Articles
All articles | Recent articles
Laser-Induced Slip Casting (LIS) – a New Additive Manufacturing Process for Dense Ceramics Demonstrated with Si3N4
J. Lüchtenborg1, T. Mühler2, F. Léonard3, J. Günster1
1 BAM Federal Institute of Materials Research and Testing, Unter den Eichen 87, D-12205 Berlin, Germany, Division 5.4 Ceramic Processing and Biomaterials
2 Clausthal University of Technology, Zehntnerstrasse 2a, D-38678 Clausthal-Zellerfeld, Germany, Institute of Non-Metallic Materials
3 BAM Federal Institute of Materials Research and Testing, Berlin, Germany, Division 8.5 Micro Non-Destructive testing
received August 15, 2017, received in revised form November 20, 2017, accepted November 21, 2017
Vol. 8, No. 4, Pages 531-540 DOI: 10.4416/JCST2017-00091
Abstract
Up to now, there exists a lack of methods for the additive manufacturing of voluminous ceramic parts with properties comparable to those of conventionally manufactured ones. A high density after sintering is needed to reach the superior properties of ceramic materials. We have developed a new additive manufacturing method, Laser-Induced Slip casting (LIS), to generate ceramic green bodies with high particle packing density and with virtually no restriction in the particle size of the feedstock, especially in terms of small particles. This is achieved by laser-induced local drying of slurries, with the process resembling many features of the well-established stereolithography, but without the excessive use of polymeric material. Thus, unlike the stereolithography process, the resulting green bodies can be processed like traditionally produced ceramic parts. This method allows large and dense additive-manufactured parts to be obtained from conventional water-based ceramic slurries. As an example, we will demonstrate the application of this novel technique with Si3N4.
Download Full Article (PDF)
Keywords
Silicon nitride, additive manufacturing, slurry based
References
1 Smith, H.: GE Aviation to grow better fuel nozzles using 3D Printing, 2013.
2 Griffith, M.L., Halloran, J.W.: Freeform fabrication of ceramics via stereolithography, J. Am. Ceram. Soc., 79, [10], 2601 – 08, (1996).
3 Zhou, W.Z., Li, D.C., Wang, H.: A novel aqueous ceramic suspension for ceramic stereolithography, Rapid Prototyping J., 16, [1], 29 – 35, (2010).
4 Hull, C.W.: Apparatus for production of three-dimensional objects by stereolitography. US Patent Application US4575330 (1984)
5 Schlier, L., Zhang, W., Travitzky, N., Greil, P., Cypris, J., Weclas, M.: Macro-cellular silicon carbide reactors for nonstationary combustion under piston engine-like conditions, Int. J. Appl. Ceram. Tec., 8, [5], 1237 – 45, (2011).
6 Melcher, R., Martins, S., Travitzky, N., Greil, P.: Fabrication of Al2O3-based composites by indirect 3D-printing, Mater. Lett., 60, [4], 572 – 75, (2006).
7 Sachs, E.M., Haggerty, J.S., Cima, M.J., Williams, P.A.: Three-dimensional printing techniques. US Patent Application US5204055 (1989)
8 Deckard, C.R.: Method and apparatus for producing parts by selective sintering. US Patent Application US4863538 (1986)
9 Bertrand, P., Bayle, F., Combe, C., Goeuriot, P., Smurov, I.: Ceramic components manufacturing by selective laser sintering, Appl. Surf. Sci., 254, [4], 989 – 92, (2007).
10 Deckers, J., Meyers, S., Kruth, J.P., Vleugels, J.: Direct selective laser sintering/melting of high density alumina powder layers at elevated temperatures, Physcs. Proc., 56, 117 – 24, (2014).
11 Nelson, J.C., Xue, S., Barlow, J.W., Beaman, J.J., Marcus, H.L., Bourell, D.L.: Model of the selective laser sintering of Bisphenol-a polycarbonate, Ind. Eng. Chem. Res., 32, [10], 2305 – 17, (1993).
12 Juste, E., Petit, F., Lardot, V., Cambier, F.: Shaping of ceramic parts by selective laser melting of powder bed, J. Mater. Res., 29, [17], 2086 – 94, (2014).
13 Feygin, M., Pak, S.S.: Laminated object manufacturing apparatus and method. US Patent Application US5876550.
14 Cappi, B., Özkol, E., Ebert, J., Telle, R.: Direct inkjet printing of Si3N4: characterization of ink, green bodies and microstructure, J. Eur. Ceram. Soc., 28, [13], 2625 – 28, (2008).
15 Yang, H.Y., Yang, S.F., Chi, X.P., Evans, J.R.G.: Fine ceramic lattices prepared by extrusion freeforming, J. Biomed. Mater. Res. B, 79B, [1], 116 – 21, (2006).
16 Crump, S.S.: Modeling apparatus for three-dimensional objects. US Patent Application US5340433 (1989)
17 Jafari, M.A., Han, W., Mohammadi, F., Safari, Danforth, A.S.C., Langrana, N.: A novel system for fused deposition of advanced multiple ceramics, Rapid Prototyping J., 6, [3], 161 – 74, (2000).
18 Zocca, A., Lima, P., Günster, J.: LSD-based 3D printing of alumina ceramics, J. Ceram. Sci. Tech., 8, [1], 141 – 47, (2017).
19 Mühler, T., Heinrich, J., Gomes, C.M., Günster, J.: Slurry-based additive manufacturing of ceramics, Int. J. Appl. Ceram. Tec., 12, [1], 18 – 25, (2015).
20 Schlordt, T., Keppner, F., Travitzky, N., Greil, P.: Robocasting of alumina lattice truss structures, J. Ceram. Sci. Tech., 3 [2] 81 – 88 (2012).
21 Miranda, P., Saiz, E., Gryn, K., Tomsia, A.P.: Sintering and robocasting of beta-tricalcium phosphate scaffolds for orthopaedic applications, Acta Biomater., 2, [4], 457 – 66 (2006).
22 Zocca, A., Franchin, G., Elsayed, H., Gioffredi, E., Bernardo, E., Colombo, P.: Direct ink writing of a preceramic polymer and fillers to produce hardystonite (Ca2ZnSi2O7) bioceramic scaffolds, J. Am. Ceram. Soc., 99, [6], 1960 – 67, (2016).
23 Lewis, J.A., Smay, J.E., Stuecker, J., Cesarano, J.: Direct ink writing of three-dimensional ceramic structures, J. Am. Ceram. Soc., 89, [12], 3599 – 609, (2006).
24 Zocca, A., Colombo, P., Gomes, C.M., Günster, J.: Additive manufacturing of Ceramics: issues, potentialities, and opportunities, J. Am. Ceram. Soc., 98, [7], 1983 – 2001 (2015).
25 Deckers, J., Vleugels, J., Kruthl, J.P.: Additive manufacturing of Ceramics: A review, J. Ceram. Sci. Tech., 5, [4], 245 – 60, (2014).
26 Schwentenwein, M., Homa, J.: Additive manufacturing of dense alumina ceramics, Int. J. Appl. Ceram. Tec., 12, [1], 1 – 7, (2015).
27 Lange, F.F.: Powder processing science and technology for increased reliability, J. Am. Ceram. Soc., 72, [1], 3 – 15, (1989).
28 Riley, F.L.: Silicon nitride and related materials, J. Am. Ceram. Soc., 83, [2], 245 – 65, (2000)
Copyright
Göller Verlag GmbH