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Additive Manufacturing of Functionally Graded Ceramic Materials by Stereolithography

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Evolution of SLA-Based Al₂O₃ Microstructure During Additive Manufacturing Process.

Svyatoslav Chugunov¹, Nikolaus A Adams², Iskander Akhatov¹

¹Center for Design, Manufacturing & Materials, Skolkovo Institute of Science and Technology, 30/1 Bolshoi Boulevard, 121205 Moscow, Russia.

Materials (Basel, Switzerland)

|September 9, 2020

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This study reveals the 3D microstructure evolution in additively manufactured ceramics, detailing particle and pore distribution across manufacturing stages for advanced modeling.

Area of Science:

Materials Science
Additive Manufacturing
Ceramic Engineering

Background:

Understanding microstructure evolution is crucial for advanced numerical modeling of additively manufactured (AM) ceramics.
Data on microstructural changes during AM ceramic processing are scarce, limiting model development.

Purpose of the Study:

To create and analyze 3D microstructural models of Al2O3 ceramics at greenbody, brownbody, and sintered stages.
To investigate the spatial distribution of ceramic particles, binder, and pores throughout the AM workflow.
To provide essential data for validating advanced numerical simulations of ceramic AM.

Main Methods:

Stereolithography (SLA)-based additive manufacturing workflow using commercial ceramic paste.
Computed Tomography (CT) for micro- and mesoscale imaging.

Keywords:

3D printing FIB/SEM aluminum oxide computed tomography debinding greenbody microstructure porosity sintering stereolithography

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Additive Manufacturing of Functionally Graded Ceramic Materials by Stereolithography

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Published on: January 25, 2019

Processing of Bulk Nanocrystalline Metals at the US Army Research Laboratory

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Published on: March 7, 2018

Production of Single Tracks of Ti-6Al-4V by Directed Energy Deposition to Determine the Layer Thickness for Multilayer Deposition

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Published on: March 13, 2018

Scanning Electron Microscopy (SEM) and Focused Ion-Beam SEM (FIB/SEM) for detailed microstructural analysis.

Main Results:

Detailed 3D spatial distribution of Al2O3 particles, organic binder, and pores was mapped at each manufacturing stage.
Porosity levels were quantified: greenbody (1.6%), brownbody (37.3%), and sintered (4.9%).
Pore characteristics and their origins were discussed, linking them to specific physical processes in ceramic AM.

Conclusions:

The study provides novel 3D microstructural data for additively manufactured ceramics.
Characterization of porosity and particle distribution offers insights into the AM process physics.
The generated 3D models serve as critical input and verification data for numerical simulations.