Preparation of low residual silicon content Si-SiC ceramics by binder jetting additive manufacturing and liquid silicon infiltration |
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| Affiliation: | 1. Centre for Nanoengineering and Advanced Materials, Department of Engineering Metallurgy, University of Johannesburg, South Africa;2. Mechanical Engineering department, Tshwane University of Technology, South Africa;1. School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, Shaanxi 710049, China;2. School of Textile Science and Engineering, Xi’an Polytechnic University, Xi’an, Shaanxi 710048, China;3. State Key Laboratory for Manufacturing System Engineering, Xi’an Jiaotong University, Xi’an, Shaanxi 710049, China;1. Sate Key Laboratory of Materials Processing and Die & Mould Technology School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China;2. Science and Technology on Reactor Fuel and Materials Laboratory, Nuclear Power Institute of China, Sichuan University, Chengdu, 610213, China;1. Materials Chemistry, RWTH Aachen University, Kopernikusstr. 10, D-52074 Aachen, Germany;2. Department of Physical Electronics, Faculty of Science, Masaryk University, Kotlářská 2, 611 37 Brno, Czech Republic;3. Department of Physics and Astronomy, Uppsala University, Lägerhyddsvägen 1, S-75120 Uppsala, Sweden;1. Chair of Ceramic Materials Engineering (CME), University of Bayreuth, Prof.-Rüdiger-Bormann-Str. 1, 95447 Bayreuth, Germany;2. State Key Laboratory of Structural Analysis, Optimization and CAE Software for Industrial Equipment, Dalian University of Technology, No. 2 Linggong Road, 116024 Dalian, China |
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| Abstract: | Complex silicon carbide (SiC) ceramic components are difficult to fabricate due to their strong covalent bonds. Binder jetting (BJ) additive manufacturing has the outstanding advantages of high forming efficiency and no thermal deformation, especially suitable for printing complex structure SiC components. This study tried to obtain low silicon content silicon carbide ceramics by binder jetting followed by phenolic resin impregnation and pyrolysis (PRIP) and liquid silicon infiltration (LSI). BJ was used for the SiC green parts fabrication, and the highest compressive strength (7.7 ± 0.3 MPa) and lowest dimensional deviations (1.2–1.6 mm) were obtained with the printing layer thickness of 0.15 mm. Subsequently, PRIP treatments were introduced to increase the carbon content for the following LSI process. As the number of PRIP cycles increased, the carbon density of SiC/C preform increased and the porosity decreased. After the LSI treatment, the final Si-SiC composites processed with 2 PIRP cycles reached the highest flexural strength (257 ± 14.26 MPa) and the best wear resistance. This was attributed to the low residual silicon content (10.2 vol%) and almost no residual carbon. Furthermore, several complex structural components were fabricated using these methods. The preparation of complex components verifies the feasibility of BJ and LSI for manufacturing high-strength and high-precision SiC ceramics. Besides, this work hopes to provide technical guidance for the preparation of complex SiC composites in the future. |
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| Keywords: | Additive manufacturing Binder jetting (BJ) SiC ceramic Liquid silicon infiltration (LSI) |
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