Dario Rafael Manca , Hossein Najaf Zadeh , Daniel Bowles , Don Clucas , Matthew Watson
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引用次数: 0
Abstract
This work employed the Stencil Additive Manufacturing (SAM) technique to fabricate α-alumina lattice structures. A ceramic slurry system based on Pluronic F-127 hydrogel was formulated to carry nano-sized α-alumina ceramic particles, achieving a solid loading of 37 vol%. The slurry exhibited non-Newtonian behaviour, making it suitable for stencil printing applications. Rheological characterisation revealed an elastic modulus of 19,600 kPa and a storage modulus of 996 kPa. Flow tests were successfully fitted to the Herschel-Bulkley model, yielding at 213.38 Pa, a flow index of 0.21, and a consistency index of 4259.24 Pa s, confirming the slurry's shear-thinning behaviour, an essential property for SAM. Stencil printing of ceramic hydrogel layers, followed by controlled drying and sintering at 1550 °C, resulted in the successful fabrication of rigid α-alumina ceramic parts. Post-sintering analysis demonstrated that crack-free specimens with heights up to 5.25 mm, maximum warping of 10 %, and 94–98 % density were achieved. The study highlights the potential of SAM for the additive manufacturing of ceramics, presenting a novel approach to fabricating complex ceramic structures. While the process shows promise, limitations such as channel closure during deposition and warping during drying must be addressed to further improve shape fidelity and accuracy. This research opens avenues for the future development of stencil-based additive manufacturing in ceramic production, which shows promise as a viable pathway to the mass manufacturing of parts.
期刊介绍:
Ceramics International covers the science of advanced ceramic materials. The journal encourages contributions that demonstrate how an understanding of the basic chemical and physical phenomena may direct materials design and stimulate ideas for new or improved processing techniques, in order to obtain materials with desired structural features and properties.
Ceramics International covers oxide and non-oxide ceramics, functional glasses, glass ceramics, amorphous inorganic non-metallic materials (and their combinations with metal and organic materials), in the form of particulates, dense or porous bodies, thin/thick films and laminated, graded and composite structures. Process related topics such as ceramic-ceramic joints or joining ceramics with dissimilar materials, as well as surface finishing and conditioning are also covered. Besides traditional processing techniques, manufacturing routes of interest include innovative procedures benefiting from externally applied stresses, electromagnetic fields and energetic beams, as well as top-down and self-assembly nanotechnology approaches. In addition, the journal welcomes submissions on bio-inspired and bio-enabled materials designs, experimentally validated multi scale modelling and simulation for materials design, and the use of the most advanced chemical and physical characterization techniques of structure, properties and behaviour.
Technologically relevant low-dimensional systems are a particular focus of Ceramics International. These include 0, 1 and 2-D nanomaterials (also covering CNTs, graphene and related materials, and diamond-like carbons), their nanocomposites, as well as nano-hybrids and hierarchical multifunctional nanostructures that might integrate molecular, biological and electronic components.