Study on surface quality,precision and mechanical properties of 3D printed ZrO2 ceramic components by laser scanning stereolithography

Zirconia (ZrO₂) ceramic bars with three different printing sizes were fabricated by a stereolithographic (SLA) 3D-printing process and subsequent sintering. An anisotropic character of the ceramics surface quality was observed. The surface roughness of the horizontal surface was below 0.41 µm, whereas it reached 1.07 µm along the fabrication direction on the vertical surface. The warpage and flatness were utilized to measure the dimensional accuracy of the 3D printed ZrO₂. Furthermore, it was evaluated that the warpage and flatness were below 40 µm and 27 µm, respectively, even if the printed size of ceramic bar reached 3 mm × 4 mm × 80 mm. In addition, the flexural strength, the fracture toughness, the hardness and the density of ZrO₂ ceramics can reach to 1154 ± 182 MPa, 6.37 ± 0.25 MPa m^1/2, 13.90 ± 0.62 GPa and up to 99.3%, respectively. Moreover, the effects of scanning paths and printing size on properties of the sintered ZrO₂ samples were analyzed. The anisotropic character of surface quality was related to the various scanning paths. The warpage and flatness of 3D printed ZrO₂ bars were apparently affected by the various printed sizes. Also, the effects of special microstructure on the mechanical properties of sintered ZrO₂ samples were investigated.     

Effect of binder system on the thermophysical properties of 3D-printed zirconia ceramics

Fabrication of 3D-printed ceramic parts with high complexity and high spatial resolution often demands low wall thickness as well as high stiffness at the green state, whereas printing simpler geometries may tolerate thicker, more compliant walls with the advantage of a rapid binder-burn-out and sintering process. In this work, the influence of the binder system on the thermophysical properties of 3D-printed stabilized zirconia ceramics was investigated. Samples were fabricated with the lithography-based ceramic manufacturing (LCM) technology using two different photosensitive ceramic suspensions (LithaCon 3Y230 and LithaCon 3Y210), with the same ZrO₂ powder. A significant difference in stiffness in the green state (~3 MPa vs. ~32 MPa for LithaCon 3Y230 and LithaCon 3Y210, respectively) was measured, associated with a rather loose or a linked network formed in the binder due to photopolymerization. Both materials reached high relative densities, that is, >99%, exhibiting a homogeneous fine-grained microstructure. No significant differences on the coefficient of thermal expansion (11.18 ppm/K vs. 11.17 ppm/K) or Young's modulus (207 GPa vs. 205 GPa) were measured, thus demonstrating the potential of tailoring binder systems to achieve the required accuracy in 3D-printed parts, without detrimental effects on material's microstructure and thermophysical properties at the sintered state.     

High-pressure structural stability,equation of state,and thermal expansion behavior of cubic HfO2

The structural stability, equation of state, and thermal expansion behavior of nanocrystalline cubic HfO₂, an ultra-high-temperature ceramic, have been investigated using X-ray diffraction at extreme conditions of pressures and temperatures. High-pressure studies show that the cubic structure is stable up to 26.2 GPa, while the high-temperature studies show the stability of the cubic structure up to 600°C. The Rietveld structure refinement of the high-pressure data reveals the progressive transition of secondary monoclinic phase to the cubic phase at higher pressures. The phase progression is accompanied by incompressibility along the b axis and a large compressibility along the c axis of the monoclinic structure. The second-order Birch-Murnaghan equation of state fit to the unit cell volume data yielded a bulk modulus of 242(16) GPa for the cubic structure. A linear thermal expansion value of α_a(c) = 8.80(15) × 10⁻⁶°C⁻¹ and a volume thermal expansion value of α_v = 26.5(4) × 10⁻⁶°C⁻¹ have been determined from the in situ high-temperature X-ray diffraction studies. The results are discussed by comparing with the high-pressure and high-temperature behavior of isostructural ZrO₂. To the best of our knowledge, this is the first experimental report on the structural stability of cubic HfO₂ at high pressures.     

Impact of ZrO2 alloying on thermo-mechanical properties of Gd3NbO7

The ZrO₂ alloying effect is widely used to optimize the thermo-mechanical properties of potential thermal barrier coatings. In this study, dense x mol% ZrO₂-Gd₃NbO₇ with C222₁ space group were manufactured via a solid-state reaction. The crystalline structure was determined through X-ray diffraction and Raman spectroscopy, when the surface morphology was observed by scanning electron microscopy. ZrO₂-Gd₃NbO₇ had identical orthorhombic crystal structures, and there was no second phase. The crystalline structure of ZrO₂-Gd₃NbO₇ shrunk with the increasing ZrO₂ content as indicated by XRD and Raman results. The heat capacity and thermal diffusivity of ZrO₂-Gd₃NbO₇ were 0.31–0.43 J g⁻¹ K⁻¹ (25–900 °C) and 0.25–0.70 mm²/s (25–900 °C), respectively. It was found that ZrO₂-Gd₃NbO₇ had much lower thermal conductivity (1.21–1.82 W m⁻¹ K⁻¹, 25–900 °C) than YSZ (2.50–3.00 W m⁻¹ K⁻¹) and La₂Zr₂O₇ (1.50–2.00 W m⁻¹ K⁻¹). The thermal expansion coefficients (TECs) were higher than 10.60 × 10⁻⁶ K⁻¹ (1200 °C), which were better than that of YSZ (10.00 × 10⁻⁶ K⁻¹) and La₂Zr₂O₇ (9.00 × 10⁻⁶ K⁻¹). The mechanical properties of Gd₃NbO₇ change little with the increasing ZrO₂ content, Vickers hardness was about 10 GPa, and Young's modulus was about 190 GPa, which was lower than YSZ (240 GPa). Compared with previous work about alloying effects, much lower thermal conductivity was obtained. Due to the high melting point, high hardness, low Young's modulus, ultralow thermal conductivity and high TECs, it is believed that ZrO₂-Gd₃NbO₇ is promising TBCs candidate.     

Li2ZrO3 based Li-ion conductors doped with halide ions & sintered in oxygen-deficient atmosphere

All-solid-state batteries have recently attracted much attention for their high energy density and safety. Li₂ZrO₃-based Li-ion conductors with high electrochemical stability have potential applications for electrolytes in all-solid-state batteries. In this work, comparative investigations of Li₂ZrO₃ and halogen doped Li₂ZrO₃ ceramics were conducted by sintering at 700 °C in air or in oxygen-deficient atmosphere which was induced by a simple setup covering with corundum crucible. The analysis of phase composition reveals that the undoped Li₂ZrO₃ ceramic sintered in air contains pure monoclinic phase, while halogen-doped Li₂ZrO₃ sintered in air and all ceramics sintered in oxygen-deficient atmosphere are simultaneously composed of monoclinic and tetragonal phases. Li₂ZrO₃ ceramic with tetragonal phases has higher conductivity (0.28 mS cm⁻¹ for undoped Li₂ZrO₃) than the pure monoclinic Li₂ZrO₃ (0.07 mS cm⁻¹), and halogen doping can further enhance the conductivity of Li₂ZrO₃ ceramics higher than 0.5 mS cm⁻¹ at room temperature.     

Preparation of ultralow thermal conductivity (Mg0.5Ca0.3Ba0.2) (AlSi)2O8 ceramics

A type of nonequimolar multicomponent ceramic solid solution (Mg_0.5Ca_0.3Ba_0.2) (AlSi)₂O₈ with a low thermal conductivity was prepared through solid-state synthesis. Results show that the (Mg_0.5Ca_0.3Ba_0.2) (AlSi)₂O₈ solid solution exhibits excellent high-temperature stability and an ultralow thermal conductivity (.3676 W m⁻¹ K⁻¹), far lower than widely used 3YSZ (2.9 W m⁻¹ K⁻¹), La₃NbO₇ (1.5 W m⁻¹ K⁻¹), and Gd₂Zr₂O₇ (1.28 W m⁻¹ K⁻¹). Furthermore, the Young modulus of the final product is 64.56 GPa. Therefore, the proposed ceramic solid solution provides a new research direction for ultralow thermal conductivity materials and has a practical application value for the field of wall thermal insulation.     

Multifunctional carbon nanofiber-reinforced Ge25Sb10S65 chalcogenide glassy composites

Carbon nanomaterials have wide applications in sensors, batteries, electromagnetic shielding, and mechanical reinforcement. Here, carbon nanofiber (CNF)-reinforced Ge₂₅Sb₁₀S₆₅ chalcogenide glassy composites with excellent mechanical and electrical properties were obtained. These glassy composites maintained the amorphous properties of glass. Thermodynamic parameters, microscopic morphology, and structural characteristics were further studied. Benefiting from the remarkable high strength and conductivity of CNFs, as well as the great interface connection between CNFs and glass, the electrical and mechanical properties of glassy composites were greatly enhanced. The Vickers hardness improved by 36% (from 200 kg/mm² to 272 kg/mm²), the tensile modulus increased from 45.9 GPa to 57 GPa, and the shear modulus increased from 22.2 GPa to 23.7 GPa when the CNF concentration increased from 0 wt% to 3.0 wt%. Furthermore, DC conductivity was raised by several orders of magnitude compared with bulk glass at 293 K (from 4.55 × 10⁻¹⁰ S/cm to 3.15 × 10⁻⁴ S/cm) owing to the formation of a continuous conductive network. Thus, these CNF-reinforced glassy composites provide a new way for realizing multifunctional composites.     

Laser additive manufacturing of melt-grown Al2O3/GdAlO3 eutectic ceramic composite: Powder designs and crack analysis with thermo-mechanical simulation

Directed energy deposition method is an efficient one-step laser additive manufacturing technology to achieve eutectic ceramic composite with high property and ultra-fine microstructures. In this paper, melt grown dense Al₂O₃/GdAlO₃(GAP) eutectic ceramic composites have been directly fabricated from the spherical powder reconstructed by an optimized spray granulation method. Effects of the powder size distribution, feeding rate, and heat treatment on the morphology and microstructure of the as-solidified eutectic ceramic composites have been investigated. Results show that the powder fluidity plays an important role in the heat conduction of the laser process. Finer powder (imperfect spherical powder with diameter less than 10 µm) gives rise to the disturbance of molten pool. Moreover, this powder greatly aggravates the phenomenon of powder’ sticking on surface of the specimen, which subsequently induces the leading growth of coarse dendrite-like GAP primary phases (higher interface temperature of dendrite tip for GAP phase) and sintered eutectic phases at the specimen edge. The finite element modeling (FEM) method is used to analysis the coupled thermal dynamic during the process after verification with infrared thermal image. It shows that longitudinal maximum principal stress exhibits a steep gradient at the edges of the as-solidified ceramic, making the specimen susceptible to cracking along the deposited direction at the first few layers. By optimizing the feedstock powder characteristics and the directed energy deposition process, completely solidified cylindrical and thin-walled Al₂O₃/GAP eutectic ceramic composites with the maximum dimensions of ? 4 × 95 mm³ and 10 × 4 × 44 mm³ have been successfully fabricated. The solidified specimens present smooth glossy surface and fine microstructures with the average eutectic spacing of 0.31 µm. The average micro-hardness and fracture toughness of 15.16 ± 0.29 GPa and 4.3 ± 0.09 MPa·m^1/2 have been obtained, respectively.     

Preparation and mechanical properties of the 2.5D ASf/ZrO2 composites after high-temperature heat treatment

In the paper, the aluminosilicate fiber-reinforced zirconia (AS_f/ZrO₂) ceramic composites were successfully fabricated by polymer impregnation and pyrolysis (PIP) method. The microstructure and high-temperature mechanical properties of the original composites were well studied. The results revealed that the composites could maintain the stability of microstructure at 1000 °C. The flexural strength increased from 58.82 ± 2.83 MPa to 88.74 ± 6.20 MPa and the flexural modulus increased from 29.26 ± 4.67 GPa to 40.76 ± 8.76 GPa. The thermal exposure improved the interfacial bonding and made the load transfer more effective. After heat treatment from 1200 °C to 1400 °C, the flexural strength gradually declined due to the crystallization of the AS fibers and ZrO₂ matrix, while the flexural modulus increased in a completely different trend. After heat treatment at 1400 °C, the composites could maintain a flexural strength of 66.95 ± 4.24 MPa with a flexural modulus of 60.42 ± 7.25 GPa. But the fracture mode gradually evolved to brittleness.     

Mechanical and thermal properties of δ-RE4Hf3O12 (RE = Yb,Lu)

Rare-earth (RE) hafnates are promising thermal and environmental barrier coating (TEBC) materials for SiC_f/SiC ceramic matrix composites. In this study, pure-phase and dense δ-RE₄Hf₃O₁₂ (RE = Yb, Lu) bulk ceramics have been fabricated via a hot-pressing method. The crystal structure, microstructure, mechanical, and thermal properties of δ-RE₄Hf₃O₁₂ were systematically investigated in order to probe their potential application as TEBCs. The high-temperature elastic moduli of δ-Yb₄Hf₃O₁₂ and δ-Lu₄Hf₃O₁₂ are measured to be 185 and 188 GPa at 1673 K, respectively, which are over 85% values of room temperature. The coefficients of thermal expansion are 7.64 × 10⁻⁶ and 7.46 × 10⁻⁶ K⁻¹ for δ-Yb₄Hf₃O₁₂ and δ-Lu₄Hf₃O₁₂, respectively. The relatively low coefficient of thermal expansion and thermal conductivity as well as their excellent high-temperature stability endow these hafnates as potential TEBC candidates.     

Thermal ablation behavior of SiBCN-Zr composites prepared by reactive spark plasma sintering

To meet the ultrahigh temperature requirements of a thermal protection system, an ultrahigh temperature phase of ZrB₂ was introduced into a SiBCN matrix that was fabricated using a reactive spark plasma sintering method. The thermal ablation behavior of SiBCN-Zr composites was investigated using an oxyacetylene flame test. The test results indicated that the ablation behavior of the modified ceramic composites was significantly improved over that of a monolithic SiBCN ceramic. The linear and mass ablation rates of the SiBCN-Zr material were found to be 0.004 mm/s and 4.75×10⁻⁴ g/s, which was indicative of excellent ablation resistance. Analysis of the material after thermal ablation testing showed that ablation products mainly consisted of the ZrSiO₄, SiO₂ and ZrO₂ phases. A reaction occurred between the SiO₂ and ZrO₂ phases in the central region of the ceramic forming ZrSiO₄ that protected the material from further thermal damage. A loose and porous oxidation layer was found from the matrix based on analysis of a cross-section image.     

Study on the effect and mechanism of zirconia on the sinterability of yttria transparent ceramic

Transparent Y₂O₃ ceramics were fabricated by solid-state reaction using high purity Y₂O₃ and ZrO₂ powder as starting material. The results indicated that ZrO₂ additive can improve the transparency of Y₂O₃ ceramic greatly. The best transmittance appears with 3 at.% ZrO₂ doped Y₂O₃ transparent ceramic with transmittance at 1100 nm of 83.1%, which is up to 98.6% of the theoretical value. The microstructure is uniform and no secondary phase is observed in the ceramic with the average grain size of 15 μm. The mechanism of ZrO₂ improving the transparency of Y₂O₃ ceramic is analyzed in detail. On this basis, Yb³⁺ doped Y₂O₃ transparent ceramic was also fabricated and spectroscopic properties were investigated.     

Properties and in vitro assessment of ZrO2-based coatings obtained by atmospheric plasma jet spraying on biodegradable Mg-Ca and Mg-Ca-Zr alloys

Magnesium (Mg)-based biodegradable alloys have gained a major interest in the biomedical field. The advantages of Mg alloys are depicted by their high biocompatibility, easy biodegradation and satisfactory mechanical properties. However, one major disadvantage of these alloys is represented by their low corrosion resistance in physiological environment. Coatings are considered to be a viable alternative used to improve corrosion, mechanical and cell viability properties of Mg- based metallic alloys. In this paper, two types of ceramic coating materials ZrO₂-Y₂O₃ and ZrO₂-CaO were deposited on Mg-Ca and Mg-Ca-Zr substrates by the atmospheric plasma jet technique. The two types of the deposited coatings exhibit similar Young modulus and a hardness in the range of 0.2–0.4 GPa. Values of the elastic modulus for the layers were measured to be in the range of 11–27 GPa for ZrO₂-Y₂O₃ and of 16–31 GPa for ZrO₂-CaO. The corrosion rate for the ZrO₂-CaO coating has superior values than that for the ZrO₂-Y₂O₃ one. The ZrO₂-CaO coated samples present a better adhesion to the substrate. The MTT colorimetric tests (3-(4,5-dimethyl-thiazol–2-yl)-2,5-diphenyl tetrazolium bromide) did not reveal significant differences in cytocompatibility between the two types of coatings, presenting a moderate cell viability.     

High Transparency Nd: Y2O3 Ceramics Prepared with La2O3 and ZrO2 Additives

High transparency Nd: Y₂O₃ ceramics were prepared by vacuum sintering with La₂O₃ and ZrO₂ sintering additives. The optimum in‐line transmittance of the sintered Nd: Y₂O₃ is 80.98% at the wavelength of 1100 nm, for which the content of La₂O₃ and ZrO₂ are 10.0 and 3.0 at.%, respectively. This specimen demonstrates homogeneous microstructure with the average grain size of 8.3 μm. The mechanism of sintering with La₂O₃ and ZrO₂ aids and the optical properties was discussed. The absorption, emission cross section, and fluorescence lifetime have been estimated as 1.62 × 10^?20 cm², 5.13 × 10^?20 cm², and 232 μs, respectively. Vickers hardness and the fracture toughness were measured of 9.18 GPa and 1.03 Mpa·m^1/2, respectively. All the results indicate that Nd: Y₂O₃ transparent ceramic is a promising candidate for laser material.     

Enhanced doping effects of multielement on anisotropic thermal expansion in ZrO2 with new compositions

Coefficient of thermal expansion (CTE) of a solid material plays a critical role for a variety of high temperature applications such as thermal barrier coating (TBC) systems during the thermal cycling process. Ceramics contain ionic bonds; hence they tend to exhibit lower CTE values than alloys/metals. Developing new ceramic thermal barrier materials using promising dopants and compositions that have higher CTE values than the conventional 6-8 wt% Y₂O₃ stabilized ZrO₂(8YSZ) will contribute to the decrease in thermal expansion mismatch between a typical ceramic 8YSZ (10 ~ 11 × 10⁻⁶°C⁻¹) top coat and a metal alloy based bond coat such as NiCrAlY (14 ~ 17×10⁻⁶°C⁻¹, Padture et al., Science, 2002;296:280–4; Liang et al., J Mater Sci Technol, 2011;27(5):408–14), which is highly desirable. This work reports design, modeling, synthesis, and characterization of promising new compositions based on Dy³⁺, Al³⁺, and Ce⁴⁺-doped YSZ that consist of the tetragonal structure and have an enhanced thermal expansion than 8YSZ. The intrinsic CTE at the atomic level has been investigated via molecular dynamics (MD) simulation. The atomic scale analysis provides new insights into the enhanced doping effects of multiple trivalent and tetravalent cations on the lattice structure, lattice energy, and thermal expansion in ZrO₂. The calculated lattice energy becomes smaller with the incorporation of Dy³⁺, Al³⁺, and Ce⁴⁺ions, which corresponds strongly to the increase in CTE. The crystalline size is reduced due to the incorporation of the Al³⁺ and Ce⁴⁺, whereas the sintering resistance is enhanced ascribed to the addition of Dy³⁺ and Al³⁺. Doping Dy³⁺, Al³⁺, and Ce⁴⁺ cations to YSZ increased the CTE value of YSZ and for Dy_0.03Y_0.075Zr_0.895O_1.948, the CTE is 12.494 × 10⁻⁶°C⁻¹ at 900°C, which has an 11% increase, as compared with that of 8YSZ.     

Fabrication and optical properties of transparent fine-grained Zn1.1Ga1.8Ge0.1O4 and Ni2+ (or Cr3+)-doped Zn1.1Ga1.8Ge0.1O4 spinel ceramics

For the first time, a Zn_1.1Ga_1.8Ge_0.1O₄ transparent spinel ceramic has been fully densified by spark plasma sintering. XRD measurements show that this ceramic is composed of a pure cubic spinel phase. SEM analysis revealed a homogeneous and dense microstructure with the average grain size being 200 ± 100 nm. The transmittance of these fine-grained ceramics reached 70 % in the visible range and is very close to 80 % at 2 µm, thus close to the T_max value deduced from the measurement of the refractive index. The ceramics exhibit excellent mechanical properties with a Young modulus of 222 GPa, a Vickers hardness of 14.25 GPa and a thermal conductivity of 7.3 W.m⁻¹. K⁻¹. By doping with Cr³⁺ ions, transparent Zn_1.1Ga_1.8Ge_0.1O₄ ceramics present both a red luminescence and a long-lasting afterglow during several minutes. Moreover, a near infrared broadband emission at 1.3 µm is also achieved with Ni²⁺ ions.     

Synthesis and characterization of ternary layered i-MAX (Mo2/3Y1/3)2AlC ceramics fabricated by spark plasma sintering

In this paper, the i-MAX phase (Mo_2/3Y_1/3)₂AlC ceramic with high purity of 98.29 wt% (1.13 wt% Y₂O₃ and 0.58 wt% Mo₂C) and high relative density of 98.59% was successfully synthesized by spark plasma sintering (SPS) at 1500°C with the molar ratio of n(Mo):n(Y):n(Al):n(C) = 4:2:3.3:2.7. The positions of C atoms in the crystal of (Mo_2/3Y_1/3)₂AlC were determined. Microstructure and physical and mechanical properties of (Mo_2/3Y_1/3)₂AlC ceramic were systematically investigated. It was found that the obtained (Mo_2/3Y_1/3)₂AlC ceramic had an average grain size of 32.1 ± 3.1 μm in length and 14.2 ± 1.7 μm in width. In terms of physical properties, the measured thermal expansion coefficient (TEC) of (Mo_2/3Y_1/3)₂AlC was 8.99 × 10⁻⁶ K⁻¹, and the thermal capacity and thermal conductivity at room temperature were 0.43 J·g⁻¹·K⁻¹ and 13.75 W·m⁻¹·K⁻¹, respectively. The room temperature electrical conductivity of (Mo_2/3Y_1/3)₂AlC ceramic was measured to be 1.25 × 10⁶ Ω⁻¹·m⁻¹. In terms of mechanical properties, Vickers hardness under 10 N load was measured as 10.54 ± 0.29 GPa, while flexural strength, fracture toughness, and compressive strength were determined as 260.08 ± 14.18 MPa, 4.51 ± 0.70 MPa·m^1/2, and 855 ± 62 MPa, respectively, indicating the promising structural applications.     

Mechanical and thermal properties of light weight boron-mullite Al5BO9

Al₅BO₉ is a promising thermal sealing material for hypersonic vehicles due to its low density, theoretically predicted low shear modulus, and low thermal conductivity. However, experimental investigations on the mechanical and thermal properties of bulk Al₅BO₉ have not been carried out. Herein, we report the mechanical and thermal properties of bulk Al₅BO₉ prepared by spark plasma sintering of solid-state reaction synthesized Al₅BO₉ powders. The bulk (B), shear (G), and Young's (E) moduli are 148 GPa, 85 GPa, and 214 GPa, respectively, which are close to the theoretical values. The Pugh's ratio G/B is 0.574, indicating its intrinsic damage tolerance, which is also revealed by Hertzian contact test. The Vickers hardness (H_v) is 10.8 GPa, being lower than mullite. The flexural strength, compressive strength, and fracture toughness are, respectively, 277 ± 35 MPa, 814 ± 75 MPa, and 2.4 ± 0.3 MPa·m^1/2, which are close to those of mullite. Al₅BO₉ has anisotropic coefficient of thermal expansion (CTE) in three crystallographic directions, ie α_a = (4.40 ± 0.21) × 10⁻⁶ K⁻¹, α_b = (7.11 ± 0.18) × 10⁻⁶ K⁻¹, α_c = (6.70 ± 0.29) × 10⁻⁶ K⁻¹ from Debye temperature to 1473 K, which are underpinned by its structural feature, ie lower α_a is resulted from the edge-shared AlO₆ octahedron chains along the [100] direction. The average CTE is (6.05 ± 0.06) × 10⁻⁶ K⁻¹. The thermal conductivity declines with temperature as κ = 1336.39/T + 1.97, consisting with predicted trend from Slack's model. The low thermal conductivity and low density guarantee Al₅BO₉ a promising candidate as ceramic wafer in the seal structure for hypersonic vehicles.     

Rheological behavior and curing deformation of paste containing 85 wt% Al2O3 ceramic during SLA-3D printing

The preparation of high solids loading Al₂O₃ paste is of great significance for improving the properties of ceramics formed by UV-curing. However, the solid contents of alumina slurry used by digital light processing (DLP) and traditional alumina paste for stereolithography (SLA) are both less than 80 wt%. With increase in solid content, the viscosity of paste increases sharply, and rheological property deteriorates. In this study, ceramic paste containing 85 wt% (62 vol%) Al₂O₃ was prepared for SLA-3D printing of ceramics, and more than 85 wt% solid content was achieved by dispersant and other additives. Effects of different dispersants on rheological and curing properties of Al₂O₃ ceramic paste were studied. At room temperature, the viscosity of 85 wt% Al₂O₃ ceramic paste was 51733 mPa s at shear rate of 30 s^?1. A novel method was proposed to control curing deformation of parts during printing. As-manufactured ceramic did not show any cracks by naked eye and exhibited excellent mechanical properties, with three-point bending strength of 540 MPa, fracture toughness of 4.19 MPa m^1/2, Vickers hardness of 16 GPa, surface roughness of 0.463 μm, and density of 3.86 g/cm³.     

Preparation of a thick sponge-like structured amorphous silica ceramic coating on 6061 aluminum alloy by plasma electrolytic oxidation in TEOS solution

Plasma electrolytic oxidation (PEO) was performed on 6061 aluminum alloy in organosilicon electrolyte using a stepwise constant potential control method for 23 min. The resulting coating was a sponge-like structured amorphous silica ceramic with a thickness of about 130 μm. Its exceptional wear resistance was attributed to the high hardness of the silica ceramic and the low elastic modulus of the sponge-like structure. The corrosion resistance was enhanced by a dense layer of approximately 2 μm between the coating and the substrate. Impressively, the indentation depth of the PEO coating during nano-indentation tests was only 50–60% of that of 6061 aluminium alloy under varying loads, while the recovery depth of the PEO coating after unloading was 2.5–3.1 times greater than that of 6061 aluminium alloy. Due to its special composition and structure, the PEO coating caused serious wear to the high hardness Si₃N₄ friction balls during the friction and wear test. In the electrochemical tests, the coating reduced the corrosion current density from 1.056 × 10⁻⁵A·cm⁻² to 1.239 × 10⁻⁷A·cm⁻², while extending the passivation region from 0.322 V to 1.032 V.