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Organisationseinheit der BAM
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Paper des Monats
- ja (3)
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.
Ceramic additive manufacturing (AM) requires a complex process chain with various post-processing steps that require expensive machines and special expertise. The key to further market penetration is AM that makes it possible to integrate into an already established ceramic process chain. Most successful AM technologies for ceramics are, however, based on processes that initially have been developed for polymeric materials. For ceramics AM, polymers or precursors are loaded with ceramic particles. This strategy facilitates the entry into AM, however the introduction of organic additives into the ceramic process chain represents a considerable technological challenge to ultimately obtain a ceramic component after additive shaping. In the present communication, two technologies based on ceramic suspensions will be introduced, the “layerwise slurry deposition” (LSD) and “laser induced slip casting” (LIS) technology. Both technologies take advantage of the high packing densities reached by conventional slip casting and moreover enable the processing of fines, even nanoparticles.
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.