Stereolithographical fabrication of dense Si3N4 ceramics by slurry optimization and pressure sintering |
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| Affiliation: | 1. Shenzhen Research Institute, Central South University, Shenzhen, 510085, China;2. State Key Laboratory for Powder Metallurgy, Central South University, Changsha, 410083, China;3. College of Mechanical and Electronic Engineering, Pingxiang College, Pingxiang, 337000, China;4. State Key Laboratory for Material Processing and Die & Mould Technology, School of Material Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China;1. Institute of Advanced Structure Technology, Beijing Institute of Technology, Beijing 100081, PR China;2. State Key Laboratory of Explosion Science and Technology, Beijing Institute of Technology, Beijing 100081, PR China;3. School of Mechanical and Automotive Engineering, Anhui Polytechnic University, Wuhu 241000, PR China;4. Beijing Key Laboratory of Lightweight Multi-Functional Composite Materials and Structures, Beijing Institute of Technology, Beijing 100081, PR China;5. People''s Liberation Army Institute of Neurosurgery, Shanghai Institute of Neurosurgery, Department of Neurosurgery, Changzheng Hospital, Second Military Medical University, Shanghai 200003, PR China;1. Institute of Advanced Structure Technology, Beijing Institute of Technology, Beijing, 100081, China;2. Beijing Key Laboratory of Lightweight Multi-functional Composite Materials and Structures, Beijing Institute of Technology, Beijing, 100081, China;3. State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, China;1. Centre for Advanced Jet Engineering Technologies (CaJET), School of Mechanical Engineering, Shandong University, Jinan 250061, PR China;2. Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Shandong University, Ministry of Education, PR China;3. National Demonstration Center for Experimental Mechanical Engineering Education (Shandong University), PR China;1. Manufacturing Science Division, Energy Science and Technology Directorate, Oak Ridge National Laboratory, Oak Ridge, TN, USA;2. Materials Science and Technology Division, Physical Sciences Directorate, Oak Ridge National Laboratory, Oak Ridge, TN, USA |
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| Abstract: | Photocurable gray-colored Si3N4 ceramic slurry with high solid loading, suitable viscosity and high curing depth is critical to fabricate dense ceramic parts with complex shape and high surface precision by stereolithography technology. In the present study, Si3N4 ceramic slurry with suitable viscosity, high solid loading (45 vol %) and curing depth of 50 μm was prepared successfully when surface modifier KH560 (1 wt%) and dispersant Darvan (1 wt%) were used. The slurry exhibits the shear thinning behavior. Based on the Beer-Lambert formula, Dp (the attenuation length) and Ec (the critical energy dose) of Si3N4 ceramic slurry with solid loading of 45 vol % were derived as 0.032 mm and 0.177 mJ/mm2, respectively. Si3N4 ceramic green parts with complex shape and high surface precision were successfully fabricated by stereolithography technology. After optimizing the debinding and sintering process for green parts, dense Si3N4 ceramics with 3.28 g/cm3 sintering density were fabricated. The microhardness and fracture toughness of as-sintered Si3N4 ceramics are ~14.63 GPa and ~5.82 MPa m1/2, respectively, which are comparable to those of the samples by traditional dry-pressed and pressureless sintering technology. These results show that ceramic stereolithography technology could be promising to fabricate high performance ceramics, especially for gray-colored monolithic Si3N4 ceramics. |
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| Keywords: | Stereolithography Silicon nitride Surface modification Rheological behavior |
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