Preparation and flowability characterization of ceramic powders for Selective Laser Melting

Mapar, Mahta; Zhang, D; Liu, Z; Yeong, Wai Yee; Chua, Chee Kai; Tay, B.Y.; Geramifard, O; Maleksaeedi, Saeed; Wiria, Florencia Edith

doi:10.1201/b15961-50

Cited by 5 publications

(2 citation statements)

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“…Common powder characteristics include angle of repose, bulk density, tapped density, Carr’s compressibility index and Hausner ratios, which are mainly for specific processes such as compaction, storage and volume filling (Rastogi and Klingzing, 1994; Shah et al , 2008). Thus, it is desirable to measure flowability at flow conditions that are representative of SLM processing conditions (Mapar et al , 2013). There is not much information on the powder performance index tailored to SLM of ceramics; hence, further research in this area is needed.…”

Section: Challenges and Potential In Laser Processing Of Ceramicsmentioning

confidence: 99%

Direct selective laser sintering and melting of ceramics: a review

Sing

Yeong

Wiria

et al. 2017

RPJ

295

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Purpose This paper aims to provide a review on the process of additive manufacturing of ceramic materials, focusing on partial and full melting of ceramic powder by a high-energy laser beam without the use of binders. Design/methodology/approach Selective laser sintering or melting (SLS/SLM) techniques are first introduced, followed by analysis of results from silica (SiO2), zirconia (ZrO2) and ceramic-reinforced metal matrix composites processed by direct laser sintering and melting. Findings At the current state of technology, it is still a challenge to fabricate dense ceramic components directly using SLS/SLM. Critical challenges encountered during direct laser melting of ceramic will be discussed, including deposition of ceramic powder layer, interaction between laser and powder particles, dynamic melting and consolidation mechanism of the process and the presence of residual stresses in ceramics processed via SLS/SLM. Originality/value Despite the challenges, SLS/SLM still has the potential in fabrication of ceramics. Additional research is needed to understand and establish the optimal interaction between the laser beam and ceramic powder bed for full density part fabrication. Looking into the future, other melting-based techniques for ceramic and composites are presented, along with their potential applications.

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Section: Challenges and Potential In Laser Processing Of Ceramicsmentioning

confidence: 99%

Direct selective laser sintering and melting of ceramics: a review

Sing

Yeong

Wiria

et al. 2017

RPJ

295

View full text Add to dashboard Cite

show abstract

“…Ceramic powder produced by crushing method has an angular shape and relatively high bulk density, which is widely used in the industry. Spherical particles atomized by spray drying technology from fine primary ceramic particles (<lpm) to tens of microns particle have a better flow ability compared with crushed products [87].…”

Section: Powder Layer Depositionmentioning

confidence: 99%

Selective laser melting of ceramic-based materials for dental applications

Mapar¹

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The employment ofthe Selective Laser Melting (SLM) technique in the processing o f ceramics has attracted attention recently. SLM is a powder-based AM process where powder spreading is one o f the fundamental. Therefore, a spray-drying process was chosen to improve powder properties to reach a proper powder for the SLM process. Also a dynamic powder characterisation methodology was used to investigate powder flow characteristic. A series o f SLM experiments were conducted using the spray-dried powder in three stages: single-track melting, single-layer melting and fabrication o f threedimensional (3D) blocks (multilayers). The objectives o f this set o f experiments were to establish the preliminary processing windows o f ceramics via SLM. Finally, multilayer or ceramic 3D blocks were experimented via SLM machine. However, the density o f the fabricated 3D parts was low and the parts were also fragile and unstable. These results showed that with current state o f technology, it is still a challenge to directly fabricate dense ceramic components using SLM. Following the insights obtained from these experiments, the critical challenges o f this project were identified and discussed, including ceramic powder layer deposition, laser-powder particles interaction, the dynamic melting and consolidation mechanism, process parameter optimisation and residual stress analysis ofthe ceramic materials processed with SLM.

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