Studies on thermoplastic 3D printing of steel–zirconia composites

Janics³

et al. 2019

JoVE

Self Cite

Technical ceramics are widely used for industrial and research applications, as well as for consumer goods. Today, the demand for complex geometries with diverse customization options and favorable production methods is increasing continuously. With fused filament fabrication (FFF), it is possible to produce large and complex components quickly with high material efficiency. In FFF, a continuous thermoplastic filament is melted in a heated nozzle and deposited below. The computer-controlled print head is moved in order to build up the desired shape layer by layer. Investigations regarding printing of metals or ceramics are increasing more and more in research and industry. This study focuses on additive manufacturing (AM) with a multi-material approach to combine a metal (stainless steel) with a technical ceramic (zirconia: ZrO 2 ). Combining these materials offers a broad variety of applications due to their different electrical and mechanical properties. The paper shows the main issues in preparation of the material and feedstock, device development, and printing of these composites. Video LinkThe video component of this article can be found at https://www.jove.com/video/57693/ 12 . Three different suspension-based AM techniques are qualified to allow the AM of ceramic-ceramic as well as metalceramic components. The utilization of suspension-based AM techniques promises improved component performance in comparison to powder- Journal of Visualized Experiments

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confidence: 99%

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confidence: 99%

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confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Fused Filament Fabrication (FFF) of Metal-Ceramic Components

Abel

Janics³

et al. 2019

JoVE

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“…The video component of this article can be found at https://www.jove.com/video/57538/ 14,15,16,17 . CerAM -T3DP is based on the selective deposition of single droplets of particle filled thermoplastic suspensions.…”

Section: Video Linkmentioning

confidence: 99%

Multi-material Ceramic-Based Components – Additive Manufacturing of Black-and-white Zirconia Components by Thermoplastic 3D-Printing (CerAM - T3DP)

Weingarten

Johne

et al. 2019

JoVE

Self Cite

To combine the benefits of Additive Manufacturing (AM) with the benefits of Functionally Graded Materials (FGM) to ceramic-based 4D components (three dimensions for the geometry and one degree of freedom concerning the material properties at each position) the Thermoplastic 3D-Printing (CerAM -T3DP) was developed. It is a direct AM technology which allows the AM of multi-material components. To demonstrate the advantages of this technology black-and-white zirconia components were additively manufactured and co-sintered defect-free.Two different pairs of black and white zirconia powders were used to prepare different thermoplastic suspensions. Appropriate dispensing parameters were investigated to manufacture single-material test components and adjusted for the additive manufacturing of multi-color zirconia components. Video LinkThe video component of this article can be found at https://www.jove.com/video/57538/ 14,15,16,17 . CerAM -T3DP is based on the selective deposition of single droplets of particle filled thermoplastic suspensions. By utilizing multiple dosing systems, different thermoplastic suspensions can be deposited beside each other layer by layer to produce bulk material as well as property gradients within the additively manufactured green components 18 . Unlike indirect AM processes, in which previously deposited materials solidify selectively over the entire layer, the CerAM -T3DP process does not require the additional effort of removing any non-solidified material prior to the deposition of the next material, making it more suitable for the AM of multi-material components.Although utilizing the CerAM -T3DP process allows the AM of FGM and the realization of ceramic-based components with unprecedented properties, there are challenges to overcome regarding the necessary thermal treatment after the AM process, in order to obtain a multimaterial composite. In particular, the paired powders in the composite material need to be successfully co-sintered, for which the sintering of the components has to be performed at the same temperature and atmosphere. Therefore, it is a prerequisite for all materials to have a comparable sintering temperature and behavior (starting temperature of sintering, shrinkage behavior). In order to avoid critical mechanical stress during cooling, the coefficient of thermal expansion of all materials has to be approximately equal 11 . The combination of materials with different properties in one component opens the door to components with unprecedented properties for manifold applications. E.g. stainless steel-zirconia composites can be used as cutting tools, wear resistant components, energy, and fuel cell Journal of Visualized Experiments

Processing of Thermoplastic Suspensions for Additive Manufacturing of Ceramic‐and Metal‐Ceramic‐Composites by Thermoplastic 3D‐Printing (T3DP)

Ceramic Transactions Series

Schwarzer

Haertel

et al. 2016

In our study we investigated the additive manufacturing (AM) of ceramic-based 11 Functionally Graded Materials (FGM) by the direct AM technology Thermoplastic 3D-Printing 12 (T3DP). Zirconia components with a varying microstructure were additively manufactured by 13 using thermoplastic suspensions with different contents of pore forming agents (PFA) and were co-14 sintered defect-free. 15 Different materials were investigated concerning their suitability as PFA for the T3DP process. 16 Different zirconia-based suspensions were prepared and used for AM of single-and multi-material 17 test components. All samples were sintered defect-free and in the end we could realize a brick wall-18 like component consisting of dense (<1% porosity) and porous (approx. 5% porosity) zirconia areas 19 to combine different properties in one component. 20 The T3DP opens the door to AM of further ceramic-based 4D-components like multi-color or multi-21 material, especially multi-functional components. 22