Digital Light Processing Followed by Pressureless Sintering of Metal-Reinforced Ceramics: Adjustment of Process Parameters and Correlation with Composites Properties

Abstract

Digital light processing (DLP) belongs to additive manufacturing techniques and is frequently used in shaping ceramics. The paper concerns the adjustment of the DLP method to metal-reinforced ceramics, especially dispersions containing high concentrations of Al2O3 (45 vol%) and molybdenum or nickel particles (0.5 vol%). Different glycol acrylates, deflocculants (polyelectrolytes and diammonium hydrogen citrate), and photoinitiators (Omnirad group) were examined regarding their influence on the rheological properties of the dispersions and the cure depth under the external halide UV lamp and LED projector built into the 3D printer. In the examined systems, the cationic polyelectrolyte KD1 dissolved in 2-butanone allowed to obtain dispersions of the lowest viscosity. Printing parameters (light exposure time, single layer height) were matched, and the properties of the materials were examined. The Vickers hardness of the sintered bodies equalled 19.4 GPa, 14.5 GPa and 17.3 GPa for Al2O3, Al2O3-Ni and Al2O3-Mo samples, respectively. The microstructure was analyzed using SEM, followed by EDS and XRD. The addition of only 0.5 vol% of Ni has improved the fracture toughness of alumina by up to 36–40% (according to Niihara and Anstis equations). The exemplary objects in the form of cog wheels were printed and densified at 1550 °C in a reductive atmosphere of Ar/H2.