Effects of particle size distribution and sintering temperature on properties of alumina mold material prepared by stereolithography

Alumina mold materials prepared by stereolithography usually have considerable sintering shrinkage, and their properties related to casting have been rarely studied. In this study, alumina molds materials were prepared by stereolithography, and the effects of particle size distribution and sintering temperature on the properties of the materials were investigated. Results show that the viscosity of the slurries decreases as the fraction of fine powder increases, and the particle size distribution affects the curing behaviors slightly. Sintering shrinkage increases as the fraction of fine powder or the sintering temperature increases. Although lower sintering shrinkage can be achieved by sintering at 1350 °C or 1450 °C, the mold materials sintered at lower temperatures would continue to shrink under the service temperature of 1550 °C, and thus 1550 °C is determined as the optimal sintering temperature. As the fraction of fine powder increases, the creep resistance first increases and then decreases, and specimens prepared with 0.1 fraction of fine powder exhibit the best creep resistance with the droop distance of 4.44 ± 0.45 mm. Specimens prepared with 0.1 fraction of fine powder and sintered at 1550 °C exhibit linear shrinkage of 6.36% along the X/Y direction and 11.39% along the Z direction, and have a flexural strength of 78.15 ± 3.50 MPa and porosity of 30.12 ± 0.08%. The resulting material possesses relatively low sintering shrinkage, proper mechanical strength, porosity and high-temperature properties that meet the requirements for casting purposes.     

Evolution of the microstructure and mechanical properties of stereolithography formed alumina cores sintered in vacuum

Stereolithography (SL) was used to form alumina ceramic cores. The effect of sintering temperature on the microstructure and mechanical properties of the alumina ceramics are investigated, which were sintered in vacuum. The results indicate that, as the sintering temperature increased the particle size of alumina slightly increased, and the interlayer spacing first decreased and then increased. The open porosity of alumina ceramics significantly decreased as the sintering temperature in vacuum increased. The flexural strength and hardness increased as the sintering temperature increased. When sintered at 1150 °C, the flexural strength was found to be 33.7 MPa, the shrinkage was 2.3 %, 2.4 %, and 5.3 % in the X, Y, and Z directions, respectively, and the open porosity was 37.9 %. These results are similar to those found from sintering at 1280 °C in air.     

Enhanced mechanical properties of 3D printed alumina ceramics by using sintering aids

Stereolithography based 3D printing provides an efficient pathway to fabricate alumina ceramics, and the exploration on the mechanical properties of 3D printed alumina ceramics is crucial to the development of 3D printing ceramic technology. However, alumina ceramics are difficult to sinter due to their high melting point. In this work, alumina ceramics were prepared via stereolithography based 3D printing technology, and the improvement in the mechanical properties was investigated based on the content, the type and the particle size of sintering aids (TiO₂, CaCO₃, and MgO). The flexural strength of the sintered ceramics increased greatly (from 139.2 MPa to 216.7 MPa) with the increase in TiO₂ content (from 0.5 wt% to 1.5 wt%), while significant anisotropy in mechanical properties (216.7 MPa in X-Z plane and 121.0 MPa in X–Y plane) was observed for the ceramics with the addition of 1.5 wt TiO₂. The shrinkage and flexural strength of the ceramics decreased with the increase in CaCO₃ content due to the formation of elongated grains, which led to the formation of large-sized residual pores in the ceramics. The addition of MgO help decrease the anisotropic differences in shrinkage and flexural strength of the sintered ceramics due to the formation of regularly shaped grains. This work provides guidance on the adjustment in flexural strength, shrinkage, and anisotropic behavior of 3D printed alumina ceramics, and provides new methods for the fabrication of 3D printed alumina ceramics with superior mechanical properties.     

A comprehensive evaluation of vat-photopolymerization resins and alumina slurries for ceramic stereolithography

Ceramic slurries play an essential role in the fabrication of complex ceramic parts in ceramic stereolithography (CSL), in which photosensitive monomer is the focus. In this study, the comprehensive properties of commonly used monomers were quantitatively studied by a new evaluation system. As a result, ACMO, PONPGDA and EOTMPTA were selected as the final three monomers with better properties. On this basis, an optimal combination of the above monomers with the best comprehensive performance was obtained by blending them at a ratio of 60:60:40. Next, the influence of different resins on the properties of alumina slurries was investigated. It was found that using the mixture of the above three monomers, an excellent as-prepared slurry with low viscosity, small shrinkage and good photo-curable ability was obtained.     

Improved mechanical properties of SiB6 reinforced silica-based ceramic cores fabricated by 3D stereolithography printing

Silica-based ceramic core is an extremely critical component in the manufacture of hollow blades during investment casting. However, the traditional preparation methods rely more on the molds, and the manufacturing costs are relatively high. In this study, silica-based ceramics with silicon hexaboride (SiB₆) addition were prepared via 3D stereolithography printing. And the effects of the SiB₆ content on mechanical properties of the obtained ceramic samples were explored. As the SiB₆ content increased to 2.0 wt%, the linear shrinkage gradually decreased, while the room temperature and high temperature flexural strength were enhanced at the SiB₆ content from 0 to 1.0 wt% and reduced as the SiB₆ content further rose. As the SiB₆ content increased to 1.0 wt%, the linear shrinkage was reduced to 1.86% resulting from the oxidation reaction of SiB₆. Furthermore, with 1.0 wt% SiB₆ addition, the flexural strength of the samples at room temperature was enhanced from 6.75 MPa to 14.63 MPa due to the sintering promotion of oxidation product B₂O₃, and the flexural strength at 1550 °C was improved from 7.68 MPa to 13.08 MPa because of the enhanced β-cristobalite content, which is suitable for high temperature casting of ceramic cores. Therefore, it demonstrates the capability of fabricating SiB₆ reinforced silica-based ceramic cores with high performance via stereolithography.     

Investigation of oleic acid as a dispersant for hydroxyapatite powders for use in ceramic filled photo-curable resins for stereolithography

Stereolithography allows production of porous hydroxyapatite scaffolds for bone regeneration but is limited by the challenging rheology of ceramic filled resins. Oleic acid, a natural fatty acid, was applied in concentrations of 0.0–0.3 wt% to improve the rheological properties of HAp resins for the fabrication of solid cylinders and scaffolds by digital light processing (DLP) printing in a wiperless system. Bonding by chemisorption was confirmed by FTIR analysis. The powders were then incorporated into a photo-curable resin of 1–6 hexanediol diacrylate at 18–30 vol%. The shear viscosity and sedimentation rates of photocurable resins containing HAp powder decreased with increasing concentration of oleic acid. The curing depth and width of resins containing the HAp were unchanged as a result of the presence of oleic acid. Oleic acid improved the printing behaviour of the resins allowing the fabrication of scaffolds with continuous macro-porosity on a wiperless DLP system.     

Digital light processing stereolithography of zirconia ceramics: Slurry elaboration and orientation-reliant mechanical properties

Digital Light Processing (DLP) is a promising technique for the preparation of ceramic parts with complex shapes and high accuracy. In this study, 3 mol% yttria-stabilized tetragonal zirconia polycrystal (Y-TZP) UV-curable slurries were prepared and printed via DLP. Two different solid loadings (40.5 and 43.6 vol%, respectively) and printing directions were investigated to assess the influence of these parameters on physical and mechanical properties of the sintered parts. Zirconia samples were sintered at 1550 °C for 1 h, achieving a very high relative density (99.2%TD), regardless of solid loading and printing direction. FE-SEM micrographs shown a homogeneous and defect-free cross section with an average grains size of 0.56 ± 0.19 µm. Finally, mechanical properties were influenced by printing direction and zirconia vol%. Indeed, the composition with the higher solid loading (i.e. 43.6 vol%) had the highest three-point flexural strength (751 ± 83 MPa) when tested perpendicular to the printing plane.     

Microstructure-based micromechanical prediction of elastic properties in hydrating cement paste

Elastic properties of hydrating cement paste can be successfully predicted by combination of the hydration model, percolation theory and micromechanical analysis. Reconstruction of hydrating microstructure is based on the 3D digital NIST model of cement hydration, which is enhanced for the prediction of two C-S-H types. Chemical phases in a percolated microstructure served as an input in a two-level analytical or one-level 3D FEM or FFT elastic homogenization. Special mesh generation for the percolated microstructure is discussed as well as its numerical implementation. Good results from FEM and FFT were found for the size of the representative volume element of 50 × 50 × 50 μm, considering water-to-cement ratio in the range from 0.25 to 0.5. While good predictions in well-hydrated cement pastes were obtained for both analytical and numerical approaches, numerical homogenization was found more accurate and versatile for the whole hydration time.     

Effect of SiC powder on the properties of SiC slurry for stereolithography

Silicon carbide (SiC) is a kind of structural ceramics with excellent properties and it is widely used in industrial fields. Stereolithography (SL) is a potential additive manufacturing technique to fabricate fine complex SiC components, the resin-based SiC slurry with superior rheological and photo-polymerization properties is important for SL. In this paper, we investigated the influence of SiC powder on the properties of the SiC slurries for SL. The physical characteristics of SiC powder such as particle size, size distribution and appearance were tested and observed, and their influence on the dispersion, sedimentation and photo-polymerization property of the SiC slurry were investigated and discussed in detail based on their correlative theory, we finally prepared SiC slurry with superior rheological and photo-polymerization properties, and fabricated the fine complex SiC green body with low defects, high accuracy and high bending strength successfully. The SiC slurry with the solid content of 40 vol% was fabricated by the SiC powder with the median diameter D₅₀ ≈ 10.0 μm and a narrow particle size distribution, it is Bingham fluid with good fluidity and the viscosity of it is 464.40 mPa s under the shear rate of 51.08 s^?1, the cured SiC parts with Z – axis dimension change of 0.75% was finally fabricated, the three points bending strength of it is 50.18 MPa. Our research work provides some fundamental understanding of the SL technique for fabricating fine complex SiC components, explored a suitable way to fabricate high quality SiC green parts through SL, and offers some valuable references for preparing SiC slurry with superior rheological and photo-polymerization properties.     

Modeling of effective elastic properties for polymer based carbon nanotube composites

Effective elastic properties of the nanocomposites filled with carbon nanotubes (CNTs) are investigated by the asymptotic expansion homogenization (AEH) method. In order to implement the homogenization method, a control volume finite element method (CVFEM) is employed in contrast to the previous studies. It is assumed that the nanocomposites have geometric periodicity with respect to local length scale and the elastic properties of nanocomposites can be represented by those of the representative volume element (RVE). Random orientation of the CNTs embedded in the nanocomposites is considered by using the orientation tensor. The effective elasticity tensor predicted by the homogenization method is compared with analytical and experimental results. In the experiment, the CNT surface is treated by oxygen plasma to improve interfacial bonding between the CNT and the matrix and to disperse the CNTs homogeneously in epoxy resin because the perfect interfacial bonding is presumed in the homogenization method. Homogeneous CNT dispersion is experimentally identified by the field emission scanning electronic microscope (FESEM). It is found that the numerically calculated elastic modulus is in good agreement with that obtained by analytic model.     

Inter-particle interactions of alumina powders in UV-curable suspensions for DLP stereolithography and its effect on rheology,solid loading,and self-leveling behavior

For the UV-curable alumina suspensions used in digital light processing (DLP) stereolithography, optimizing the dispersant type is important for achieving low viscosity, high solid loading, and remarkable self-leveling behavior. However, the inter-particle interactions in UV-curable alumina suspensions dispersed using different dispersants are overlooked. Herein, the effect of inter-particle interactions on rheology, solid loading, and self-leveling behavior of UV-curable alumina suspensions was systematically investigated. Three different commercial dispersants were used: oleic acid (OA), alkane-acrylic phosphate ester (PM1590), and copolymer dispersant (BYK111). After dispersing, BYK111 endowed alumina powders with thicker adsorption polymer layer to provide stronger steric repulsion force and facilitated better wetting of alumina powers in the photocurable resin, resulting in a reduced network structure degree, which decreased the viscosity (1.04 Pa s at 30 s^?1); homogeneous packing of alumina powders, which enhanced the maximum solid loading (55 vol%); and inhibition of particle flocculation, which facilitated the spontaneous spreading of suspension.     

Alumina dissolution process to fabricate bimodal pore architecture alumina with superior green and sintered properties

Herein, a straightforward, adaptable, and cost-effective approach has been proposed to realize the concept of dissolution of alumina in acidic aqueous media to fabricate porous alumina showing exceptional green machining properties and exhibiting good thermomechanical properties through in situ generated blowing agents and thermo-foaming process. The process involves dissolving alumina in concentrated sulfuric acid to generate aluminum hydroxide and aluminum sulfate, which act as blowing agents to produce pores in the final structure through a decomposition process at elevated temperatures. By varying the concentration of deionized water and acidification using sulfuric acid, different alumina slurries are prepared. Sintering shrinkage is well countered through simultaneous consolidation and decomposition process during the heat treatment, and a minimum shrinkage of 0.88% is achieved. In addition to its pore-forming properties, aluminum sulfate also provides strong binding effects to green bodies, contributing to their exceptional green machining properties. The resulting porous alumina exhibits a green flexural strength of up to 17 MPa, making it capable of bearing loads and forces during green machining. The sintered porous alumina fabricated in the study has a porosity range of 34.43%–59.24% and a flexural strength of 27.84–53.21 MPa. The prepared porous alumina also exhibits satisfactory thermal resistivity, with a minimum thermal conductivity of 1.23 W/m K, and has intra/intergranular space in the nano range. The coexistence of a combination of bimodal pores in a single monolithic matrix makes it exceptionally porous and suitable for an extensive spectrum of applications.     

Development of a numerical simulation model for predicting the curing of ceramic systems in the stereolithography process

The control of ceramic green parts dimensions produced by stereolithography is a central concern of the ceramic additive manufacturing industry. The presence of ceramic particles within the photopolymerizable system induces UV-laser beam scattering phenomenon, disrupting the polymerization process. This study focuses on the development of a numerical simulation model of the curing process, considering the scattering phenomenon. This paper presents each stages of the development of the numerical simulation model, supported and finally validated by experimentation on a commercial photopolymerizable alumina paste. Firstly, the numerical simulation model is presented. Then, a Greco-Latin square design of experiments is conducted to reduce the number of experiments. Subsequently, material-dependent parameters are identified through simulations and experimental measurements, and a scattering law is proposed. Finally, the simulation model enables to simulate easily and with accuracy the cure widths and the cure depth. It also provides visualization of the exposure distribution and the scattering phenomenon.     

Processing and properties of tape-cast alumina/zirconia laminates composites

In the present work, laminar ceramic structures formed by layers of alumina and partially stabilized zirconia were fabricated by water-based tape casting. Rheological, physical and mechanical properties of slurries and laminates were evaluated. The laminates consisted of stacked alumina and zirconia green tapes produced by thermopressing. Pyrolysis was carried out at 450 °C and sintering at 1500 °C. The alumina/zirconia laminates were studied for a better understanding of the formation behavior and crack propagation at the laminate interface. The flexural strength values of laminates depend on the stress state on their surface. The laminates with the highest amount of zirconia layers presented low strength values (6.7 MPa), while the laminates with more alumina layers had a higher strength level (57.7 MPa). This is because these laminates have alumina layers on the surface which are in a state of residual compressive stress.     

Effect of synergism of solid loading and sintering temperature on microstructural evolution and mechanical properties of 60 vol% high solid loading ceramic core obtained through stereolithography 3D printing

Solid loading has a significant effect on the curing behavior of slurry and the microstructure and properties of the ceramic core. A high-solid loading slurry can effectively improve the sintering densification of ceramic particles and improve the interlayer bonding strength and mechanical properties at both 25 °C room and higher temperatures. Herein, based on the photopolymerization theory of ceramic slurry, the solid loading was increased from 45 to 60 vol% by adjusting the composition ratio of the resin ceramic powder. Additionally, the optimal sintering temperature of the 60 vol% solid loading ceramic core was 1200 °C. The synergistic effect of the solid loading and sintering temperature controls the sintering shrinkage of the sample within 3.2%; the porosity, high temperature, and room temperature flexural strength were approximately 30%, 24 MPa, and 10 MPa, respectively. The printing preparation of high-solid loading ceramic cores can be used to guide optimizing process parameters on an industrial scale.     

Numerical and analytical effective elastic properties of degraded cement pastes

Cement pastes are heterogeneous materials composed of hydrates, anhydrous products and pores of various shapes. They are generally characterized by a high particle concentration and phase contrasts, in particular in the case of degraded materials which exhibit important porosity. This paper compares the performance of several classical effective medium approximation schemes (Mori–Tanaka, Zheng-Du, self-consistent) through their ability to estimate the mechanical parameters of cement paste samples obtained numerically. For this purpose, finite element simulations are performed on 3D structures to compute for each sample accurate values of these mechanical properties. For these simulations, the cement paste is considered as a matrix of C–S–H in which are embedded inclusions of anhydrous, hydration products, and pores. In order to evaluate the importance of the particle shape, two types of samples are generated, one with only spherical inclusions and the other containing both spherical and prismatic particles. Simulations with three perpendicular loading directions and both uniform and mixed boundary conditions are performed in order to verify that the dispersion in the computed elastic moduli is low, or equivalently that the generated structures are close to representative volume elements (RVEs). It is shown that the considered effective medium approximation schemes, except the self-consistent one, provide relatively good estimations of the overall mechanical parameters when compared to simulation results, including when both particle volume fraction and phase contrast are high. The analytical methods taking into account the particle shapes also give estimates close to the corresponding numerical simulations, the latter confirming the influence of the particle form.     

Mechanical and lamination properties of alumina green tapes obtained by aqueous tape-casting

Mechanical characterisation and lamination were carried out on alumina green tapes prepared by aqueous tape casting using two acrylic emulsions having different glass transition temperatures (T_g) as binders. The tensile strength and strain were strongly dependent on the binder nature and content. Namely, the mechanical properties of the green tapes reflected those of the binders at room temperature: the green tapes obtained with the higher T_g binder showed a brittle behaviour, whereas those obtained with the lower T_g binder showed an elastoplastic behaviour. The mechanical properties of the green tapes prepared by mixing the two acrylic binders lies in between, giving the possibility of tailoring the flexibility and strength in the range of the values obtained for pure binders. Lamination gave rise to an increase of both green and sintered densities, compared with monolayer specimens, whatever the composition of the binder system. Such improvements significantly depended on lamination pressure, but were insensitive to lamination temperature for the two temperatures tested higher than the T_g of the two binders. ©     

空调器外观件的涂饰

为提高空调器室外机的耐候性，需对其进行涂装处理。介绍了空调器外观件如钣金件及塑料件的涂饰，以及整机装后的清洗工艺，空调器外观件应选用耐蚀性基体制造，并采用耐候性涂料涂装，钣金件和塑料件的清洗应分别采用中性无盐清洁剂和含非离子表面活性剂的水溶液。     

Fabrication of complex shaped alumina parts by gelcasting on 3D printed moulds

Alumina ceramic components were produced using gelcasting and 3D printing techniques to generate the end product. The 3D printed mould made from (acrylonitrile butadiene styrene) ABS filament provides a convenient demoulding method by dissolution of the mould using acetone as a solvent. This process enables low cost production of complex shaped ceramic components. The effect of the suspension solid loading on the properties and microstructure of complex shaped alumina parts was investigated. The produced ceramic components had densities up to 99.0%, hardness of 18 GPa, flexural strength of 374 MPa and a fracture toughness of 3.8 MPa√m after sintering in air for 3 h, in good agreement with published values.