Fabrication of ZrO2 and ATZ materials via UV-LCM-DLP additive manufacturing technology

Borlaf, Mario; Szubra, Natalia; Serra-Capdevila, Albert; Kubiak, Władysław W.; Graule, Thomas

doi:10.1016/j.jeurceramsoc.2019.11.037

Cited by 67 publications

(29 citation statements)

References 33 publications

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“…The customization concerns the device's ability for VIS and UV polymerization. The UV polymerization is used for the development of formulations [25,27]. In this study, the commercial VIS unit was used as the dispersion provided by Lithoz calls for a wavelength of 460 nm.…”

Section: Lithography-based Ceramics Manufacturing (Lcm)mentioning

confidence: 99%

Effects of the Layer Height and Exposure Energy on the Lateral Resolution of Zirconia Parts Printed by Lithography-Based Additive Manufacturing

et al. 2020

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Lithography-based ceramics manufacturing (LCM) processes enable the sophisticated 3 dimensional (3D) shaping of ceramics by additive manufacturing (AM). The build-up occurs, like many other AM processes, layer by layer, and is initiated by light. The built-in digital mirror device (DMD) enables the specific exposure of desired pixels for every layer, giving as a consequence a first estimation of the printing resolution in the x and y axes. In this work, a commercial zirconia slurry and the CeraFab 7500, both from Lithoz GmbH (Vienna, Austria), were used to investigate the potential of reaching this resolution. The results showed that the precision of a part is strongly dependent on the applied exposure energy. Higher exposure energies resulted in oversized dimensions of a part, whereas too low energy was not able to guarantee the formation of a stable part. Furthermore, the investigation of the layer thickness showed that the applied exposure energy (mJ/cm2) was acting in a volume, and the impact is visible in x, y, and z dimensions. The lowest applied exposure energy was 83 mJ/cm2 and showed the most accurate results for a layer thickness of 25 μm. With this energy, holes and gaps smaller than 500 μm could be printed; however, the measurements differed significantly from the dimensions defined in the design. Holes and gaps larger than 500 μm showed deviations smaller than 50 μm from the design and could be printed reliably. The thinnest printable gaps were between 100 and 200 μm. Concerning the wall thickness, the experiments were conducted to a height of 1 cm. Taking into account the stability and deformation of the walls as well, the best results after sintering were achieved with thicknesses of 200–300 μm.

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Section: Lithography-based Ceramics Manufacturing (Lcm)mentioning

confidence: 99%

Effects of the Layer Height and Exposure Energy on the Lateral Resolution of Zirconia Parts Printed by Lithography-Based Additive Manufacturing

et al. 2020

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“…Figure 1 shows the viscosity of zirconia photosensitive slurries used in additive manufacturing by VP 1, [32][33][34][35][36]38 according to volume fraction (at a shear rate of 30 s -1 ) and the dotted rectangle identifies the preferred characteristics for suspensions (at least 40 vol% solid loading and up to 3 Pa.s viscosity). It is important to note that the three studies that achieved these characteristics used solvent-based slurries.…”

Section: Introductionmentioning

confidence: 99%

3Y-TZP DLP Additive Manufacturing: Solvent-free Slurry Development and Characterization

Camargo

Erbereli

Taylor³

et al. 2021

Mat. Res.

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Vat photopolymerization (VP) stands out among ceramic additive manufacturing processes for its ability to print sub-100 micrometer complex features. One of the main challenges of this process is the preparation of a homogeneous and stable ceramic slurry with a high solid load and low viscosity. In this work, different dispersants and resins were tested, aiming to provide a solvent-free slurry suitable for DLP additive manufacturing. Disperbyk-111 and PEGDA 250 stood out in the tests, providing a 40 vol% ceramic slurry with no noticeable sedimentation and viscosity of 2.3 Pa.s at 30 s -1 despite the relatively high specific surface area (15 m 2 /g) of the 3Y-TZP powder used compared to powders usually used for VP slurries. The adsorption of Disperbyk-111 on ceramic particles surface was investigated by FTIR. Finally, ceramic bodies were 3D printed, debound and sintered at 1500 ºC for 2 h, confirming the ability to manufacture detailed dense ceramic parts.

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“…However, ZrO2 is sensitive to hydrothermal aging [4][5][6], and its hardness [2,7] is lower than that of zirconia toughened alumina (ZTA) [8][9] and Al2O3 ceramics [10], which limits its use as biomaterials or wear-resistant devices. There have been some works to improve the mechanical properties of ZrO2 ceramics through the ATZ method to make them more reliable and stable [6,[11][12][13][14][15][16][17][18][19].…”

Section: Introductionmentioning

confidence: 99%

“…Moreover, there are a few nanoparticles in Al2O3 and ZrO2 grains, which exerts the effect of intracrystalline nano-toughening. This kind of microstructure is difficult to be realized by the previous preparation methods of nano-ATZ ceramics [6,[11][12][13][14][15][16][17][18][19]. More importantly, ZrO2 contained unprecipitated Al2O3, which may be very beneficial to improve the aging resistance of ZrO2 ceramics.…”

Section: Introductionmentioning

confidence: 99%

Microstructural evolution and mechanical properties of nano-ATZ ceramics by solid solution precipitation

Yang

Yuan

et al. 2021

Preprint

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Alumina toughened zirconia (ATZ) nanoceramics with high-strength, high-toughness and high-hardness were prepared by in-situ nanoprecipitation from solid solution micro-powders. The submicron Al2O3 (~ 450 nm) and ZrO2 (~ 350 nm) grains contained low-density precipitated nano-ZrO2 (~ 40 nm) and nano-Y4Al2O9 (YAM, ~ 90 nm) particles, respectively, making high-performance nano-ATZ ceramics with ultrafine intracrystalline nanostructure yet achieved. There was a parallel or eutectic lattice orientation relationship between the submicrocrystals and its internal nanoparticles of their crystal planes, which is very conducive to the improvement of the mechanical properties of nano-ATZ ceramics. The fracture toughness and hardness of 30wt%Al2O3/70wt%ZrO2(3mol%Y2O3) can be as high as 5.68 ± 0.17 MPa·m1/2 (single-edge V-notched beam method, SEVNB) and 16.32 ± 0.45 GPa, respectively, which are improved by ~ 25 % and ~ 20 % compared with those of 3Y-TZP ceramics. Therefore, this method can be used to prepare nano-ATZ ceramics contained ultrafine nanoparticles and uniform distribution of Al2O3 phases.

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Fabrication of ZrO2 and ATZ materials via UV-LCM-DLP additive manufacturing technology

Cited by 67 publications

References 33 publications

Effects of the Layer Height and Exposure Energy on the Lateral Resolution of Zirconia Parts Printed by Lithography-Based Additive Manufacturing

Effects of the Layer Height and Exposure Energy on the Lateral Resolution of Zirconia Parts Printed by Lithography-Based Additive Manufacturing

3Y-TZP DLP Additive Manufacturing: Solvent-free Slurry Development and Characterization

Microstructural evolution and mechanical properties of nano-ATZ ceramics by solid solution precipitation

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