Additive Manufacturing of Advanced Ceramic Filter Structures
KETHARAM A. 1, GOULAS T. 1, JANARTHANAN A. 1, SAREMI-YARAHMADI S. 1, VAIDHYANATHAN B. 1
1 Loughborough University, Loughborough, United Kingdom
Filtration of molten metals with ceramic ?lters is an established method to remove the unwanted inclusions/additions/debris. Additive manufacturing (3D printing) of these filter structures is an emerging field, as it allows to design tailored, complex pore structures that improves the capture of these inclusions with less material wastage compared to conventional methods. In this work, 3D printing of alumina filters was investigated – starting from the powder to the manufacturing of a product prototype. Both Robocasting (direct ink writing) and Direct Light processing (DLP) methods were used to produce filter structures with desired precision. Alumina suspensions were made with suitable viscosity using dispersants and binders. Alumina powders with different particle sizes (0.2 -10 µm) were used to prepare the suspensions to achieve good particle packing and green density, which in turn results in high sintered density. Three different lattice structures were printed namely Gyroid, Honeycomb and Fluorite. Samples with 30 mm diameter, different unit cells and strand thicknesses were printed and compared. Samples can be printed successfully up to 50 mm diameter using the lab scale printer (Flashforge Hunter). nTopology software was used to design these filter structures. The printed structures were binder removed and sintered at 1650oC/5 hrs to achieve highly dense samples without any cracks. The shrinkage characteristics of the sintered samples were investigated. Honeycomb lattice showed the highest volume shrinkage, and the fluorite structure showed the lowest shrinkage. This phenomenon is corroborated at both microscopic (using SEM) and macroscopic (using optical microscopy) scales. Among the gyroid structures, shrinkage increases with the increase in strand thickness but no significant difference in shrinkage is noticed with changes in unit cell sizes. The unique design freedom provided by the AM process, allows the ability to tailor/control the pore structure and shrinkage characteristics – thereby helping to realise hitherto unexplored ceramic filter structures.