陶瓷3D打印技术的研究与进展

3D打印技术是一种新型的陶瓷成型制造工艺,它无需模具,可快速制备出形状复杂的陶瓷零部件。系统综述了6种现有3D打印技术在陶瓷制造领域的研究进展,包括三维印刷成型技术、喷射打印成型技术、激光选区烧结成型技术、光固化快速成型技术、熔化沉积成型技术以及叠层实体制造技术。重点介绍了一种新型3D打印方法——浆料直写成型技术,与现有3D打印技术相比,直写成型技术能够在常温下、无需任何紫外光或者激光的辐射,通过简单的陶瓷原料制备出三维多孔立体精细结构,在先进陶瓷制备领域具有极大的潜力。从浆料体系、直写成型设备以及多功能应用3个方面详细阐述了浆料直写成型技术的研究进展。最后论述了陶瓷3D打印技术所具有的独特优势和面临的机遇与挑战。     

陶瓷3D打印模型设计技术回顾与展望

本文回顾了以往陶瓷3D打印模型设计技术并介绍了今后陶瓷3D打印模型技术的发展趋势,详细描述了陶瓷熔融沉积成型技术、立体光刻成型技术、选择性激光烧结技术、三维打印技术以及层压实体成型技术等方面的特点。面对陶瓷3D打印模型设计及工艺所存在的问题,对3D打印技术在陶瓷领域未来的发展方向进行了展望。     

陶瓷3D打印技术的研究进展

3D打印技术作为新一代成型技术,具有成型速度快以及精度高等优点,采用该技术制作的多功能陶瓷零件在工业、航空、医疗等领域有广阔的应用前景。本文主要对陶瓷3D打印技术进行介绍,且分析了陶瓷3D打印技术的国内外发展情况,在陶瓷3D打印过程中,通过比较和分析陶瓷3D打印技术的工作原理、最新研究成果以及应用领域,指出陶瓷3D打印技术的一些优势和缺陷,并且对陶瓷3D打印技术的发展方向进行了展望。     

3D打印成型陶瓷零件坯体及其致密化技术

3D打印技术在陶瓷零件成型方面具有较大应用潜力,被认为是近净尺寸成型高性能复杂结构陶瓷零件的一种新途径。本文比较了陶瓷零件或其坯体的激光选区熔化、薄材叠加制造、熔融沉积造型、光固化、三维打印和激光选区烧结等不同3D打印工艺及其致密化手段的优势和不足,认为较低的相对密度和强度是阻碍3D打印陶瓷零件实现产品应用的主要障碍。本团队近年来采用造粒混合法制备出具有良好流动性的3D打印复合陶瓷粉体,再通过激光选区烧结(SLS)和冷等静压(CIP)技术分别进行坯体成型及均匀致密化处理,制备出了高性能、复杂结构的Al_2O_3致密陶瓷零件。本文回顾了这些工作,并补充介绍了溶解沉淀和溶剂蒸发这两种制备复合陶瓷粉体的新方法,利用SLS/CIP复合工艺进一步制造了ZrO_2、SiC、高白土等其它材质的复杂陶瓷零件,为3D打印陶瓷用于航空航天、医疗、艺术等领域奠定了基础。     

空心叶片铸造用陶瓷型芯的3D打印及性能调控研究进展

陶瓷型芯在航空发动机空心涡轮叶片的熔模铸造中起到关键作用。3D打印技术作为新一代的成型技术,具有无需模具、制造周期短、精度高等优点,正在逐渐替代传统的陶瓷型芯制备工艺。本文总结了光固化技术、选择性激光烧结、直写成型技术和分层挤出成型等目前在陶瓷型芯领域使用较多的3D打印技术,针对3D打印陶瓷型芯打印精度低、力学性能与气孔率适配性差、结构性能各向异性等局限性探讨了性能优化研究现状,并对该领域的发展进行了展望。     

浆料直写成形Zr02陶瓷制备及烧结

为浆料直写成形工艺制备了一种高固相含量的水基Zr02陶瓷浆料,并用该工艺打印陶瓷坯体,1350～1550℃烧结后制备Zr02陶瓷样品.研究烧结温度对样品收缩率、密度、气孔率、相结构、力学性能、微观形貌和表面质量的影响,并与其他制造工艺进行性能比较.结果表明:在1550℃烧结2h,直写成形Zr02陶瓷综合性能最佳,其晶粒...     

陶瓷光固化3D打印技术研究进展及应用

与传统加工方法相比,光固化3D打印技术具有个性化、定制化、高分辨率等优点,可满足陶瓷精细结构的成型,在陶瓷材料加工方面展示出很大的潜力.这里首先介绍了光固化3D打印技术及常见的陶瓷材料,从陶瓷浆料制备、素坯热处理工艺方面进行讨论.同时对该技术在生物医学领域特别是在骨科、齿科中的应用进行总结.     

陶瓷部件的浆料打印快速成型

采用Sanders公司的四打印头快速成型机进行了陶瓷部件的浆料打印成型实验,实际测试了所用四打印头快速成型机的打印工作条件,考察了石蜡和挥发性介质两种浆料技术路线,并采用石蜡为介质制备了钛酸钡陶瓷浆料,研究了其流变性能,实验表明,虽然偶联剂的加入可以降低石蜡介质浆料的粘度,但是粘度足够低的可打印浆料的固相含量太低[约3％（in volume)以下],打印成型后不能完全烧结,因此,要通过打印成型出可完全烧结的陶瓷部件只能采用挥发液体作为浆料介质,以便在打印成型过程中通过介质挥发提高成型部件的固相含量。     

3D打印陶瓷材料的研究与应用

作为新一代成形技术,3D打印技术具有操作简单、成形速度快、精度高等优点,而采用3D打印技术制备出的多功能化陶瓷零件,在建筑、工业、医学、航天航空等领域将会得到广泛的应用,其发展前景十分广阔。笔者主要介绍3D打印陶瓷方面的成形技术和材料,综述了3D打印陶瓷的国内外研究现状与应用进展,并对可应用于3D陶瓷的打印技术和打印材料进行了展望。     

Cf/SiC复合材料的原料高效改性及其3D打印制备研究进展

选用3D打印制备的碳纤维增强碳化硅陶瓷基（Cf/SiC）复合材料被广泛应用在航空航天、国防军事等重大领域。碳纤维（Cf）作为陶瓷基复合材料的主要候选增强体之一,由于表面惰性的存在,为了提高其与碳化硅（SiC）陶瓷基体的粘附性,对原料Cf的表面改性工作是十分必要的。粉末原料的高效改性制备是3D打印成型陶瓷的重要途径。本文综述了近年来国内外针对Cf改性的各种方法及特点,对Cf/SiC复合材料的3D打印成型及其高效制备方法进行归纳总结。     

Fused deposition fabrication of high-quality zirconia ceramics using granular feedstock

Benefiting from the mature technology of ceramic injection molding, Fused deposition modeling based on highly-filled ceramic-polymer granular feedstocks has been showing great potential and advantage for fabricating 3D ceramics. Herein, 3D zirconia ceramics using granular feedstock were fabricated, and typical morphology, surface quality, and effect of the thermal accumulation on 3D structure were clarified. Typical morphology of printing steps on the surface were quantitatively characterized, and determined by the surface curvature and layer height of the printed structure. Aligned triangular pores were confirmed at the junction of the deposited filaments with elliptical cross-section morphology. Simple square plates with different size were used to illustrate the influence of thermal accumulation on the morphology of 3D structure. Small printing size increased the thermal accumulation during deposition, resulting in decreased printing quality caused by the secondary over-melting of former deposited layers. Except for the pores at the junctions, dense zirconia ceramics with uniform structure and smooth surface could be achieved. A low-cost and high-quality route for the preparation of 3D ceramics was demonstrated via FDM of highly-filled granular feedstocks.     

大壁厚3D打印SiO2陶瓷快速制备技术研究

选用复合分散剂制备低粘度陶瓷料浆,采用自主研发的陶瓷3D打印机,以DLP(digital light processing)工艺制备出了大壁厚(>3 mm)SiO₂空心内六角陶瓷部件,坯体精度均在50 μm内。分析了3D打印陶瓷素坯在空气气氛和氩气气氛下的热分解过程,研究了气氛对大壁厚(>3 mm)SiO₂陶瓷部件脱脂与烧结的影响。结合扫描电子显微镜(SEM)分析了大壁厚(>3 mm)3D打印SiO₂陶瓷坯体快速脱脂烧结的工艺,氩气气氛有利于大壁厚SiO₂陶瓷快速脱脂烧结。氩气气氛下,控制气流量,进行了大壁厚(>3 mm)SiO₂陶瓷部件的快速制备,脱脂烧结周期大大缩短,为21.8 h,较自国外某公司进口的料浆及其工艺的制备周期(以进口的该公司料浆及工艺制备的相同产品制备周期为283 h)缩短92.3%,较公开报道的3D打印相同工艺制备的SiO₂陶瓷空心叶片制备周期缩短82%以上。     

陶瓷增材制造(3D打印)技术研究进展

高性能陶瓷是现代技术发展和应用不可或缺的关键材料。常规的陶瓷制造技术难以满足对个性化、精细化、轻量化和复杂化的高端产品快速制造的需求。新兴的增材制造技术(3D打印)在高性能陶瓷的成型制造领域具有巨大的发展潜力,有望突破传统陶瓷加工和生产的技术瓶颈,为陶瓷关键零部件的应用开辟新的途径。本文针对陶瓷材料及其快速成型和后处理工艺,重点阐述了三维打印技术、光固化成型技术、选择性激光烧结技术等主流陶瓷增材制造技术的研究现状,并指出了目前存在的问题及发展趋势。     

Digital light processing-stereolithography three-dimensional printing of yttria-stabilized zirconia

Digital light processing (DLP)-stereolithography three-dimensional (3D) printing is a well known technique for fabricating components with complex geometries. However, the application of DLP 3D printing to functional ceramics such as 8 mol% yttria-stabilized zirconia (8YSZ), which is one of the most extensively used electrolyte materials for solid oxide fuel cells, is still a great challenge. Therefore, the fabrication of fully 8YSZ monoliths via DLP 3D printing was attempted herein, including the preparation of UV-curable ceramic suspensions, shaping of green bodies, and debinding and sintering. The results show that intact green bodies printed using a 30 vol% 8YSZ-photosensitive resin suspension with 0.1 wt% oleic acid as the dispersant under the optimized printing conditions was sufficiently dense without connected pores after vacuum debinding and sintering in air. The successful fabrication of 8YSZ monoliths with design flexibility via 3D printing provides a simple method for preparing functional ceramic components and may expand the application of 3D printing technology to the energy field.     

A review of 3D printed porous ceramics

Three-dimensional (3D) printing of ceramics has gained widespread attentions in recent years. Many excellent reviews have reported the printing of ceramics. However, most of them focus on printing of dense ceramics or general ceramic aspects, there is no systematical review about 3D printing of porous ceramics. In this review paper, the 3D printing technologies for fabricating of porous ceramic parts are introduced, including binder jetting, selective laser sintering, direct ink writing, stereolithography, laminated object manufacturing, and indirect 3D printing processes. The techniques to fabricate hierarchical porous ceramics by integrating 3D printing with one or more conventional porous ceramics fabrication approaches are reviewed. The main properties of porous ceramics such as pore size, porosity, and compressive strength are discussed. The emerging applications of 3D printed porous ceramics are presented with a focus on the booming application in bone tissue engineering. Finally, summary and a perspective on the future research directions for 3D printed porous ceramics are provided.     

Enhanced mechanical properties of 3D printed alumina ceramics by using sintering aids

Stereolithography based 3D printing provides an efficient pathway to fabricate alumina ceramics, and the exploration on the mechanical properties of 3D printed alumina ceramics is crucial to the development of 3D printing ceramic technology. However, alumina ceramics are difficult to sinter due to their high melting point. In this work, alumina ceramics were prepared via stereolithography based 3D printing technology, and the improvement in the mechanical properties was investigated based on the content, the type and the particle size of sintering aids (TiO₂, CaCO₃, and MgO). The flexural strength of the sintered ceramics increased greatly (from 139.2 MPa to 216.7 MPa) with the increase in TiO₂ content (from 0.5 wt% to 1.5 wt%), while significant anisotropy in mechanical properties (216.7 MPa in X-Z plane and 121.0 MPa in X–Y plane) was observed for the ceramics with the addition of 1.5 wt TiO₂. The shrinkage and flexural strength of the ceramics decreased with the increase in CaCO₃ content due to the formation of elongated grains, which led to the formation of large-sized residual pores in the ceramics. The addition of MgO help decrease the anisotropic differences in shrinkage and flexural strength of the sintered ceramics due to the formation of regularly shaped grains. This work provides guidance on the adjustment in flexural strength, shrinkage, and anisotropic behavior of 3D printed alumina ceramics, and provides new methods for the fabrication of 3D printed alumina ceramics with superior mechanical properties.     

First printing of continuous fibers into ceramics

This article reports a novel method for three-dimensional (3D) printing of continuous fibers into ceramics to improve the mechanical properties of printed ceramics, which is difficult in other 3D printing technologies. The ceramics were derived by pyrolysis of thermoplastic ceramic precursor feedstocks, which were prepared by two methods. One is homogeneously mixing thermoplastic resins and ceramic precursors. The feedstocks prepared by this method exhibit good thermoplastic properties and can be extruded into filaments. Ceramics were obtained by heating the feedstocks to 1100°C in argon atmosphere. The ceramics were amorphous and remained stable during 1100-1300°C; at 1400°C they decomposed into β–SiC with simultaneous volatile gas generation. Above 1400°C, their quality decreased significantly due to cracking of ceramic skeletons. The other method is directly heating, extruding and printing the ceramic precursor. The precursors showed good printability and complex ceramic structures were printed with continuous carbon fibers inside. The continuous carbon fibers improved the flexural strength of pyrolytic ceramics, which is about 7.6 times better than that of the ceramics without fibers. The novel method unravels the potential of 3D printing of continuous fibers into ceramics with complex lightweight structures to improve the strength.     

陶瓷部件3D 打印技术的研究进展

近年来,三维连续网络结构的陶瓷／金属复合材料由于兼具陶瓷材料的耐磨、高强、高硬、抗氧化、耐蚀及钢铁材料的导热性及良好的韧性受到人们的广泛关注。三维连续网络结构的陶瓷／金属复合材料的陶瓷结构的构建是制备复合材料的难题。3D打印技术突破了传统的加工模式,不依赖复杂模具和机械加工,并可根据材料不同的性能要求,开发出不同结构的陶瓷骨架,这将使陶瓷／金属复合材料领域发生巨大变化。本文介绍了陶瓷3D 打印技术的原理、分类、工艺特点及研究进展,并对3D打印技术未来的发展方向进行了展望。