[en] This paper introduces a fast, low-temperature, pressureless process to chemically bind ceramic parts with the help of infrared (IR) irradiation and phosphate binder condensation. Ceramic components are synthesized from slurries of ceramic powders and Al(H2PO4)3 binder that are irradiated with short-waved IR light capable of heating the system to 350°C. This irradiation is found to be sufficient to drive phosphate condensation, binding the ceramic powders together within a matter of seconds. The IR-irradiated components show an increase in density and Vickers hardness. Layer-by-layer spraying and irradiation is demonstrated as a route to additive manufacturing using various ceramic chemistries. While further optimization is needed to control desired microstructure, this process of using chemically bonded ceramic binders with IR heating for additive manufacturing shows the potential to find applications in various ceramic systems, including refractories, bone implants, electronics, and thermal barrier coatings.
Disciplines :
Chimie
Auteur, co-auteur :
Somers, Nicolas ; Université de Liège - ULiège > Complex and Entangled Systems from Atoms to Materials (CESAM) ; School of Materials Science and Engineering, Georgia Institute of Technology, Atlanta, United States
Montón, Alejandro; School of Materials Science and Engineering, Georgia Institute of Technology, Atlanta, United States
Özmen, Eren; School of Materials Science and Engineering, Georgia Institute of Technology, Atlanta, United States
Losego, Mark D.; School of Materials Science and Engineering, Georgia Institute of Technology, Atlanta, United States
Langue du document :
Anglais
Titre :
Infrared irradiation to drive phosphate condensation as a route to direct additive manufacturing of oxide ceramics
This research was supported by a grant from the Office of Naval Research (grant number N00014‐21‐1‐2258) under the direction of Dr. Antti Makinen. A portion of this work was also conducted in the Materials Innovation and Learning Laboratory (the MILL), an open‐access materials characterization facility supported by the School of Materials Science and Engineering and the College of Engineering at Georgia Tech.
Rahaman MN. Ceramic processing and sintering. CRC Press; 2003. 875 p.
Groover MP. Fundamentals of modern manufacturing: materials, processes, and systems. 4th ed. Wiley; 2010. 1025 p.
Pfeiffer S, Florio K, Puccio D, Grasso M, Maria B, Aneziris CG, et al. Direct laser additive manufacturing of high performance oxide ceramics: a state-of-the-art review. J Eur Ceram Soc. 2021;41(13):6087–114. https://doi.org/10.1016/j.jeurceramsoc.2021.05.035
Grossin D, Navarrete-segado P, Ozmen E, Monton A, Urruth G, Maury F, et al. A review of additive manufacturing of ceramics by powder bed selective laser processing (sintering/melting): calcium phosphate, silicon carbide, zirconia, alumina, and their composites. Open Ceram. 2021;5:100073.
Klimov AS, Bakeev IY, Dvilis ES, Oks EM, Zenin AA. Electron beam sintering of ceramics for additive manufacturing. Vacuum. 2019;169:108933. https://doi.org/10.1016/j.vacuum.2019.108933
Deckers J, Vleugels J, Kruth JP. Additive manufacturing of ceramics: a review. J Ceram Sci Technol. 2014;5:245–60.
Chen Q, Schmidt F, Gorke O, Asif A, Weinhold J, Aghaei E, et al. Ceramic stereolithography of bioactive glasses: influence of resin composition on curing behavior and green body properties. Biomedicines. 2022;10:395.
Chaudhary R, Fabbri P, Leoni E, Mazzanti F, Akbari R. Additive manufacturing by digital light processing: a review. Prog Addit Manuf. 2023;8(2):331–51. https://doi.org/10.1007/s40964-022-00336-0
Elsayed H, Javed H, Sabato AG, Smeacetto F, Bernardo E. Novel glass-ceramic SOFC sealants from glass powders and a reactive silicone binder. J Eur Ceram Soc. 2018;38(12):4245–51. https://doi.org/10.1016/j.jeurceramsoc.2018.05.024
Elsayed H, Bertolini R, Biasetto L, Paulina O, Kraxner J, Galusek D, et al. Novel functional glass—ceramic coatings on titanium substrates from glass powders and reactive silicone binders. Polymers. 2022;14:4016.
Wang X, Schmidt F, Hanaor D, Kamm PH, Li S. Additive manufacturing of ceramics from preceramic polymers: a versatile stereolithographic approach assisted by thiol-ene click chemistry. Addit Manuf. 2019;27:80–90.
Schmidt J, Colombo P. Digital light processing of ceramic components from polysiloxanes. J Eur Ceram Soc. 2018;38:57–66. https://doi.org/10.1016/j.jeurceramsoc.2017.07.033
Chen H, Wang X, Xue F, Huang Y, Zhou K, Zhang D. Journal of the European Ceramic Society 3D printing of SiC ceramic: direct ink writing with a solution of preceramic polymers. J Eur Ceram Soc. 2018;38(16):5294–300. https://doi.org/10.1016/j.jeurceramsoc.2018.08.009
Radovanovic E, Gozzi MF, Gonc MC, Yoshida IVP. Silicon oxycarbide glasses from silicone networks. J Non Cryst Solids. 1999;248:37–48.
Narisawa M. Silicone resin applications for ceramic precursors and composites. Materials. 2010;3:3518–36.
Grant LO, Alameen MB, Carazzone JR, Higgs III CF, Cordero ZC. Mitigating distortion during sintering of binder jet printed ceramics. Proceedings of the 29th Annual International Solid Freeform Fabrication Symposium. 2018. p. 135–42.
Shrivastav V, Sundriyal S, Kim K, Sinha RK, Tiwari UK, Deep A. Metal–organic frameworks-derived titanium dioxide–carbon nanocomposite for supercapacitor applications. Int J Energy Res. 2020;44:6269–84.
Liu Y, Xu X, Shao Z, Ping S. Metal–organic frameworks derived porous carbon, metal oxides and metal sulfides-based compounds for supercapacitors application. Energy Storage Mater. 2020;26:1–22. https://doi.org/10.1016/j.ensm.2019.12.019
Gautam S, Agrawal H, Thakur M, Akbari A, Sharda H, Kaur R, et al. Metal oxides and metal organic frameworks for the photocatalytic degradation: a review. J Environ Chem Eng. 2020;8(3):103726. https://doi.org/10.1016/j.jece.2020.103726
Fujii E, Torii H, Tomozawa A, Takayama R, Hirao T. Iron oxide films with spinel, corundum and bixbite structure prepared by plasma-enhanced metalorganic chemical vapor deposition. J Cryst Growth. 1995;151:134–9.
Zou G, Chen J, Zhang Y, Wang C, Huang Z, Li S, et al. Carbon-coated rutile titanium dioxide derived from titanium–metal organic framework with enhanced sodium storage behavior. J Power Sources. 2016;325:25–34. https://doi.org/10.1016/j.jpowsour.2016.06.017
Wang M, Liu J, Du H, Hou F, Guo A, Zhao Y, et al. A new practical inorganic phosphate adhesive applied under both air and argon atmosphere. J Alloys Compd. 2014;617:219–21. https://doi.org/10.1016/j.jallcom.2014.08.043
Colorado HA, Hiel C, Hahn HT. Chemically bonded phosphate ceramics composites reinforced with graphite nanoplatelets. Compos Part A. 2011;42(4):376–84. https://doi.org/10.1016/j.compositesa.2010.12.007
Jeong SY, Wagh AS. Cementing the gap between ceramics, cements, and polymers. Mater Technol. 2003;18(3):162–8.
Zhu X, Yue M, Qu Z, Ma Y, Li H, Takagi K, et al. High-temperature DIC based on aluminium dihydrogen phosphate speckle. Measurement. 2019;133:133–8.
Xu X, Zhang J, Jiang P, Liu D, Jia X, Wang X. Direct ink writing of aluminum-phosphate-bonded Al2O3 ceramic with ultra-low dimensional shrinkage. Ceram Int. 2022;48(1):864–71. https://doi.org/10.1016/j.ceramint.2021.09.168
Morris JH, Perkins PG, Rose AEA, Smith WE. The chemistry and binding properties of aluminium phosphates. Chem Soc Rev. 1977;6:173–94.
Hopp V, Masoudi Alavi A, Hahn D, Quirmbach P. Structure–property functions of inorganic chemical binders for refractories. Materials. 2021;14(16):4636.
Yu Z, Yang D, Wang R, Jiang Q, Zhu K, Cui J. Investigation on properties of Al2O3–SiO2 complex shaped refractory fabricated by layered extrusion forming. Ceram Int. 2020;46(11):18985–93. https://doi.org/10.1016/j.ceramint.2020.04.226
Hopp V, Masoudi Alavi A, Hahn D, Quirmbach P. Structure–property functions of inorganic chemical binders for refractories. Materials. 2021;14:4636.
Grover SE, Jeong SY, Wagh A, West TR, Lafayette W. Low-temperature synthesis of berlinite-bonded alumina ceramics. Proceedings of the 1999 American Ceramic Society Annual Meeting, Indianapolis, IN, April 25–28, 1999.
Li Y, Chen G, Zhu S, Li H, Ma Z, Liu Y, et al. Preparation of an aluminium phosphate binder and its influence. Bull Mater Sci. 2019;42(5):1–8. https://doi.org/10.1007/s12034-019-1912-3
Jeongc SY, Wagh AS. Cementing The Gap Between Ceramics, Cements, And Polymers. Mater Technol, 2003;18(3):162–168. https://doi.org/10.1080/10667857.2003.11753035
Gilshtein E, Pfeiffer S, Rossell MD, Sastre J, Gorjan L. Millisecond photonic sintering of iron oxide doped alumina ceramic coatings. Sci Rep. 2021;11:3536.
Gilshtein E, Pfeiffer S, Siegrist S, Vlnieska V, Graule T, Romanyuk YE. Photonic sintering of oxide ceramic films: effect of colored FexOy nanoparticle pigments. Ceramics. 2022;5:351–61.
Shin SH, Park J, Lee H, Kong S, Park J, Won Y, et al. Fabrication of scandia-stabilized zirconia thin films by instant flash light irradiation. Coatings. 2020;10(6):560.
Abu Osman NA, Ibrahim F, Wan Abas WAB, Abd Rahman HS, Ting HN. Biomed 2008, Proceedings 21, pp. 351–353, 2008.
Wei H, Wang T, Zhang Q, Jiang Y, Mo C. Study of composition and structure of aluminum phosphate binder. J Chin Chem Soc. 2020;67:116–24.
Sun D-L, Deng J, Chao Z. Catalysis over zinc-incorporated berlinite (ZnAlPO4) of the methoxycarbonylation of 1,6-hexanediamine with dimethyl carbonate to form dimethylhexane-1,6-dicarbamate. Chem Cent J 2007;1:27, https://doi.org/10.1186/1752-153X-I-27
Tang S, Yang Y, Fan Z, Yang L, Yang Z, Ling Q, et al. A novel composite binder design for direct ink writing alumina-based ceramics with enhanced strength at low sintering temperature. Ceram Int. 2022;48(6):7963–74. https://doi.org/10.1016/j.ceramint.2021.11.343
Gojzewski H, Guo Z, Grzelachowska W, Ridwan MG, Hempenius MA, Grijpma DW, et al. Layer-by-layer printing of photopolymers in 3D: how weak is the interface? ACS Appl Mater Interfaces. 2020;12(7):8908–14.
Lim D, Chung J, Yun J, Park M-S. Fabrication of 3D printed ceramic part using photo-polymerization process. Polymers. 2023;15:1601.
