Effect of processing parameters in the properties and quality of alumina-based samples manufactured via digital light processing
VERZA J. 1, LUZ A. 1
1 Federal University of São Carlos, São Carlos, Brazil
The production of ceramic parts with complex geometries has been facilitated with the advent of additive manufacturing techniques and, specifically, those based on vat photopolymerization have gained special attention in recent years. One of the main challenges to obtain high-quality ceramic pieces via photopolymerization consists in designing ceramic suspensions with suitable rheology, including high solid loading (> 40 vol%) and low viscosity (< 3 Pa.s). In this context, this work evaluated some processing parameters (e.g., dispersant concentration, curing depth, and the influence of thermal treatments on resin removal, densification, and microstructure consolidation) used in the manufacture of Al2O3 ceramic pieces via digital light processing (DLP). Light-curing suspensions were prepared using reactive alumina powder (d50 = 0.52 µm), poly(ethylene glycol) diacrylate (PEGDA) as the monomer, phenylbis(2,4,6 trimethylbenzoyl)phosphine oxide (PPO) as the photoinitiator, and DISPERBYK111 as the dispersant. Plain PEGDA or suspensions comprised by this resin and the other selected additives had their rheological and sedimentation behavior analyzed as a function of time. The printed ceramic samples had their dimensional linear variation, apparent density, relative density, cold crushing strength, and microstructure evaluated after the debinding and sintering steps at 1550°C and 1660°C for 2 h. Based on the results, a stable light-curing suspension containing 40 vol.% of solids could be obtained. Alumina specimens were printed via DLP, resulting in ceramics with a relative density of 73.22 ± 0.33 % and crushing strength of 32.0 ± 0.6 MPa after the firing step at 1600°C. Nonetheless, additional tests highlighted that a further increase in the suspension solid loading could be beneficial to improve the relative density and surface quality of the produced pieces after debinding.