Journal of Inorganic Materials, Volume. 39, Issue 7, 741(2024)

Progress of Ultra-high Temperature Oxide Ceramics: Laser Additive Manufacturing and Microstructure Evolution

Qian CHEN, Haijun SU, Hao JIANG, Zhonglin SHEN, Minghui YU, and Zhuo ZHANG
References(72)

[3] JAMES C W, EDGAR A S. Progress in structural materials for aerospace systems. Acta Materialia, 51(2003).

[5] LIU L, WANG S Z, ZHANG B Q et al. Present status and prospects of nanostructured thermal barrier coatings and their performance improvement strategies: a review. Journal of Manufacturing Processes, 97, 12(2023).

[7] LIU Y, SU H J, SHEN Z L et al. Effect of seed orientations on crystallographic texture control in faceted Al2O3/YAG eutectic ceramic during directional solidification. Journal of Materials Science & Technology, 146, 86(2023).

[8] DUAN B H, MAO L, LV M R et al. Interface interaction during the preparation of TiAl-(Nb, V) quaternary intermetallic single crystals by directional solidification based on Y2O3 doped BaZrO3/Al2O3 composite ceramic mold. Journal of the European Ceramic Society, 43(2023).

[9] LIU Y, SU H J, SHEN Z L et al. High temperature calcium- magnesium-alumina-silicate (CMAS) corrosion behavior of directionally solidified Al2O3/YAG eutectic ceramic. Journal of Materials Science & Technology, 165, 66(2023).

[10] SUN H F, SUN L C, REN X M et al. Outstanding molten calcium- magnesium-aluminosilicate (CMAS) corrosion resistance of directionally solidified Al2O3/Y3Al5O12 eutectic ceramic at 1500 °C. Corrosion Science, 220, 111289(2023).

[11] WAKU Y, NAKAGAWA N, WAKAMOTO T et al. A ductile ceramic eutectic composite with high strength at 1873 K. Nature, 389, 49(1997).

[12] NAKAGAWA N, OHTSUBO H, MITANI A et al. High temperature strength and thermal stability for melt growth composite. Journal of the European Ceramic Society, 25, 1251(2005).

[13] ARMSTRONG M, MEHRABI H, NAVEED N. An overview of modern metal additive manufacturing technology. Journal of Manufacturing Processes, 84, 1001(2022).

[14] LIU J K, HUANG J Q, ZHENG Y F et al. Challenges in topology optimization for hybrid additive-subtractive manufacturing: a review. Computer-Aided Design, 161, 103531(2023).

[15] KIM Y S, CHANG W, JEONG H J et al. High performance of protonic ceramic fuel cells with 1-μm-thick electrolytes fabricated by inkjet printing. Additive Manufacturing, 71, 103590(2023).

[16] LI J G, AN X L, LIANG J J et al. Recent advances in the stereolithographic three-dimensional printing of ceramic cores: challenges and prospects. Journal of Materials Science & Technology, 117, 79(2022).

[17] ZHANG H, ZHAI Q, CAO Y et al. Design and facile manufacturing of tri-layer laminated polyolefin microfibrous fabrics with tailoring pore size for enhancing waterproof breathable performance. Materials & Design, 228, 111829(2023).

[18] PFEIFFERP S, FLORIO K, PUCCIO D et al. Direct laser additive manufacturing of high performance oxide ceramics: a state-of-the-art review. Journal of the European Ceramic Society, 41(2021).

[19] LEE H, LIM C H J, LOW M J et al. Lasers in additive manufacturing: a review. International Journal of Precision Engineering and Manufacturing-Green Technology, 4, 307(2017).

[20] GLARDON R, KARAPATIS N, ROMANO V et al. Influence of Nd: YAG parameters on the selective laser sintering of metallic powders. CIRP Annals, 50(2001).

[21] KRUTH J P, WANG X, LAOUI T et al. Laser and materials in selective laser sintering. Assembly Automation, 23(2003).

[22] HU K M, LIN K J, GU D D et al. Mechanical properties and deformation behavior under compressive loading of selective laser melting processed bio-inspired sandwich structures. Materials Science and Engineering: A, 762, 138089(2019).

[23] SHISHKOVSKY I, YADROITSEV I, BERTRAND P et al. Alumina-zirconium ceramics synthesis by selective laser sintering/ melting. Applied Surface Science, 254(2007).

[24] SHEN Z L, SU H J, YU M H et al. Large-size complex-structure ternary eutectic ceramic fabricated using laser powder bed fusion assisted with finite element analysis. Additive Manufacturing, 72, 103627(2023).

[25] LIU H F, SU H J, SHEN Z L et al. Direct formation of Al2O3/ GdAlO3/ZrO2 ternary eutectic ceramics by selective laser melting: microstructure evolutions. Journal of the European Ceramic Society, 38(2018).

[26] GU D D, DU L, DAI D H et al. Influence of thermal behavior along deposition direction on microstructure and microhardness of laser melting deposited metallic parts. Applied Physics A, 125(2019).

[27] GU D D, SHI X Y, POPRAWE R et al. Material-structure- performance integrated laser-metal additive manufacturing. Science, 372(2021).

[28] KOKARE S, OLIVEIRA J P, GODINA R. A LCA and LCC analysis of pure subtractive manufacturing, wire arc additive manufacturing, and selective laser melting approaches. Journal of Manufacturing Processes, 101, 67(2023).

[29] SU H J, LIU H F, JIANG H et al. One-step preparation of melt-grown Al2O3/GdAlO3/ZrO2 eutectic ceramics with large size and irregular shape by directed energy deposition. Additive Manufacturing, 70, 103563(2023).

[30] WU D J, SHI J, NIU F Y et al. Direct additive manufacturing of melt growth Al2O3-ZrO2 functionally graded ceramics by laser directed energy deposition. Journal of the European Ceramic Society, 42(2022).

[31] LIU H F, SU H J, SHEN Z L et al. Preparation of large-size Al2O3/GdAlO3/ZrO2ternary eutectic ceramic rod by laser directed energy deposition and its microstructure homogenization mechanism. Journal of Materials Science & Technology, 85, 218(2021).

[32] DEBROY T, WEI L H, ZUBACK J S et al. Additive manufacturing of metallic components—process, structure and properties. Progress in Materials Science, 92, 112(2018).

[33] BALLA V K, BOSE S, BANDYOPADHYAY A. Processing of bulk alumina ceramics using laser engineered net shaping. International Journal of Applied Ceramic Technology, 5(2008).

[34] FAN Z Q, ZHAO Y T, LU M Y et al. Yttria stabilized zirconia (YSZ) thin wall structures fabricated using laser engineered net shaping (LENS). International Journal of Advanced Manufacturing Technology, 105, 4491(2019).

[35] FAN Z Q, ZHAO Y T, TAN Q Y et al. Nanostructured Al2O3-YAG-ZrO2 ternary eutectic components prepared by laser engineered net shaping. Acta Materialia, 170, 24(2019).

[36] SHEN Z L, SU H J, LIU H F et al. Directly fabricated Al2O3/ GdAlO3 eutectic ceramic with large smooth surface by selective laser melting: rapid solidification behavior and thermal field simulation. Journal of the European Ceramic Society, 42(2022).

[37] FAN Z Q, ZHAO Y T, TAN Q Y et al. New insights into the growth mechanism of 3D-printed Al2O3-Y3Al5O12 binary eutectic composites. Scripta Materialia, 178, 274(2020).

[38] PENA J I, MERINO R I, HARLAN N R et al. Microstructure of Y2O3 doped Al2O3-ZrO2 eutectics grown by the laser floating zone method. Journal of the European Ceramic Society, 22(2002).

[39] SU H J, ZHANG J, YU J C et al. Directional solidification and microstructural development of Al2O3/GdAlO3 eutectic ceramic in situ composite under rapid growth conditions. Journal of Alloys and Compounds, 509(2011).

[40] SONG K, ZHANG J, LIN X et al. Microstructure and mechanical properties of Al2O3/Y3Al5O12/ZrO2 hypereutectic directionally solidified ceramic prepared by laser floating zone. Journal of the European Ceramic Society, 34(2014).

[41] SU H J, ZHANG J, TIAN J J et al. Preparation and characterization of Al2O3/Y3Al5O12/ZrO2 ternary hypoeutectic in situ composites by laser rapid solidification. Journal of Applied Physics, 104(2008).

[42] LIU H F, SU H J, SHEN Z L et al. One-step additive manufacturing and microstructure evolution of melt-grown Al2O3/GdAlO3/ZrO2 eutectic ceramics by laser directed energy deposition. Journal of the European Ceramic Society, 41(2021).

[43] FAN Z Q, YIN Y, TAN Q Y et al. Unveiling solidification mode transition and crystallographic characteristics in laser 3D-printed Al2O3-ZrO2 eutectic ceramics. Scripta Materialia, 210, 114433(2022).

[44] WANG X, ZHONG Y J, SUN Q et al. Crystallography and interfacial structure in a directionally solidified Al2O3/Y3Al5O12/ ZrO2 eutectic crystal. Scripta Materialia, 145, 23(2018).

[45] LARREA A, FUENTE G F, MERINO R I et al. ZrO2-Al2O3 eutectic plates produced by laser zone melting. Journal of the European Ceramic Society, 22(2002).

[46] WAKU Y, NAKAGAWA N, WAKAMOTO T et al. High- temperature strength and thermal stability of a unidirectionally solidified Al2O3/YAG eutectic composite. Journal of Materials Science, 33, 1217(1998).

[47] HUANG Y F, WU D J, ZHAO D K et al. Process optimization of melt growth alumina/aluminum titanate composites directed energy deposition: effects of scanning speed. Additive Manufacturing, 35, 101210(2020).

[48] ZHAO D K, WU D J, NIU F Y et al. Heat treatment of melt- grown alumina ceramics with trace glass fabricated by laser directed energy deposition. Materials Characterization, 196, 112639(2023).

[49] WU D J, SAN J D, NIU F Y et al. Directed laser deposition of Al2O3-ZrO2 melt-grown composite ceramics with multiple composition ratios. Journal of Materials Science, 55, 6794(2020).

[50] HU Y B, WANG H, CONG W L et al. Directed energy deposition of zirconia-toughened alumina ceramic: novel microstructure formation and mechanical performance. Journal of Manufacturing Science and Engineering, 142, 021005(2019).

[51] WU D J, NIU F Y, HUANG Y F et al. Effects of TiO2 doping on microstructure and properties of directed laser deposition alumina/ aluminum titanate composites. Virtual and Physical Prototyping, 14(2019).

[52] ZHAO D K, WU D J, SHI J et al. Microstructure and mechanical properties of melt-grown alumina-mullite/glass composites fabricated by directed laser deposition. Journal of Advanced Ceramics, 11(2022).

[53] PAPPAS J M, DONG X Y. Effects of processing conditions on laser direct deposited alumina ceramics. ASME 2020 15th International Manufacturing Science and Engineering Conference, New York, 8260(2020).

[54] LIU H F, SU H J, SHEN Z L et al. Effect of scanning speed on the solidification process of Al2O3/GdAlO3/ZrO2 eutectic ceramics in a single track by selective laser melting. Ceramics International, 45(2019).

[55] FAN Z Q, LU M Y, HUANG H. Selective laser melting of alumina: a single track study. Ceramics International, 44(2018).

[56] WU D J, ZHAO D K, HUANG Y F et al. Shaping quality, microstructure, and mechanical properties of melt-grown mullite ceramics by directed laser deposition. Journal of Alloys and Compounds, 871, 159609(2021).

[57] YAN S, WU D J, NIU F Y et al. Al2O3-ZrO2 eutectic ceramic via ultrasonic-assisted laser engineered net shaping. Ceramics International, 43(2017).

[58] YAN S, WU D J, NIU F Y et al. Effect of ultrasonic power on forming quality of nano-sized Al2O3-ZrO2 eutectic ceramic via laser engineered net shaping (LENS). Ceramics International, 44(2018).

[59] MOHANTY P, MAHAPATRA R, PADHI P et al. Ultrasonic cavitation: an approach to synthesize uniformly dispersed metal matrix nanocomposites—a review. Nano-Structures & Nano-Objects, 23, 100475(2020).

[60] WU D J, LIU H C, LU F et al. Al2O3-YAG eutectic ceramic prepared by laser additive manufacturing with water-cooled substrate. Ceramics International, 45(2019).

[61] YAN S, WU D J, HUANG Y F et al. C fiber toughening Al2O3- ZrO2 eutectic via ultrasonic-assisted directed laser deposition. Materials Letters, 235, 228(2019).

[62] WU D J, LU F, ZHAO D K et al. Effect of doping SiC particles on cracks and pores of Al2O3-ZrO2 eutectic ceramics fabricated by directed laser deposition. Journal of Materials Science, 54, 9321(2019).

[63] YAN S, WU D J, MA G Y et al. Formation mechanism and process optimization of nano Al2O3-ZrO2 eutectic ceramic via laser engineered net shaping (LENS). Ceramics International, 43(2017).

[64] CHEN X T, GUO W, WANG H M et al. Highly transparent cubic γ-Al2O3 ceramic prepared by high-pressure sintering of home- made nanopowders. Journal of the European Ceramic Society, 43(2023).

[65] NIU F Y, WU D J, LU F et al. Microstructure and macro properties of Al2O3 ceramics prepared by laser engineered net shaping. Ceramics International, 44(2018).

[66] LIU X D, YUAN Y C, WANG R J et al. Pressureless sintering behaviour of Al2O3/ZrO2 amorphous/solid solution powder with ultra-fine ZrO2 nanoparticle precipitation. Ceramics International, 49(2023).

[67] PASTOR J, POZA P, LLORCA J et al. Mechanical properties of directionally solidified Al2O3-ZrO2(Y2O3) eutectics. Materials Science and Engineering: A, 308(2001).

[68] WILKES J, HAGEDORN Y C, WILHELM M et al. Additive manufacturing of ZrO2-Al2O3ceramic components by selective laser melting. Rapid Prototyping Journal, 19(2013).

[69] WANG S H, CHU Z F, LIU J C. Microstructure and mechanical properties of directionally solidified Al2O3/GdAlO3 eutectic ceramic prepared with horizontal high-frequency zone melting. Ceramics International, 45(2019).

[70] SHEN Z L, SU H J, LIU Y et al. Laser additive manufacturing of melt-grown Al2O3/GdAlO3 eutectic ceramic composite: powder designs and crack analysis with thermo-mechanical simulation. Journal of the European Ceramic Society, 42(2022).

[71] MEDVEDOVSKI E. Alumina-mullite ceramics for structural applications. Ceramics International, 32, 369(2006).

[72] SU H J, ZHANG J, CUI C J et al. Rapid solidification behaviour of Al2O3/Y3Al5O12 (YAG) binary eutectic ceramic in situ composites. Materials Science and Engineering: A, 479(2008).

[73] NIU F Y, WU D J, MA G Y et al. Rapid fabrication of eutectic ceramic structures by laser engineered net shaping. Procedia CIRP, 42, 91(2016).

[74] HENNICHE A, OUYANG J, MA Y et al. Microstructure, mechanical and thermo-physical properties of hot-pressed Al2O3- GdAlO3-ZrO2 ceramics with eutectic composition. Progress in Natural Science: Materials International, 27(2017).

[75] MAZEROLLES L, PIQUET N, TRICHET M et al. New microstructures in ceramic materials from the melt for high temperature applications. Aerospace Science and Technology, 12(2008).

[76] SU H J, ZHANG J, YU J Z et al. Rapid solidification and fracture behavior of ternary metastable eutectic Al2O3/YAG/YSZ in situ composite ceramic. Materials Science and Engineering: A, 528(2011).

Tools

Get Citation

Copy Citation Text

Qian CHEN, Haijun SU, Hao JIANG, Zhonglin SHEN, Minghui YU, Zhuo ZHANG. Progress of Ultra-high Temperature Oxide Ceramics: Laser Additive Manufacturing and Microstructure Evolution[J]. Journal of Inorganic Materials, 2024, 39(7): 741

Download Citation

EndNote(RIS)BibTexPlain Text
Save article for my favorites
Paper Information

Category:

Received: Dec. 5, 2023

Accepted: --

Published Online: Aug. 30, 2024

The Author Email:

DOI:10.15541/jim20230560

Topics