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Additive Manufacturing of High Performance Oxide Ceramics via Selective Laser Melting

ISBN: 978-3-86359-165-6

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Kurzübersicht

Oxide ceramics such as Al2O3 and ZrO2 are widely utilized in various engineering fields due to their excellent mechanical properties along with outstanding thermal and wear resistance. Their biocompatibility, strength and aesthetics also qualify these oxide ceramics for medical applications. Limitations to geometry and shrinking during conventional sintering processes often prevent utilization of these high-strength ceramics in various applications. These limitations may be overcome by employing Additive Manufacturing (AM) techniques, allowing for layer-wise generation of complex-shaped components directly from CAD data.

Additive Manufacturing of High Performance Oxide Ceramics via Selective Laser Melting

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Oxide ceramics such as Al2O3 and ZrO2 are widely utilized in various engineering fields due to their excellent mechanical properties along with outstanding thermal and wear resistance. Their biocompatibility, strength and aesthetics also qualify these oxide ceramics for medical applications. Limitations to geometry and shrinking during conventional sintering processes often prevent utilization of these high-strength ceramics in various applications. These limitations may be overcome by employing Additive Manufacturing (AM) techniques, allowing for layer-wise generation of complex-shaped components directly from CAD data. The present work studies AM of ceramic specimens, based on Al2O3 / ZrO2 powder by means of Selective Laser Melting (SLM). Towards this end, the powder material is qualified in terms of flowing ability and optical characteristics, aiming at developing a new process in which pure ceramics are completely melted by a laser beam, yielding net-shaped specimens of almost 100 % densities without any post processing. Formation of cracks is suppressed by high-temperature preheating, at which new preheating concepts are developed and compared in terms of thermoanalyses and the resulting property profiles. Employment of the eutectic Al2O3 / ZrO2 mixture ratio results in fine-grained microstructures and flexural strengths of up to 1150 MPa. Dominating effects of high-temperature SLM on the surface quality are analyzed. Furthermore, filigree structures of < 300 µm wall thickness and a profile roughness of Rz < 70 µm are achieved. For demonstration purposes fully ceramic dental restorations have been manufactured, highlighting the possibilities of manufacturing individual complex shaped high-strength ceramic components by means of SLM. Current limitations and an outlook towards future research complete this work.

Zusatzinformation

Autor Hagedorn, Yves-Christian
ISBN/Artikelnr. 978-3-86359-165-6
Gewicht 0.350 kg
Erscheinungsdatum 06.01.2014
Lieferzeit 3-4 Tage
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