多孔氧化锆陶瓷光固化工艺及压缩性能研究
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摘要
在传统陶瓷成型工艺中,制备具有复杂多孔结构的高性能陶瓷样件向来是一大难点,随着增材制造技术的引入,对于所成型样件结构的限制大大减少,但如何利用增材技术实现多孔样件的稳定制备是关键问题。针对光固化陶瓷增材成型这一制备工艺,进行了成型以及烧结过程工艺参数的研究与优化,结果表明,对于面投影式光固化陶瓷成型适用的曝光时间为5s、成型层厚为30μm、烧结温度为1480℃,利用该参数可成型具有规则多孔单元的氧化锆结构,其显微硬度及致密度分别为13.91GPa以及95%。利用工业CT模型重建,并与理论模型比对,发现多孔样件在宏观尺度上均匀;而利用压缩测试与有限元仿真对照,静态应力分布、弹性阶段动态压缩结果以及断口微观形貌均表明多孔样件在压缩性能上已达到其理论强度。通过光固化成型高性能多孔氧化锆样件,可为航空领域中轻量化设计提供新的选择。
Fabrication of high performance ceramics with complex structures was the difficulty of traditional ceramic processing methods, with additive technology, the manufacturing restriction greatly reduces. However, how to use additive technology to realize the stable preparation of porous sample is still a key problem. The process of photocuring and sintering was studied and optimized for stereolithography of zirconia. The results show that the optimum parameters include 5 s of exposure time, 30μm of layer thickness and 1480℃ of sintering temperature for the DLP method. With these parameters, zirconia structure with regular porous units could be prepared, and the microhardness and relative density were13.91 GPa and 95% respectively. The industrial CT model was reconstructed and compared with the theoretical model,indicating the homogeneity at the macroscopic scale; the stress distribution, the compressive curve in elastic stage and the morphology of the cross section corresponded well with the FEM results, indicating the optimal value of compressive properties. High performance porous zirconia samples formed by stereolithography can provide a new choice for lightweight design in aviation field.
Fabrication of high performance ceramics with complex structures was the difficulty of traditional ceramic processing methods, with additive technology, the manufacturing restriction greatly reduces. However, how to use additive technology to realize the stable preparation of porous sample is still a key problem. The process of photocuring and sintering was studied and optimized for stereolithography of zirconia. The results show that the optimum parameters include 5 s of exposure time, 30μm of layer thickness and 1480℃ of sintering temperature for the DLP method. With these parameters, zirconia structure with regular porous units could be prepared, and the microhardness and relative density were13.91 GPa and 95% respectively. The industrial CT model was reconstructed and compared with the theoretical model,indicating the homogeneity at the macroscopic scale; the stress distribution, the compressive curve in elastic stage and the morphology of the cross section corresponded well with the FEM results, indicating the optimal value of compressive properties. High performance porous zirconia samples formed by stereolithography can provide a new choice for lightweight design in aviation field.
引文
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[21]周伟召,李涤尘,陈张伟,等.陶瓷浆料光固化快速成形特性研究及其工程应用[J].航空制造技术,2010,53(8):36-42.ZHOU Weizhao,LI Dicheng,CHEN Zhangwei,et al.Curing behaviors of ceramic suspension in stereolithography and its engineering applications[J].Aeronautical Manufacturing Technology,2010,53(8):36-42.
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[2]周伟召,李涤尘,周鑫南,等.基于光固化的直接陶瓷成形工艺[J].塑性工程学报,2009,16(3):198-201.ZHOU Weizhao,LI Dicheng,ZHOU Xinnan,et al.Direct fabrication process of ceramics based on stereolithography[J].Journal of Plasticity Engineering,2009,16(3):198-201.
[3]FERRAGE L,BERTRAND G,LENORMAND P,et al.Areview of the additive manufacturing(3DP)of bioceramics:alumina,zirconia(PSZ)and hydroxyapatite[J].Journal of the Australian Ceramic Society,2017,53(1):11-20.
[4] DECKERS J, VLEUGELS J, KRUTH J. Additive manufacturing of ceramics:a review[J].Jouanal of Ceramic Science and Technology,2014,5(4):245-260.
[5]ZOCCA A,COLOMBO P,GOMES C,et al.Additive manufacturing of ceramics:issues,potentialities and opportunities[J].Journal of the American Ceramic Society,2015,98(7):1983-2001.
[6]李克航.采用光固化成型技术制备氧化铝陶瓷的研究[D].天津:天津大学,2017.LI Kehang.Research the light curing technology preparation of alamina cerarnic[D].Tianjin:Tianjin University,2107.
[7]黄淼俊,伍海东,黄容基,等.陶瓷增材制造(3D打印)技术研究进展[J].现代技术陶瓷,2017(4):20-38.HUANG Miaojun,WU Haidong,HUANG Rongji,et al.A Review on ceramic additive manufacturing(3D Printing)[J].Advanced Ceramics,2017(4):20-38.
[8]ROEDEL S,SOUZA JúLIO C M,SILVA F S,et al.Optimized route for the production of zirconia structures with controlled surface porosity for biomedical applications[J].Ceramics International,2018,44:12496-12503.
[9]MONACO C,PRETE F,LEONELLI C,et al.Microstructural study of microwave sintered zirconia for dental applications[J].Ceramics International,2015,41(1):1255-1261.
[10]SHAO H,ZHAO D,LIN T,et al.3D gel-printing of zirconia ceramic parts[J].Ceramics International,2017,43(16):13939-13942.
[11]GHAZANFARI A,LI W,LEU M C,et al.Additive manufacturing and mechanical characterization of high density fully stabilized zirconia[J].Ceramics International,2017,43(8):6082-6088.
[12]赵旭,龚俊,宁会峰,等.树脂基三维立体光刻陶瓷浆料性能研究[J].陶瓷学报,2018(1):77-81.ZHAO Xu,GONG Jun,NING Huifeng,et al.Properties of ceramic suspensions for lithography[J].Journal of Ceramics,2018(1):77-81.
[13]OSMAN R B,VEEN A J V D,HUIBERTS D,et al.3D-printing zirconia implants;a dream or a reality?An in-vitro study evaluating the dimensional accuracy,surface topography and mechanical properties of printed zirconia implant and discs[J].Journal of the Mechanical Behavior of Biomedical Materials,2017,75:521-528.
[14]LI K,ZHAO Z.The effect of the surfactants on the formulation of UV-curable SLA alumina suspension[J].Ceramics International,2017,43(8):4761-4767.
[15]GRIFFITH M L,HALLORAN J W.Freeform fabrication of ceramics via stereolithography[J].Journal of the American Ceramic Society,1996,79(10):2601-2608.
[16]HE R,LIU W,WU Z,et al.Fabrication of complex-shaped zirconia ceramic parts via a DLP stereolithography-based 3D printing method[J].Ceramics International,2018,44:3412-3416.
[17]ZHOU M,LIU W,WU H,et al.Preparation of a defectfree alumina cutting tool via additive manufacturing based on stereolithography-optimization of the drying and debinding processes[J].Ceramics International,2016,42:11598-11602.
[18]LIAN Q,YANG F,XIN H,et al.Oxygen-controlled bottomup mask-projection stereolithography for ceramic 3D printing[J].Science Direct,2017-12-01,https://doi.org/10.1016/j.ceramint.2017.08.014.
[19]MITTERAMSKOGLER A G,GMEINER A R,FELZMANNR.Light curing strategies for lithography-based additive manufacturing of customized ceramics[J].Science Direct,2014-10-01,https://doi.org/10.1016/j.addma.2014.08.003.
[20]XING H,ZOU B,LI S,et al.Study on surface quality,precision and mechanical properties of 3D printed Zr O2 ceramic components by laser scanning stereolithography[J]. Ceramics International,2017,43:16340-16347.
[21]周伟召,李涤尘,陈张伟,等.陶瓷浆料光固化快速成形特性研究及其工程应用[J].航空制造技术,2010,53(8):36-42.ZHOU Weizhao,LI Dicheng,CHEN Zhangwei,et al.Curing behaviors of ceramic suspension in stereolithography and its engineering applications[J].Aeronautical Manufacturing Technology,2010,53(8):36-42.
[22]WU H,CHENG Y,LIU W,et al.Effect of the particle size and the debinding process on the density of alumina ceramics fabricated by 3D printing based on stereolithography[J].Ceramics International,2016,42:17290-17294.
[23]MAURYA R,GUPTA A,OMAR S,et al.Effect of sintering on mechanical properties of ceria reinforced yttria stabilized zirconia[J].Ceramics International,2016,42(9):11393-11403.
[24]WANG C J,HUANG C Y,WU Y C.Two-step sintering of fine alumina-zirconia ceramics[J].Ceramics International,2009,35(4):1467-1472.