with high precision such as gel casting and injection molding, postprocessing could be relatively simple due to the fact that they are near‐net‐forming technologies. However, even for ceramic near‐net forming techniques, sintered bodies often require further machining using carbide or diamond cutting tools, or laser to ensure adequate levels of precision in the size and shape of the fabricated product, eg, zirconia ceramic ferrule with the internal bore diameter of 125 μm used for optical fiber connector produced by injection molding. For micro‐injection molding, the high molds expense could not be avoided .…”

Section: Introductionmentioning

confidence: 99%

3D printing of dense structural ceramic microcomponents with low cost: Tailoring the sintering kinetics and the microstructure evolution

Liu

Tian

et al. 2018

J Am Ceram Soc

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In this study, we have successfully developed a unique 3D printing approach based on mask-image-projection stereolithography (MIP-SL) to fabricate structural ceramics microcomponents with low cost and high efficiency. Ultra-dense submicron crystalline ceramics without fierce grain growth could be obtained via tailoring the sintering kinetics. The ZrO 2 ceramic microcomponents reached the highest relative density (RD) of 99.7% with the average grain size of 0.52 μm upon sintering at 1550°C while the Al 2 O 3 ceramic microcomponents reached its highest RD of 98.31% with the average grain size of 2.6 μm upon sintering at 1600°C.Oxide ceramics microcomponents of fully flexible design can be produced easily without visible defects via the method developed in this study, which demonstrates significant potential in the applications of microelectromechanical systems, micro-optical electronics systems and micro-opto-electro-mechanical systems. The method developed in this study has addressed the problem successfully by healing the interlayer interface defects in densification process via the sintering kinetic window and microstructure evolution. The current work provides a promising opportunity to fabricate structural ceramic microcomponents with complex shape, high precision, and high surface smoothness. K E Y W O R D S

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Section: Introductionmentioning

confidence: 99%

3D printing of dense structural ceramic microcomponents with low cost: Tailoring the sintering kinetics and the microstructure evolution

Liu

Tian

et al. 2018

J Am Ceram Soc

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“…In this sense, for the AZ25 composition, the energy demand required for migration and diffusion of grain boundary in TSS1 T 2 was possibly lower than in TSS2 T 2 13 . Incomplete densification is achieved due to insufficient diffusion of the grain boundary 40 . For Zhang et al, 13 the increase in T 2 first activates the diffusion of the grain boundary and, consequently, promotes densification, resulting in higher density.…”

Section: Resultsmentioning

confidence: 98%

Microstructure and mechanical properties of Al₂O₃/ZrO₂ composites by two‐step sintering

Ojaimi

Ferreira

Chinelatto

et al. 2020

Int J Applied Ceramic Tech

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Composites of Al2O3/ZrO2 (containing 25, 50, and 75 vol% ZrO2) were prepared by mixing Al2O3 and ZrO2 suspensions. The microstructural control via two‐step sintering (TSS) was the main objective of this work. For this purpose, different sintering curves were constructed, aiming to achieve the best temperature combination for the sintering steps that provides higher density and finer microstructure. The results were compared with single‐step sintering (SSS). Furthermore, microhardness and fracture toughness were measured for the best TSS specimens under each composition. The results showed that the high densities were obtained, and the reduction of grain size was greater than 40% for two‐step sintered specimens, compared to SSS ones. Consequently, microhardness values increased. However, fracture toughness values remained unchanged.

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“…Additive manufacturing (AM) is a toolless-forming method that is used to improve the fabrication of ceramic parts with more complex geometries, higher resolutions, and fewer post-processing than other ceramic forming [4][5][6]. Among the AM techniques used for ceramics, the stereolithography apparatus (SLA) is a direct approach of manufacturing ceramic parts without using molds or post-processing, and it is becoming popular owing to its high resolution and surface quality [6][7][8][9]. SLA uses a laser as the projector, which scans the photosensitive suspensions, resulting in its point-by-point polymerization.…”

Section: Introductionmentioning

confidence: 99%

Three-dimensional printing of blue-colored zirconia accessories using digital light processing-based stereolithography

Wang

et al. 2021

Journal of Asian Ceramic Societies

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Digital light processing (DLP) based stereolithography opens new possibilities for fabricating ceramic accessories with complex structures. The cure depth is a critical criterion for analyzing the production efficiency of ceramic accessories. As predicted using the absorption model, the absorbance from the photoinitiator and dye has a direct effect on the cure depth. In this study, blue-colored powder composed of 3 mol% yttria-stabilized tetragonal zirconia polycrystals (3Y-TZP) and CoAl 2 O 4 powder was prepared through ball-milling. The cure depth of a single layer exposed to varying energy levels was measured, and the values of the depth sensitivity S d and critical energy E c were also calculated. The results showed that the absorbance of blue-colored 3Y-TZP powder increased with CoAl 2 O 4 content, which increased the critical energy E c and depth sensitivity reciprocal 1/S d . Compared with the pure 3Y-TZP, the cure depth decreased, which was attributable to the absorbance of CoAl 2 O 4 . In addition, blue-colored accessories were fabricated using the DLP method, and the microstructures of the accessories were characterized through scanning electron microscopy.

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Fabrication of fine-grained alumina ceramics by a novel process integrating stereolithography and liquid precursor infiltration processing

Cited by 33 publications

References 22 publications

3D printing of dense structural ceramic microcomponents with low cost: Tailoring the sintering kinetics and the microstructure evolution

3D printing of dense structural ceramic microcomponents with low cost: Tailoring the sintering kinetics and the microstructure evolution

Microstructure and mechanical properties of Al₂O₃/ZrO₂ composites by two‐step sintering

Three-dimensional printing of blue-colored zirconia accessories using digital light processing-based stereolithography

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Fabrication of fine-grained alumina ceramics by a novel process integrating stereolithography and liquid precursor infiltration processing

Cited by 33 publications

References 22 publications

3D printing of dense structural ceramic microcomponents with low cost: Tailoring the sintering kinetics and the microstructure evolution

3D printing of dense structural ceramic microcomponents with low cost: Tailoring the sintering kinetics and the microstructure evolution

Microstructure and mechanical properties of Al2O3/ZrO2 composites by two‐step sintering

Three-dimensional printing of blue-colored zirconia accessories using digital light processing-based stereolithography

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Microstructure and mechanical properties of Al₂O₃/ZrO₂ composites by two‐step sintering