Fused deposition modeling of mullite structures from a preceramic polymer and γ-alumina

Gorjan, Lovro; Tonello, Riccardo; Sebastian, Tutu; Colombo, Paolo; Clemens, Frank

doi:10.1016/j.jeurceramsoc.2019.02.032

Cited by 59 publications

(39 citation statements)

References 25 publications

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“…The feedstock is a multicomponent polymer system highly filled with powder of the desired ceramic material [ 9 , 11 , 12 , 13 ]. Once the so-called green parts are shaped by FFF, the polymer components are removed in the debinding stage by a catalytic reaction [ 14 ], dissolution in a solvent [ 12 , 15 , 16 ] and/or thermal decomposition [ 9 , 17 , 18 , 19 ]. Finally, the parts are sintered to obtain nearly dense components.…”

Section: Introductionmentioning

confidence: 99%

Influence of the Infill Orientation on the Properties of Zirconia Parts Produced by Fused Filament Fabrication

et al. 2020

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The fused filament fabrication (FFF) of ceramics enables the additive manufacturing of components with complex geometries for many applications like tooling or prototyping. Nevertheless, due to the many factors involved in the process, it is difficult to separate the effect of the different parameters on the final properties of the FFF parts, which hinders the expansion of the technology. In this paper, the effect of the fill pattern used during FFF on the defects and the mechanical properties of zirconia components is evaluated. The zirconia-filled filaments were produced from scratch, characterized by different methods and used in the FFF of bending bars with infill orientations of 0°, ±45° and 90° with respect to the longest dimension of the specimens. Three-point bending tests were conducted on the specimens with the side in contact with the build platform under tensile loads. Next, the defects were identified with cuts in different sections. During the shaping by FFF, pores appeared inside the extruded roads due to binder degradation and or moisture evaporation. The changes in the fill pattern resulted in different types of porosity and defects in the first layer, with the latter leading to earlier fracture of the components. Due to these variations, the specimens with the 0° infill orientation had the lowest porosity and the highest bending strength, followed by the specimens with ±45° infill orientation and finally by those with 90° infill orientation.

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Section: Introductionmentioning

confidence: 99%

Influence of the Infill Orientation on the Properties of Zirconia Parts Produced by Fused Filament Fabrication

et al. 2020

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“…Quite recently FFF-printing of a comparable system (50 vol.% alumina), ethylene vinyl acetate (EVA) as binder, SA as surfactant) allowed for similar sinter densities around (sinter temperature 1600 °C) 98%–99% Th. [ 25 ]. The listed shrinkage values ( Table 5 ) must be explained in detail: The given deviation values do not represent the standard deviation, but the absolute deviation from the arithmetic mean value.…”

Section: Resultsmentioning

confidence: 99%

“…The fabrication of ceramic or metallic parts by FFF has the major advantage that experience derived from powder injection molding (PIM) helps to develop highly filled feedstocks (ceramic: >45 vol.%, metal: >60 vol.% solid load) with a similar binder composition [ 23 , 24 ]. Considering only ceramics, up to now mostly sintered alumina or mullite [ 23 , 24 , 25 , 26 ], zirconia [ 27 , 28 , 29 ], or silicon nitride [ 30 ] parts have been realized, typical binder components are paraffin wax, (modified) polyolefines, or thermoplastic elastomers. Fatty-acid derivatives, like stearic acid, or commercial additives with proprietary composition, are widely established as surfactants or plasticizers [ 23 , 24 , 25 , 27 , 28 , 30 , 31 ].…”

Section: Introductionmentioning

confidence: 99%

“…Considering only ceramics, up to now mostly sintered alumina or mullite [ 23 , 24 , 25 , 26 ], zirconia [ 27 , 28 , 29 ], or silicon nitride [ 30 ] parts have been realized, typical binder components are paraffin wax, (modified) polyolefines, or thermoplastic elastomers. Fatty-acid derivatives, like stearic acid, or commercial additives with proprietary composition, are widely established as surfactants or plasticizers [ 23 , 24 , 25 , 27 , 28 , 30 , 31 ]. Like feedstocks in ceramic injection molding, two component binder mixtures are often applied, one low molecular mass material allows a low melt viscosity at moderate temperatures and one high molecular mass fraction (backbone polymer) delivers a certain mechanical stability at lower temperatures after shaping.…”

Section: Introductionmentioning

confidence: 99%

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New Feedstock System for Fused Filament Fabrication of Sintered Alumina Parts

Nötzel

Hanemann

2020

Materials

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Only a few 3D-printing techniques are able to process ceramic materials and exploit successfully the capabilities of additive manufacturing of sintered ceramic parts. In this work, a new two component binder system, consisting of polyethyleneglycol and polyvinylbutyral, as well stearic acid as surfactant, was filled with submicron sized alumina up to 55 vol.% and used in fused filament fabrication (FFF) for the first time. The whole process chain, as established in powder injection molding of ceramic parts, starting with material selection, compounding, measurement of shear rate and temperature dependent flow behavior, filament fabrication, as well as FFF printing. A combination of solvent pre-debinding with thermal debinding and sintering at a reduced maximum temperature due to the submicron sized alumina and the related enhanced sinter activity, enabled the realization of alumina parts with complex shape and sinter densities around 98 % Th. Finally the overall shrinkage of the printed parts were compared with similar ones obtained by micro ceramic injection molding.

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“…3D 打印(增材制造)是以数字模型为基础, 将材料逐层堆积制造出实体物品的新兴制造技术, 具有个性化、快速化和节约化等特点, 是材料先进制备与成型技术研究的前沿热点之一, 在结构陶瓷材料领域具有广阔的应用前景。结构陶瓷材料一般熔点较高, 以激光束作为能量源的直接激光选区烧结 (SLS) 、激光选区熔覆 (SLM)或激光工程化净尺寸成型(LENS)等技术存在难以获得高密度的陶瓷材料、坯体内应力大和开裂或晶粒尺寸不易控制等问题 [1][2][3] 。立体光固化(SLA) 和数字光处理(DLP)技术虽然打印精度高、产品表面质量高, 但陶瓷颗粒与光敏树脂的折射率差异带来的散射会影响层间结合和打印精度, 打印浆料中粉体易团聚或沉降也会影响打印浆料的稳定性 [4][5] 。直写成型(DIW)方法虽然可以得到高密度陶瓷材料, 但也存在打印精度低和浆料稳定性差等问题 [6][7] 。熔融沉积成型(FDM)使用的耗材混合料为固态, 不存在陶瓷颗粒悬浮稳定性差的问题。该方法适用粉体广, 易于得到致密陶瓷材料, 适合制备大尺寸部件。研究者尝试将该技术用于 ZrO 2 、Al 2 O 3 和 Si 3 N 4 等结构陶瓷材料的制备, 在耗材混合料和多孔陶瓷的制备等方面取得了一定的进展 [8][9][10][11] 。传统 FDM 打印一般采用柔性的线材作为耗材, 而陶瓷粉体和有机物混合料脆性较大, 无法制备出柔性线材, 或者因线材柔性不足而断裂导致打印过程中断。近年来 Texas 大学 [12] 、Fraunhofer 研究所 [13] 和深圳大学 [14] [15] 提出了非随机多孔陶瓷抗压强度和气孔率之间的关系, 如式(2)所示。图 6 3D 打印多孔氧化锆陶瓷 Fig. 6 3D printing porous zirconia ceramics…”

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3D Printed Zirconia CeramicsviaFused Deposit Modeling and Its Mechanical Properties

Zhang¹,

Yang²,

Xu³

et al. 2021

Journal of Inorganic Materials

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Dense and porous zirconia ceramics were 3D printed with granular feedstock and screw extrusion mechanism on the basis of the traditional fused deposition method. The printability of granular feedstock, microstructure of the body and mechanical properties of ceramic materials were studied. The unsupported structure with maximum inclination 165° and span 5.5 mm were obtained. Effects of the two filling modes of printing on the flexural strength and Weibull modulus of the dense zirconia ceramics were compared. The results showed that the "single line+rectangle" filling mode was more conducive to achieve higher density and better mechanical properties than the traditional single line filling mode. Materials with bending strength of 637.8 MPa and Weibull modulus of 9.1 were obtained. The compressive behavior of porous zirconia ceramics prepared with different porosities were studied, showing an exponential law between compressive strength and porosity. There was only elasticity stage on the stress-strain curve for the samples with high porosity, while collapse stage may appear for the samples with low porosity. There was 第 4 期张力, 等: 熔融沉积法 3D 打印制备氧化锆陶瓷及其力学性能研究 437 no collapse stage for both samples.

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Fused deposition modeling of mullite structures from a preceramic polymer and γ-alumina

Cited by 59 publications

References 25 publications

Influence of the Infill Orientation on the Properties of Zirconia Parts Produced by Fused Filament Fabrication

Influence of the Infill Orientation on the Properties of Zirconia Parts Produced by Fused Filament Fabrication

New Feedstock System for Fused Filament Fabrication of Sintered Alumina Parts

3D Printed Zirconia CeramicsviaFused Deposit Modeling and Its Mechanical Properties

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