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Chinese Journal of Lasers, Volume. 51, Issue 10, 1002316(2024)

Effects of Laser Power on Molten Pool Morphology, Microstructure, and Mechanical Properties of Al2O3‐ZrO2 Eutectic Ceramics Shaped by Laser Powder Bed Fusion

Zhiwei Xiong, Kai Zhang*, Tingting Liu**, and Wenhe Liao
Author Affiliations
  • School of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing 210094, Jiangsu, China
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    Figures & Tables(12)
    Diagram of experiment process

    Fig. 1. Diagram of experiment process

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    Morphology and size of original powder. (a) Al2O3 powder particle morphology; (b) particle size distribution of Al2O3 powder; (c) ZrO2 powder particle morphology; (d) particle size distribution of ZrO2 powder

    Fig. 2. Morphology and size of original powder. (a) Al2O3 powder particle morphology; (b) particle size distribution of Al2O3 powder; (c) ZrO2 powder particle morphology; (d) particle size distribution of ZrO2 powder

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    Real-time images of LPBF single deposition track of Al2O3-ZrO2 eutectic ceramics under different laser powers captured by high-speed camera. (a) P=60 W; (b) P=100 W; (c) P=140 W; (d) P=180 W; (e) measured results of l and w under different laser powers

    Fig. 3. Real-time images of LPBF single deposition track of Al2O3-ZrO2 eutectic ceramics under different laser powers captured by high-speed camera. (a) P=60 W; (b) P=100 W; (c) P=140 W; (d) P=180 W; (e) measured results of l and w under different laser powers

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    Block samples of Al2O3-ZrO2 eutectic ceramics shaped by LPBF under different laser powers. (a) P=60 W; (b) P=80 W; (c) P=100 W; (d) P=120 W; (e) P=140 W; (f) P=160 W; (g) P=180 W; (h) P=200 W; (i) overall photograph of samples

    Fig. 4. Block samples of Al2O3-ZrO2 eutectic ceramics shaped by LPBF under different laser powers. (a) P=60 W; (b) P=80 W; (c) P=100 W; (d) P=120 W; (e) P=140 W; (f) P=160 W; (g) P=180 W; (h) P=200 W; (i) overall photograph of samples

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    Three-dimensional morphology reconstruction results of block samples of Al2O3-ZrO2 eutectic ceramics shaped by LPBF under different laser powers. (a) P=80 W; (b) P=120 W; (c) P=160 W; (d) P=200 W; (e) surface roughness of block samples of Al2O3-ZrO2 eutectic ceramics shaped by LPBF under different laser powers

    Fig. 5. Three-dimensional morphology reconstruction results of block samples of Al2O3-ZrO2 eutectic ceramics shaped by LPBF under different laser powers. (a) P=80 W; (b) P=120 W; (c) P=160 W; (d) P=200 W; (e) surface roughness of block samples of Al2O3-ZrO2 eutectic ceramics shaped by LPBF under different laser powers

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    Optical microscope images of surfaces and relative density values of polished block samples of Al2O3-ZrO2 eutectic ceramics shaped by LPBF under different laser powers. (a) P=80 W; (b) P=120 W; (c) P=160 W; (d) P=200 W; (e) relative density

    Fig. 6. Optical microscope images of surfaces and relative density values of polished block samples of Al2O3-ZrO2 eutectic ceramics shaped by LPBF under different laser powers. (a) P=80 W; (b) P=120 W; (c) P=160 W; (d) P=200 W; (e) relative density

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    XRD test results. (a) Pristine powder; (b) block samples of Al2O3-ZrO2 eutectic ceramics shaped by LPBF under different laser powers

    Fig. 7. XRD test results. (a) Pristine powder; (b) block samples of Al2O3-ZrO2 eutectic ceramics shaped by LPBF under different laser powers

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    Typical microstructure and elemental distribution results of block samples of Al2O3-ZrO2 eutectic ceramics shaped by LPBF under different laser powers. (a) Microstructure at P=120 W; (b) distribution of Al element on line 1 in Fig.8(a); (c) distribution of Zr element on line 1 in Fig.8(a)

    Fig. 8. Typical microstructure and elemental distribution results of block samples of Al2O3-ZrO2 eutectic ceramics shaped by LPBF under different laser powers. (a) Microstructure at P=120 W; (b) distribution of Al element on line 1 in Fig.8(a); (c) distribution of Zr element on line 1 in Fig.8(a)

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    Upper surface microstructures of Al2O3-ZrO2 eutectic ceramic samples shaped by LPBF under different laser powers.(a) P=60 W; (b) P=100 W; (c) P=140 W; (d) P=180 W; (e) statistical results of cellular-like grain sizes under different laser powers

    Fig. 9. Upper surface microstructures of Al2O3-ZrO2 eutectic ceramic samples shaped by LPBF under different laser powers.(a) P=60 W; (b) P=100 W; (c) P=140 W; (d) P=180 W; (e) statistical results of cellular-like grain sizes under different laser powers

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    Microhardness and fracture toughness of Al2O3-ZrO2 eutectic ceramic samples shaped by LPBF under different laser powers

    Fig. 10. Microhardness and fracture toughness of Al2O3-ZrO2 eutectic ceramic samples shaped by LPBF under different laser powers

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    • Table 1. Element contents of block samples of Al2O3-ZrO2 eutectic ceramics shaped by LPBF under different laser powers

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      Table 1. Element contents of block samples of Al2O3-ZrO2 eutectic ceramics shaped by LPBF under different laser powers

      ElementMass fraction /%
      Total100.00
      O38.45
      Al32.39
      Zr29.16

    • Table 2. Typical microstructure characteristics and mechanical properties of Al2O3-ZrO2 eutectic ceramic samples prepared by different techniques

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      Table 2. Typical microstructure characteristics and mechanical properties of Al2O3-ZrO2 eutectic ceramic samples prepared by different techniques

      Microstructure

      feature

      Manufacturing

      technology

      		Grain size /μmMicrohardness /GPa

      Fracture toughness /

      （MPa·m1/2）

      Solidification

      pattern

      LPBF

      （This work）

      1.46±0.29

      1.76±0.32

      3.24±0.50

      17.190±0.105

      16.890±0.123

      16.380±0.193

      6.670±0.220

      6.150±0.174

      5.570±0.075

      LENS［13］8.2416.754.1
      Sintered stateSLA［10］

      1.93（Al2O3），1.22（ZrO2）

      2.77（Al2O3），1.71（ZrO2）

      13.43

      14.21

      2.87

      3.88

      DLP［12］3.22（Al2O3），0.58（ZrO2）17.407.76
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    Zhiwei Xiong, Kai Zhang, Tingting Liu, Wenhe Liao. Effects of Laser Power on Molten Pool Morphology, Microstructure, and Mechanical Properties of Al2O3‐ZrO2 Eutectic Ceramics Shaped by Laser Powder Bed Fusion[J]. Chinese Journal of Lasers, 2024, 51(10): 1002316

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    Paper Information

    Category: Laser Additive Manufacturing

    Received: Dec. 1, 2023

    Accepted: Jan. 10, 2024

    Published Online: Apr. 17, 2024

    The Author Email: Zhang Kai (zhangkai@njust.edu.cn), Liu Tingting (liutingting@mail.njust.edu.cn)

    DOI:10.3788/CJL231464

    CSTR:32183.14.CJL231464

    Topics

    laser devices and laser physics
    Lasers and Laser Optics
    Laser physics
    laser manufacturing
    Instrumentation, Measurement and Metrology