Spray drying granulation of potassium sodium niobate (KNN) for binder jetting: Feedstock preparation and influence on sintered material properties

IF 2.9 Q1 MATERIALS SCIENCE, CERAMICS

Open Ceramics Pub Date : 2025-01-23 DOI:10.1016/j.oceram.2025.100743

Marco Mariani , Francesco Bertolini , Elisa Mercadelli , Guillermo Frias Blanco , Carlo Baldisserri , Antonio Javier Sanchez-Herencia , Carmen Galassi , Begoña Ferrari , Nora Lecis

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Abstract

Binder jetting of potassium sodium niobate (K_0.5Na_0.5NbO₃) offers potential for generating shape-dependent responses with high industrial output. However, the printing stage relies heavily on the properties of the dry feedstock, making its performance optimization crucial. In this regard, morphological functionalization through granulation can be a useful methodology.

This study characterizes two powders in dry and wet states to develop colloidal suspensions for spray drying granulation. Particle size, shape, and ζ-potential are measured to stabilize them in an aqueous slurry. Granule morphology and flowability are assessed and compared with the original feedstock. Disk-shaped specimens are then printed and sintered.

Spray drying granulation successfully produces spherical and fine feedstocks compatible with the typical layer thickness (50 μm) of binder jetting. Densified parts displayed significant residual porosity (20–40 %) along the building direction, affecting piezoelectric performance: strain coefficients were reduced, but increased voltage coefficients yielded high figures-of-merit.

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喷射粘结剂用铌酸钾钠喷雾干燥造粒：原料制备及其对烧结材料性能的影响

结合剂喷射铌酸钾钠（K0.5Na0.5NbO3）提供了产生高工业产量的形状相关响应的潜力。然而，印刷阶段在很大程度上依赖于干燥原料的性能，使其性能优化至关重要。在这方面，形态功能化通过肉芽可以是一个有用的方法。本研究表征了两种粉末在干燥和潮湿的状态，以发展胶体悬浮液用于喷雾干燥造粒。测量颗粒大小，形状和ζ电位以稳定它们在水泥浆中。评估了颗粒形态和流动性，并与原始原料进行了比较。然后打印和烧结盘状试样。喷雾干燥造粒成功地生产出与典型的粘结剂喷射层厚（50 μm）相匹配的球形细料。致密化的零件沿建筑方向显示出显著的残余孔隙率（20 - 40%），影响压电性能：应变系数降低，但电压系数增加产生高的价值值。

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