Influence of resin composition on rheology and polymerization kinetics of alumina ceramic suspensions for digital light processing (DLP) additive manufacturing |
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| Affiliation: | 1. University of Shanghai for Science and Technology, Shanghai, 200082, China;2. State Key Laboratory of High Performance Ceramics and Superfine Microstructure, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai, 200050, China;3. Center of Materials Science and Optoelectronics Engineering, University of Chinese Academy of Sciences, Beijing, 100049, China;1. School of Materials Science and Engineering, Zhejiang Sci-Tech University, Hangzhou, 310018, People''s Republic of China;2. College of Textile Science and Engineering, Zhejiang Sci-Tech University, Hangzhou, 310018, People''s Republic of China;3. The Key Lab of Industrial Textile Material and Manufacturing Technology, Zhejiang Province, Hangzhou, 310018, People''s Republic of China;4. Zhejiang Jinda New Materials Co., Ltd., Zhejiang Province, Haining, 314419, People''s Republic of China;1. Refractory & Ceramic Materials Division (RCMD), Central Metallurgical R&D Institute (CMRDI), P.O. Box 87, Helwan, 11421, Cairo, Egypt;2. Chemistry Department, Faculty of Science, Helwan University, 11795, Cairo, Egypt;3. Composite Materials Division (CMD), Central Metallurgical R&D Institute (CMRDI), P.O. Box 87, Helwan, 11421, Cairo, Egypt;4. Chemistry Department, Graduate School of Science, Kyushu University, 819-0395, Fukuoka, Japan;1. State Key Laboratory of Silicate Materials for Architectures, Wuhan University of Technology, Wuhan, 430070, Hubei, China;2. School of Materials Science and Engineering, Wuhan University of Technology, Wuhan, 430070, Hubei, China;3. School of Logistics Engineering, Wuhan University of Technology, Wuhan, 430070, Hubei, China;4. Advanced Ceramics Institute of Zibo New & High-Tech Industrial Development Zone, Zibo, 255000, China;5. State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan, 430074, Hubei, China;6. Penn State University, University Park, PA, 16802, USA;7. Ningbo volken Technology Co., Ltd, Ningbo, 315000, Zhengjiang, China;1. State 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. Engineering Research Center of Ceramic Materials for Additive Manufacturing, Ministry of Education, Wuhan, 430074, China;3. State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi''an, Shaanxi, 710072, China;4. Key Laboratory of Metal High Performance Additive Manufacturing and Innovative Design, MIIT China, Northwestern Polytechnical University, Xi''an, Shaanxi, 710072, China;1. School of Electromechanical Engineering, Guangdong University of Technology, Guangzhou, 510006, China;2. Guangdong Metal Ceramic 3D Technology Co., Ltd., Foshan, 528225, China;3. Guangdong Fenghua Zhuoli Technology Co., Ltd., Foshan, 528200, China;1. School of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China;2. Institute of Additive Manufacturing (3D Printing), Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China;3. School of Physics, Nanjing University of Aeronautics and Astronautics, Nanjing, 210000, China;4. School of Mechanical Engineering, Southeast University, Nanjing, 211189, China;5. Prismlab China Ltd., 200000, Shanghai, China |
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| Abstract: | Alumina ceramics with optimized microstructures and mechanical properties were obtained by the attractive digital lighting processing (DLP) additive manufacturing methodology in the present study. A acrylate-based resin system was designed for the alumina powders with a mean particle size of 0.5 μm. The influence of oligomer on the viscosity and polymerization kinetics of the ceramic suspensions has been elaborately discussed by rheology, curing depth and photo-DSC characterizations. The results indicated that the introduction of oligomer has improved the cross-linking density of resins and decreased the critical dose of energy for resin polymerization, which contributed to a tougher ceramic-resin slice with higher dimensional accuracy. Densifying processes including debinding and high temperature sintering of the ceramic parts were conducted according to the TG-DTA characterizations, alumina ceramics with uniform microstructures and eliminated delamination or intralaminar cracks were finally obtained. The flexural strength was 471 MPa for the ceramics obtained from the resin composition containing 20 wt% oligomer, Weibull modulus for the ceramics were determined to be 17.31 by evaluating thirty all sides polished ceramics, indicating the highly uniform property of the ceramics fabricated by DLP additive manufacturing. |
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| Keywords: | Additive manufacturing Alumina ceramic Resin composition Polymerization kinetics Photo-DSC |
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