Ceramic parts fabricated by ceramic laser fusion

Abstract

Rapid prototyping technology offers an ideal method for manufacturing ceramic workpieces. Not only can it produce parts without tooling, it poses no limitation in shape and complexity of the parts to be fabricated. This article aims to study the manufacturing technologies of a new rapid prototyping process named Ceramic Laser Fusion. A self-developed rapid prototyping system is employed to fabricate complex ceramic parts using slurry composed of silica powder as basic material, inorganic fire-resistant binder as additive, and water as solvent. Three-dimensional parts can be made by repeatedly executing the single-layer generating cycle which includes slurry feeding, layer paving, layer drying, remnants cleaning, platform descending and laser scanning. The laser fusion experiment shows that hollow ceramic pump impeller, complicated ceramic fan and turbine blades as well as ceramic molds for metal casting can be made at a production rate of 32 cm3/h. Ceramic Laser Fusion is capable of paving very thin layers; green portion provides solid-state support to prevent deformation of workpieces, and can be removed by water or sodium hydroxide solvent. Further advances in stacking thinner layers will lead to the production of parts with fine details and higher precision.