Research Progress on Ultrahigh Temperature Oxide Eutectic Ceramics by Laser Additive Manufacturing

doi:10.15541/jim20210608

Abstract

Abstract:

Melt-grown oxide eutectic ceramics possess a large area of clean and firmly bonded phase interfaces through liquid-solid phase transformation, which makes them present excellent high-temperature properties such as strength retention, creep resistance, thermal stability, oxidation and corrosion resistance. As a result, directionally solidified oxide eutectic composite ceramics have been regarded as one of candidates for new generation of high temperature structural materials which can service above 1400 ℃ in oxidation environment for a long period. In recent years, laser additive manufacturing based on melt growth has developed into the most promising technique for preparing ultrahigh-temperature oxide eutectic ceramics due to its unique advantage in one-step fabricating highly dense parts with large sample size and complex shape. In this paper, laser additive manufacturing technology was summarized in terms of forming principle, technical features and classification. The research status and the encountered technical problems in additively manufacturing melt-grown oxide eutectic ceramics were reviewed. Moreover, the research progress on laser additive manufacturing oxide eutectic ceramics was introduced from the aspects of laser forming process, solidification defect control, solidification microstructure evolution, and mechanical properties. Finally, the key bottlenecks of realizing engineering applications of the laser 3D-printed oxide eutectic ceramics were pointed out, and the future development directions of this field were prospected. The focus of the future work can be summarized into four points: developing high-quality spherical eutectic ceramic powders, preparing large-scale eutectic parts with complex shapes, accurate controlling solidification defects, as well as strengthening and toughening eutectic composites.

Key words: oxide eutectic ceramic, laser additive manufacturing, selective laser melting, laser directed energy deposition, review

CLC Number:

TQ174

LIU Haifang, SU Haijun, SHEN Zhonglin, JIANG Hao, ZHAO Di, LIU Yuan, ZHANG Jun, LIU Lin, FU Hengzhi. Research Progress on Ultrahigh Temperature Oxide Eutectic Ceramics by Laser Additive Manufacturing[J]. Journal of Inorganic Materials, 2022, 37(3): 255-266.

Figures/Tables 13

Fig. 1 Schematic diagram of laser additive manufacturing[28] (a) Selective laser melting; (b) Laser directed energy deposition

Table 1 Comparison of the SLM and LDED technologies[28]

Technology	Scanning control	Molten pool size/mm	Energy density /(W·cm^-2)	Building rate /(cm³·min^-1)	Manufacturing precision	Preferred applications
SLM	Scanner	<0.2	10⁶-10⁷	~1.3	High	Net-shaping small- and medium-sized components
LDED	Laser nozzle	>3	~10⁵	11.5	Low	Preparing large-scale components

Fig. 2 LDED-processed oxide eutectic ceramic through independent controlling the delivery of ceramic powders[39]

Fig. 3 Preparation technology and characteristics of spherical ceramic powders[68] (a) Schematic diagram of centrifugal spray drying method; (b) Morphology of the initial ceramic powders; (c) Morphology of the modified ceramic powders; (d) Particle size distribution of the modified ceramic powders; (e) Powder feeding test

Fig. 4 Effect of scanning length on the formation of crack[68] (a, b) 15 mm; (c) 10 mm; (d) 4 mm

Fig. 5 Effect of assisted ultrasonic on porosity[43] (a) Sample sections before ultrasonic addition; (b) Sample sections after ultrasonic addition

Fig. 6 Al2O3/GAP/ZrO2 eutectic ceramics prepared at different environments (a) Atmospheric atmosphere; (b) Ar atmosphere with oxygen content >200 μg/L; (c) Ar atmosphere with oxygen content <50 μg/L

Fig. 7 Oxide eutectic ceramics prepared by laser additive manufacturing (a) SLM-processed Al2O3/ZrO2 eutectic ceramic with shape of framework for a dental restoration[30]; (b) LDED-processed Al2O3/ZrO2 eutectic ceramics with various shapes[43]; (c) LDED-processed Al2O3/GAP/ZrO2 eutectic ceramic rod[70]

Fig. 8 Microstructure characteristics of the LAM-processed oxide eutectic ceramic along the building direction[68] (a) Periodic banded structure; (b) Magnified image of the banded structure

Fig. 9 Microstructure characteristics in vicinity of the banded structure of the LDED-processed Al2O3/GAP/ZrO2 eutectic ceramic[68] (a) Banded structure; (b) Microstructure characteristic of the banded structure; (c) Microstructure at the lower boundary of the banded structure; (d) Microstructure at the upper boundary of the banded structure

Fig. 10 Microstructure characteristics of the LDED-processed Al2O3/YAG/ZrO2 eutectic ceramic in a deposited layer[47] (a) Eutectic colony structure; (b) Microstructure inside the colony; (c-e) TKD (Transmission kikuchi diffraction) orientation maps of the phases of Al2O3, YAG and ZrO2, respectively; (f) Pole figures of Al2O3, YAG and ZrO2, corresponding to (c-e), respectively

Fig. 11 Orientation variations of eutectic phases of the LDED-processed Al2O3/YAG eutectic ceramic during solidification process[46] (a) EBSD orientation maps of Al2O3 and YAG in bottom zone of the molten pool; (b) Orientation variations of Al2O3 and YAG along the height direction of the molten pool

Table 2 Mechanical property comparison of the oxide eutectic ceramics prepared by laser additive manufacturing and directional solidification (DS)

Eutectic system	Hardness /GPa	Fracture toughness /(MPa·m^1/2)	Preparation method
Al₂O₃/YAG	21.50	5.86	LDED^[41]
Al₂O₃/ZrO₂	16.22	7.67	LDED^[35]
Al₂O₃/YAG/ZrO₂	18.90	3.84	LDED^[47]
Al₂O₃/GAP/ZrO₂	15.30	7.80	SLM^[69]
Al₂O₃/YAG	17.50	3.60	DS^[77]
Al₂O₃/ZrO₂	16.53	6.50	DS^[78]
Al₂O₃/YAG/ZrO₂	16.70	8.00	DS^[79]
Al₂O₃/GAP/ZrO₂	17.90	8.50	DS^[80]

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