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Fully-Enclosed Ceramic Micro-burners Using Fugitive Phase and Powder-based Processing.

Truong Do1, Changseop Shin1, Patrick Kwon1

  • 1Department of Mechanical Engineering, Michigan State University, East Lansing, MI, USA.

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Summary
This summary is machine-generated.

A novel powder-based fabrication method creates cost-effective ceramic microchemical systems (μCSs) for harsh environments. This technique enables the production of intricate ceramic components, like micro-burners for gas sensing, using alumina powders and a burnout fugitive phase.

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Area of Science:

  • Materials Science
  • Chemical Engineering
  • Microfabrication

Background:

  • Conventional microchemical systems (μCSs) using silicon or polymers are limited in harsh environments.
  • Growing interest in process intensification necessitates advanced ceramic manufacturing.

Purpose of the Study:

  • Introduce a cost-effective, versatile powder-based fabrication framework for ceramic μCS components.
  • Develop ceramic μCS suitable for high-temperature and corrosive applications.

Main Methods:

  • Utilized a one-pot process involving compaction of metal-oxide sub-micron powders with a graphite fugitive phase.
  • Employed binder-free pure alumina powder for precise dimensional control and reduced shrinkage.
  • Investigated key steps: powder compaction, graphite burnout during partial sintering, machining, and final densification.

Main Results:

  • Successfully fabricated near-full density ceramic structures with internal cavities and microchannels.
  • Demonstrated precise dimensional control and minimal shrinkage due to the binder-free approach.
  • Created a ceramic micro-burner with a combustion chamber and internal channels.

Conclusions:

  • The proposed powder-based fabrication framework is a viable, cost-effective method for producing complex ceramic μCS.
  • The fabricated ceramic micro-burner is suitable for gas sensing applications in demanding conditions.
  • This approach advances ceramic microfabrication for harsh environment applications.