Additive manufacturing of Al2O3 ceramics with MgO/SiC contents by laser powder bed fusion process

Asif Ur Rehman; Abid Ullah; Tingting Liu; Rashid Ur Rehman; Metin U Salamci

doi:10.3389/fchem.2023.1034473

Additive manufacturing of Al₂O₃ ceramics with MgO/SiC contents by laser powder bed fusion process

Front Chem. 2023 Feb 3:11:1034473. doi: 10.3389/fchem.2023.1034473. eCollection 2023.

Authors

Asif Ur Rehman^{1

2

3}, Abid Ullah^{2

3

4}, Tingting Liu⁵, Rashid Ur Rehman⁶, Metin U Salamci^{2

3

7}

Affiliations

¹ ERMAKSAN, Bursa, Türkiye.
² Department of Mechanical Engineering, Faculty of Engineering, Gazi University, Ankara, Türkiye.
³ Additive Manufacturing Technologies Research and Application Center-EKTAM, Gazi University, Ankara, Türkiye.
⁴ CAS Key Laboratory of Mechanical Behavior and Design of Materials, Department of Modern Mechanics, University of Science and Technology of China, Hefei, Anhui, China.
⁵ School of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing, Jiangsu, China.
⁶ Incheon National University, Incheon, South Korea.
⁷ Advanced Manufacturing Technologies Center of Excellence-URTEMM, Ankara, Türkiye.

Abstract

Laser powder bed fusion is a laser-based additive manufacturing technique that uses a high-energy laser beam to interact directly with powder feedstock. LPBF of oxide ceramics is highly desirable for aerospace, biomedical and high-tech industries. However, the LPBF of ceramics remains a challenging area to address. In this work, a new slurry-based approach for LPBF of ceramic was studied, which has some significant advantages compared to indirect selective laser sintering of ceramic powders. LPBF of Al₂O₃ was fabricated at different MgO loads up to 80 wt%. Several specimens on different laser powers (70 W-120 W) were printed. The addition of magnesia influenced the microstructure of the alumina ceramic significantly. The findings show that when the laser power is high and the magnesia load is low, the surface quality of the printing parts improves. It is feasible to produce slurry ceramic parts without binders through LPBF. Furthermore, the effects of SiC and MgO loads on the microstructure and surface morphology of alumina are compared and analysed.

Keywords: additive manufacturing; ceramic; defects; laser processing; oxidation; sintering.

Grants and funding

This work was supported by the Frontier Leading Technology Basic Research Project of Jiangsu (No. BK20202007), the National Natural Science Foundation of China (Grant No. 52005262), BK20190463 and No. B18028. This work was also supported by the National Natural Science Foundation of China (grant number 51775281). This project has also received financial support from the European Union's Horizon 2020 (H2020) research and innovation program under the Marie Skłodowska-Curie, grant agreement No. 764935. This work has also received funding from the H2020 research and innovation program under the Marie Skłodowska-Curie grant agreement No. 101034425 for the project titled A2M2TECH. This study has also received financial support from The Scientific and Technological Research Council of Türkiye (TUBITAK) with grant No 120C158 for the same A2M2TECH project under the TUBITAK's 2236/B program.