Reaction moulding of metal and ceramic powders

A processing route for fabrication of products from hard metal and ceramic powders is described in which a reactive monomer such as ethylcyanoacrylate is used as carrier and binder with the opportunity of recovery through thermal depolymerization. A feasibility study has examined some of the main technical points including monomer–powder reactivity and rheology, debinding rates and compact green density. The stability of ethylcyanoacrylate with various powder volume fractions of silicon nitride and 316L stainless steel has been examined, with p-toluenesulphonic acid used as polymerization inhibitor, and it was found that mixes with higher powder volume fractions required higher levels of inhibitor. Assessment of the flow behaviour of several of the compositions showed them to be significantly non-Newtonian and the high viscosity of blends with a high loading of stainless steel suggests some premature polymerization. Measurement of green density of polymerized compacts demonstrated that high packing efficiency could be achieved. Thermogravimetry showed that rates of binder loss depended upon sample size and powder thermal conductivity.     

Freeform Fabrication of Ceramics via Stereolithography

Ceramic green bodies can be created using stereolithography methods where a ceramic suspension consisting of 0.40–0.55 volume fraction ceramic powder is dispersed within an ultraviolet-curable solution. Three ceramic materials were investigated: silica for investment casting purposes, and alumina and silicon nitride for structural parts. After mixing the powders in the curable solution, the ceramic suspension is photocured, layer by layer, fabricating a three-dimensional ceramic green body. Subsequent binder removal results in a sintered ceramic part. Three-dimensional objects have been fabricated from a 0.50 volume fraction silica suspension.     

Formation of permeable ceramics with a granular structure

A mechanism of formation of a permeable ceramic structure based on a granular filler and a fine-grained sintering binder is proposed. It is observed that the finely dispersed component lowers the permeability of the structure. The impossibility of obtaining a granular permeable structure in the case of using a binder made of reaction-sintered silicon nitride is demonstrated. Permeable ceramics is produced from granulated powder, which makes it possible to avoid the fine-grained component in the volume of permeable channel-shaped pores.     

Elaboration of PIM feedstocks with 316L fine stainless steel powders for the processing of micro-components

The paper is concerned with the way to prepare feedstocks for powder injection moulding of fine stainless steel powders. The way to prepare adequate feedstocks is described, and injection moulding experiments are determined. The effects of powder volume loading, as well as mixing conditions are investigated and the results indicate that powder loading, injection moulding conditions and sintering kinetics largely influence the resulting shrinkage after sintering. Finally, the modelling and associated numerical simulations are used the help process design.     

椎间融合器金属粉末注塑成型最佳烧结温度实验研究

采用喂料流动性能试验得到的最佳喂料配方和试样模具进行椎间融合器金属粉末注塑成型最佳烧结温度试验研究。结果表明,该配方喂料的最佳烧结温度为1 350℃,在该温度下烧结的316L不锈钢的物理性能最优,拉伸强度为486.8 MPa,烧结相对密度达到96.6%。与传统机械工艺得到的316L不锈钢相比,材料的物理性能和金相组织均差异不大。     

Aqueous tape casting of silicon nitride

Slurries consisting of a low cost silicon nitride powder, sintering aids yttria and alumina, dispersants, binders, defoamers and water as a solvent were optimised for tape casting by electroacoustic and viscosity measurements and by casting experiments. The slurries exhibit shear-thinning behaviour due to the highly shear-thinning binder emulsion. Crack free tapes with a maximum thickness of approx. 250 μm and a binder content of 13–15 wt.% could be obtained. The green tapes with a high flexibility and green strength could be laminated easily by compression at room temperature. After sintering a dense microstructure developed. A significant shrinkage anisotropy parallel and perpendicular to the cast direction was observed.     

Powder-binder separation in injection moulded green parts

For powder injection moulding (PIM) the ceramic powder is mixed with a thermoplastic binder system to achieve an injectable feedstock. In contrast to injection moulding of polymeric components, the binder must be removed after the shaping step before sintering the ceramic part to full density. During the mould filling process shear forces act on the blend that might cause separations of powder particles and binder. In this case polymer films form at the mould surface and at internal interfaces which induce microstructural defects in the debinded part. In particular for multi-component parts this effect is critical since binder films in the joining zone weaken the bonding strength between the two components that might even lead to delamination.For detecting binder separations within the injection moulded bulk material and at joining zones of two-component parts the microstructure of green samples has been studied. Since conventional machining techniques like grinding and polishing modify the original structure, e.g. when particles are pulled out of the matrix and binder smears onto the surface, a special ceramographic method for the preparation of cross-sections was applied. This approach bases on broad ion beam techniques and enables the simultaneous polishing of hard ceramic particles and soft polymer molecules without destroying the structure or producing a relief at the surface. In the analysed samples binder accumulations were found along flow lines, at weld lines, at boundaries of so-called dead water regions and at the interface of two-component parts.     

Differential sintering in ceramic injection moulding: particle orientation effects

The sintering shrinkage in three orthogonal directions was measured in sections cut from large rectangular injection moulded ceramic blocks. Two powders were used: a comminuted alumina and a chemically-derived zirconia. Pronounced anisotropy of shrinkage was observed in the former whereas the equiaxed zirconia showed uniform shrinkage throughout the moulding. The pattern of shrinkage anisotropy was consistent with that observed by other investigators and indicates that slight particle anisotropy can introduce differential sintering. The sintering shrinkage in the alumina powder was found to be most pronounced perpendicular to the main flow direction.     

The effect of water on the behaviour of alumina–paraffin suspensions for low-pressure injection moulding (LPIM)

The properties of ceramic powder–paraffin suspensions for low-pressure injection moulding (LPIM) is of critical importance to the successful production of high quality ceramic parts. Due to the high hygroscopicity of fine alumina powder, water introduced into the suspension at any stage of the production prior to sintering, may significantly influence its rheological behaviour and hence determine the process parameters as well as the properties of the sintered ceramics. In the industrial environment humidity cannot easily be avoided. Its effect is usually detrimental — it causes flocculation, which is usually the source of defects in sintered ceramics. However, according to the results of the present work, the effect can also be put to good use. Penetration of water into the as-moulded green parts facilitates binder removal and prevents defect formation during this processing step.     

Fabrication of coloured zirconia ceramics by infiltrating water debound injection moulded green body

Abstract

Abstract

The authors developed a new technique combining ceramic injection moulding and liquid precursor infiltration, presenting a new strategy for fabrication of coloured zirconia ceramics. The authors’ strategy includes ceramic injection moulding 3Y‐TZP powder using a water debinding binder system, debinding moulded parts in water and drying, immersing debound parts in solutions containing different colouring ions and then sintering and creating coloured zirconia ceramics. The fabricated coloured ceramic bars exhibit a core shell structure, and the thickness of the coloured shell can be tailored by adjusting immersion time and temperature. Using solutions containing different colouring ions, ceramic bars with various colours can be prepared.     

α-β Sialon Ceramics Made from Different Silicon Nitride Powders

The present work is concerned with the sintering of an α-β sialon ceramic using five different silicon nitride powders from a single source. The parameters varied in the silicon nitride were the amount of "free' silicon, iron content, α:β ratio, and grain size as measured by BET surface. The sintering atmosphere was varied by use of protective powder beds with passive (boron nitride) and active (SiO-generating) properties. Five sintering temperatures between 1600° and 1800°C were used. Microstructural characterization as well as density, hardness, and fracture toughness measurements were carried out. The sintering conditions were found to be critical for obtaining fully dense materials and low weight change. The optimum sintering temperature was 1750°C. The silicon nitride powder with a high content of free silicon resulted in a material which was more susceptible to the sintering atmosphere conditions. An α-β sialon made from a silicon nitride powder with a high β-α phase ratio resulted in a higher β-α ratio in the sintered material.     

氮化硅陶瓷的烧结

氮化硅陶瓷广泛用作高温结构材料,是很有前途的陶瓷材料之一。本文研究了氮化硅陶瓷烧结动力学,分析了影响氮化硅陶瓷烧结的因素,为氮化硅陶瓷烧结提供了依据     

Micro powder injection moulding of alumina micro-channel part

A feedstock consisting of submicron alumina powder and a formulated binder, was developed to fabricate alumina micro-channel part by micro powder injection moulding. During small scale-mixing, the mixing torques of feedstocks with four different powder loadings were used to establish a suitable powder loading. The thermal and rheological properties of the selected feedstock were examined and used to establish conditions for large scale mixing, debinding and injection moulding. The micro-channel parts were pressureless sintered at different temperatures. The results showed that the moulded, debound and sintered micro-channel parts had good shape retention. The dimensions of the micro-channel part changed with the different processing steps. High densification of the micro-channel parts was achieved at sintering temperatures of 1350 °C and above. Above 1350 °C, the grain grew significantly with increasing the sintering temperatures and thus it led to a decrease in the microhardness.     

加入纳米氮化硅对氮化硅陶瓷性能与结构影响

本文以亚微米级氮化硅为起始原料，加入纳米氮化硅来增强基体，添加氧化铝和氧化钇为烧结助剂，等静压成型，采用无压烧结的方式来制备具有优良性能的氮化硅陶瓷。主要研究了纳米氮化硅的分散；纳米氮化硅的加入量对氮化硅陶瓷力学性能的影响；纳米氮化硅的加入量对氮化硅陶瓷使用性能的影响；纳米氮化硅的加入量对氮化硅陶瓷显微结构的影响。研究结果表明：乙醇作为溶剂在分散介质为聚乙二醇的情况下，超声波震荡40分钟时，纳米氮化硅分散效果最好；随纳米氮化硅加入量的增加，显气孔率增加，吸水率增大；加入3wt％的纳米氮化硅时，试样的体积密度最大，抗弯强度、洛氏硬度、断裂韧性最好，具有较理想的显微结构。     

A Nanocomposite Ceramic Based on the Powder of a Carbon-In-Silicon Carbide Solid Solution

The synthesis of a nanocomposite powder of a solid solution of carbon in silicon carbide with controlled content of nitride phases is considered. A method of activated sintering for molding a pore-free nanocomposite ceramic with superior mechanical properties is proposed. Microstructure of the sintered ceramic is examined.     

Tape casting of non-aqueous silicon nitride slips

Tape casting is a powerful method for the manufacturing of flat, large area ceramic components. Silicon nitride is a reference material for high temperature structural applications. Between them, thick film/coating technologies and ceramic–ceramic joining are receiving an increased attention. In this work, the rheological behavior on non-aqueous silicon nitride slips for tape casting was investigated considering different solvent and binding systems, by controlling the total binder and plasticizer content and the binder to plasticizer ratio. A phosphate ester was used as dispersant. The characteristics of the green tapes obtained in different conditions were studied in terms of density, thickness and microstructure and related with the rheological properties of the slips. Once the slip properties were adjusted, manufacturing parameters, such as the casting speed and the gap between the blades and the carrier substrate, were also analyzed in order to improve the green tape properties and the process reliability. In order to obtain sinterable compacts, Al₂O₃ and Y₂O₃ were used as sintering aids. The effect of the sintering aids in both the rheological behavior and the green characteristics was also studied.     

Characterisation of micro gears produced by micro powder injection moulding

The paper describes the fabrication of micro gears of diameter and height 1 mm by micro powder injection moulding. 316L stainless steel powder of 2.4 µm (d₅₀) is mixed with a multi-component wax-based binder system. The feedstock is then injection-moulded into micro gears followed by debinding and sintering. The microstructure of the micro gear at its tooth and hub is studied by electron backscattered diffraction. The average grain size at the hub is ~ 5 µm. However, a high content of annealing twin and a significant grain growth is found at the tooth.     

氮化硅陶瓷材料微波烧结研究现状

氮化硅是一种具有优良性能的陶瓷材料,是一种理想的高温结构材料和高速切削刀具材料,近年来随着微波技术的发展,氮化硅的微波烧结越来越受关注。本文简述了氮化硅陶瓷材料传统烧结与微波烧结的研究现状;比较分析了各种烧结技术制备的氮化硅陶瓷的微观结构和力学性能,得出了微波烧结氮化硅陶瓷的优越性;最后提出氮化硅陶瓷微波烧结在未来研究中还需解决的问题。