TY - JOUR A1 - Karl, D. A1 - Kamutzki, F. A1 - Zocca, Andrea A1 - Görke, O. A1 - Günster, Jens A1 - Gurlo, A. T1 - Towards the colonization of Mars by in-situ resource utilization: Slip cast ceramics from Martian soil simulant N2 - Here we demonstrate that by applying exclusively Martian resources a processing route involving suspensions of mineral particles called slurries or slips can be established for manufacturing ceramics on Mars. We developed water-based slurries without the use of additives that had a 51 wt. % solid load resembling commercial porcelain slurries in respect to the particle size distribution and rheological properties. These slurries were used to slip cast discs, rings and vases that were sintered at temperatures between 1000 and 1130 °C using different sintering schedules, the latter were set-up according the results of hot-stage microscopic characterization. The microstructure, porosity and the mechanical properties were characterized by SEM, X-ray Computer tomography and Weibull analysis. Our wet processing of minerals yields ceramics with complex shapes that show similar mechanical properties to porcelain and could serve as a technology for future Mars colonization. The best quality parts with completely vitrificated matrix supporting a few idiomorphic crystals are obtained at 1130 °C with 10 h dwell time with volume and linear shrinkage as much as ~62% and ~17% and a characteristic compressive strength of 51 MPa. KW - Ceramic KW - Mars PY - 2018 U6 - https://doi.org/10.1371/journal.pone.0204025 SN - 1932-6203 VL - 13 IS - 10 SP - e0204025, 1 EP - 7 PB - Public Library of Science CY - San Francisco, Kalifornien, Vereinigte Staaten AN - OPUS4-46612 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Palmer, T.A. A1 - Günster, Jens A1 - Günther, D. T1 - The materials science of additive manufacturing - Introduction N2 - Additive Manufacturing (AM) covers a wide range of processes, ranging from rapid prototyping technologies for polymers to directed energy deposition and powder bed fusion processes for metals and ceramics. In all cases, AM processes involve the layer-by-layer deposition of material from a digital file. Even though these processes may be known by a variety of commercial names, the general characteristics of the processes are similar, as are their impacts on different material systems. The flexibility of the process provides unprecedented design freedom by allowing the direct fabrication of complex geometries with unique material combinations. However, the interactions between the high energy density sources (laser and electron beams) and the materials being deposited create complex processing conditions that have a significant impact on the material properties. With the wide ranging possibilities inherent in AM produced components, a fundamental understanding of the process/structure/property relationships across different material systems will allow for specific material properties to be obtained. This Focus Issue of Journal of Materials Research is dedicated to the most recent advances in the characterization of processing/structure/property relationships in AM produced metallic, ceramic, and polymer systems. The breadth of different properties and behaviors across these different materials systems makes the characterization of AM materials extremely complex and a fertile subject for investigation. Many of these issues are addressed in this collection of papers. Such a wide range of unique research areas and the breadth of materials examined in this issue is evidence of the scope of materials issues in additive manufacturing and a glimpse into the future. We are grateful to both the authors and reviewers of the many high-quality manuscripts submitted to this JMR Focus Issue on The Materials Science of Additive Manufacturing. KW - Additive manufacturing PY - 2014 U6 - https://doi.org/10.1557/jmr.2014.246 SN - 0884-2914 VL - 29 IS - 17 SP - 1791 PB - Materials Research Society CY - Warrendale, Pa. AN - OPUS4-32543 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Yao, Dongxu A1 - Xia, Y. A1 - Zuo, K.-h. A1 - Jiang, D. A1 - Günster, Jens A1 - Zeng, Y.-P. A1 - Heinrich, J.G. T1 - The effect of fabrication parameters on the mechanical properties of sintered reaction bonded porous Si3N4 ceramics N2 - Porous silicon nitride ceramics were prepared via sintered reaction bonded silicon nitride at 1680 °C. The grain size of nitrided Si3N4 and diameter of post-sintered ß-Si3N4 are controlled by size of raw Si. Porosity of 42.14–46.54% and flexural strength from 141 MPa to 165 MPa were obtained. During post-sintering with nano Y2O3 as sintering additive, nano Y2O3 can promote the formation of small ß-Si3N4 nuclei, but the large amount of ß-Si3N4 (>20%) after nitridation also works as nuclei site for precipitation, in consequence the growth of fine ß-Si3N4 grains is restrained, the length is shortened, and the improvement on flexural strength is minimized. The effect of nano SiC on the refinement of the ß-Si3N4 grains is notable because of the pinning effect, while the effect of nano C on the refinement of the ß-Si3N4 grains is not remarkable due to the carbothermal reaction and increase in viscosity of the liquid phase. KW - Porous ceramics KW - Silicon nitride KW - Reaction bonding KW - Anisotropic grain growth KW - Ceramic PY - 2014 U6 - https://doi.org/10.1016/j.jeurceramsoc.2014.06.018 SN - 0955-2219 SN - 1873-619X VL - 34 IS - 15 SP - 3461 EP - 3467 PB - Elsevier CY - Oxford AN - OPUS4-32542 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Lüchtenborg, Jörg A1 - Kober, D. A1 - Weber, A. P. A1 - Melcher, J. A1 - Günster, Jens T1 - Textured dense zinc oxide layers for active noise canceling windows N2 - Dense ZnO films with a strong c‐axis texture have been deposited on transparent conductive oxide glass, glass, and Si wafers, respectively, with a two‐step pressureless wet chemical method using zinc acetate dihydrate as Zn‐precursor. The crystallographic structure of the films has been studied with XRD and scanning electron microscopy. Optical measurements reveal a high transparency of the ZnO films with a thickness of up to 10 μm. This new cost‐effective route for ZnO film deposition does not require expensive sophisticated equipment and is easily upscaled. KW - ZnO PY - 2019 U6 - https://doi.org/10.1111/jace.15928 SN - 0002-7820 VL - 102 IS - 3 SP - 988 EP - 996 PB - Wiley AN - OPUS4-47519 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Hu, H.-L. A1 - Zeng, Y.-P. A1 - Zuo, K.-H. A1 - Xia, Y. A1 - Yao, Dongxu A1 - Günster, Jens A1 - Heinrich, J. A1 - Li, S. T1 - Synthesis of porous Si3N4/SiC ceramics with rapid nitridation of silicon N2 - Porous Si3N4/SiC ceramics were prepared with Si and SiC as raw materials, Y2O3 as sintering additive and ZrO2 as nitrided catalyst through a rapid nitration process. The nitriding rate as a function of temperature and duration was investigated. The porous Si3N4/SiC ceramics with 8 wt% monoclinic ZrO2 addition that was nitrided at 1400 °C for 2 h exhibited the highest nitridation degree of 95%. The experimental results also demonstrated that the reciprocal formation of ZrO2 and ZrN can effectively enhance the level of nitridation by suppressing the melting of silicon in micro-regions. The effects of nitriding time on the mechanical properties of the specimens with ZrO2 as a catalyst was also studied. After nitrided at 1400 °C for various durations from 2 to 8 h, the porous Si3N4/SiC ceramics with the properties of a porosity over 39.8%, a flexural strength over 88.9 MPa and a linear shrinkage lower than 0.6% were achieved. The systematic investigation reveals the catalytic mechanism of ZrO2 in the synthesis of Si3N4/SiC ceramics. KW - Si3N4 PY - 2015 U6 - https://doi.org/10.1016/j.jeurceramsoc.2015.06.028 SN - 0955-2219 SN - 1873-619X VL - 35 IS - 14 SP - 3781 EP - 3787 PB - Elsevier Ltd. CY - Oxford AN - OPUS4-34956 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Wirth, Cynthia A1 - Müller, Ralf A1 - Günster, Jens A1 - Mühler, T. A1 - Görke, R. A1 - Heinrich, J.G. T1 - Submicrometer silica spheres generated by laser fuming N2 - The production of agglomerate-free SiO2 particles exhibiting a monomodal distribution of particle sizes of around 300 nm by means of direct laser fuming of micrometric SiO2 powders has been successfully demonstrated. With a 12 kW cw CO2 laser system, a production rate of up to 1 kilogram powder per hour was achieved. Almost ideal spherical amorphous SiO2 particles in a broad particle size distribution between 10 nm and several 100 nm (d50 ≈ 300 nm) were synthesized. Several observations suggest weak agglomeration forces between the particles. A temperature reduction of 200 °C for sintering powder compacts was observed. KW - Laser KW - SiO2 KW - Nanopowder PY - 2013 U6 - https://doi.org/10.4416/JCST2012-00033 SN - 2190-9385 N1 - Geburtsname von Wirth, Cynthia: Gomes, C. M. - Birth name of Wirth, Cynthia: Gomes, C. M. VL - 4 IS - 1 SP - 11 EP - 18 PB - Göller CY - Baden-Baden AN - OPUS4-31423 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Zocca, Andrea A1 - Gomes, Cynthia A1 - Linow, Ulf A1 - Marx, Heidi A1 - Melcher, J A1 - Colombo, P A1 - Günster, Jens T1 - Structural optimization of printed structures by self-organized relaxation N2 - Purpose – This paper aims to present an additive manufacturing-based approach in which a new strategy for a thermally activated local melting and material flow, which results in densification of printed structures, is introduced. Design/methodology/approach – For enabling this self-organized relaxation of printed objects by the viscous flow of material, two interconnected structures are printed simultaneously in one printing process, namely, Structure A actually representing the three dimensional object to be built and Structure B acting as a material reservoir for infiltrating Structure A. In an additional process step, subsequent to the printing job, an increase in the objects’ temperature results in the melting of the material reservoir B and infiltration of structure A. Findings – A thermally activated local melting of the polymethylsilsesquioxane results in densification of the printed structures and the local formation of structures with minimum surface area. Originality/value – The present work introduces an approach for the local relaxation of printed three-dimensional structures by the viscous flow of the printed material, without the loss of structural integrity of the structure itself. This approach is not restricted only to the materials used, but also offers a more general strategy for printing dense structures with a surface finish far beyond the volumetric resolution of the 3D printing process. KW - Printing KW - 3D PY - 2016 U6 - https://doi.org/10.1108/RPJ-07-2014-0087 SN - 1355-2546 VL - 22 IS - 2 SP - 344 EP - 349 PB - Emerald AN - OPUS4-37447 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Mühler, T. A1 - Helsch, G. A1 - Heinrich, J.G. A1 - Yao, Dongxu A1 - Gräf, S. A1 - Müller, F.A. A1 - Günster, Jens T1 - Strategies for the selective volume sintering of ceramics N2 - The present study is dealing with the basic physics for a novel way to generate a free-formed ceramic body, not like common layer by layer, but directly by Selective Volume Sintering (SVS) in a compact block of ceramic powder. To penetrate with laser light into the volume of a ceramic powder compact it is necessary to investigate the light scattering properties of ceramic powders. Compared with polymers and metals, ceramic materials are unique as they offer a wide optical window of transparency. The optical window typically ranges from below 0.3 up to 5 µm wave length. In the present study thin layers of quartz glass (SiO2) particles have been prepared. As a function of layer thickness and the particle size, transmission and reflection spectra in a wave length range between 0.5 and 2.5 µm have been recorded. Depending on the respective particle size and by choosing a proper relation between particle size and wave length of the incident laser radiation, it is found that light can penetrate a powder compact up to a depth of a few millimeters. With an adjustment of the light absorption properties of the compact the initiation of sintering in the volume of the compact is possible. KW - Additive Manufacturing PY - 2014 U6 - https://doi.org/10.1557/jmr.2014.174 SN - 0884-2914 VL - 29 IS - 17 SP - 2095 EP - 2099 PB - Materials Research Society CY - Warrendale, Pa. AN - OPUS4-32544 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Mühler, T. A1 - Wirth, Cynthia A1 - Ascheri, Mary A1 - Nicolaides, Dagmar A1 - Heinrich, J. A1 - Günster, Jens T1 - Slurry-based powder beds for the selective laser sintering of silicate ceramics N2 - Selective laser sintering of ceramic powders is a promising technique for the additive manufacturing of complex- and delicate-shaped ceramic parts. Most techniques have in common that the powder to be sintered is spread to a thin layer as a dry powder by means of a roller or shaker system. These layers have a relatively low density. On the other hand, appreciable densities can be reached with the use of ceramic slurries as the starting material. Therefore, the layer-wise slurry deposition (LSD) process has been developed. Layer stacks, i.e. powder beds, built up by employing the LSD technology exhibit a density comparable to ceramic powder compacts processed by means of conventional forming technologies. Writing the layer information with a focused laser beam in these dense ceramic powder compacts enables the manufacture of ceramic bodies with a high density and precision in contour. KW - Additive Fertigung KW - Keramik PY - 2015 U6 - https://doi.org/10.4416/JCST2015-0007 SN - 2190-9385 VL - 6 IS - 2 SP - 113 EP - 118 PB - Göller CY - Baden-Baden AN - OPUS4-34962 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Mühler, T. A1 - Heinrich, J. A1 - Wirth, Cynthia A1 - Günster, Jens T1 - Slurry-based additive manufacturing of ceramics N2 - Most additive manufacturing (AM) techniques have in common that material is spread out as thin layers of a dried powder/granulate by a roller or a shaker system. These layers are mostly characterized by a low packing rate. On the other hand, appreciable densities can be reached by the use of ceramic slurries. In this context, the layer-wise slurry deposition (LSD) has been developed. Specific features of the LSD process are reflected on the basis of already existing additive manufacturing technologies. The microstructure of laser-sintered bodies will be discussed, and strategies for an improved microstructure during sintering will be introduced. KW - Additive manufacturing KW - Ceramic KW - Selective laser sintering PY - 2015 U6 - https://doi.org/10.1111/ijac.12113 SN - 1546-542X SN - 1744-7402 N1 - Geburtsname von Wirth, Cynthia: Gomes, C. M. - Birth name of Wirth, Cynthia: Gomes, C. M. VL - 12 IS - 1 SP - 18 EP - 25 PB - American Ceramic Soc. CY - Westerville, Ohio AN - OPUS4-29937 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -