直写3D打印陶瓷基多孔结构的研究进展

doi:10.15541/jim20230070

无机材料学报 ›› 2023, Vol. 38 ›› Issue (10): 1133-1148.DOI: 10.15541/jim20230070 CSTR: 32189.14.10.15541/jim20230070

所属专题：【制备方法】3D打印(202409)

直写3D打印陶瓷基多孔结构的研究进展

王鲁凯(), 冯军宗, 姜勇刚, 李良军, 冯坚()

国防科技大学空天科学学院, 新型陶瓷纤维及其复合材料重点实验室, 长沙 410073

收稿日期:2023-02-13 修回日期:2023-05-12 出版日期:2023-10-20 网络出版日期:2023-05-24
通讯作者: 冯坚, 研究员. E-mail: fengj@nudt.edu.cn
作者简介:王鲁凯(1993-), 男, 博士研究生. E-mail: wanglukai18@nudt.edu.cn
基金资助:
湖南省自然科学基金(2018JJ2469)

Direct-ink-writing 3D Printing of Ceramic-based Porous Structures: a Review

WANG Lukai(), FENG Junzong, JIANG Yonggang, LI Liangjun, FENG Jian()

Science and Technology on Advanced Ceramic Fibers and Composites Laboratory, College of Aerospace Science and Engineering, National University of Defense Technology, Changsha 410073, China

Received:2023-02-13 Revised:2023-05-12 Published:2023-10-20 Online:2023-05-24
Contact: FENG Jian, professor. E-mail: fengj@nudt.edu.cn
About author:WANG Lukai (1993-), male, PhD candidate. E-mail: wanglukai18@nudt.edu.cn
Supported by:
Hunan Provincial Natural Science Foundation of China(2018JJ2469)

摘要/Abstract

摘要：

陶瓷基多孔结构既继承致密陶瓷材料耐高温、电绝缘、化学稳定的优异性能, 又兼具多孔结构低密度、高比表面积、低热导率的独特优势, 已被广泛应用于隔热、骨组织工程、过滤及污染物清除、电子元器件等领域。但是, 陶瓷基多孔结构的传统成孔方法在宏观尺度创造复杂几何外形与微纳尺度调控孔结构形态方面仍面临巨大挑战。近几十年来, 研究人员一直致力于创新陶瓷基多孔结构的加工成型方法, 以直写3D打印为代表的增材制造技术成为当前研究的热点, 并迅速发展出一系列成熟理论与创新方法。本文首先概述了陶瓷基多孔结构的传统成孔方法与增材制造成孔方法, 进一步详细介绍了直写组装成孔工艺过程, 主要包括假塑性墨水配方、固化策略、干燥及后处理, 分析了传统成孔方法与直写3D打印二者的组合技术在构筑陶瓷基多级孔结构方面的可行性, 总结了直写3D打印技术在制造复杂陶瓷基多孔结构领域的新观点、新进展和新发现, 最后结合陶瓷基多孔结构实际应用现状对直写3D技术的未来发展与挑战进行了展望。

关键词: 增材制造, 直写3D打印, 陶瓷, 多孔材料, 功能应用, 综述

Abstract:

Ceramic-based porous structures not only inherit the excellent properties of dense ceramic materials such as high-temperature resistance, electrical insulation, and chemical stability, but also have unique advantages similar to porous structures, including low density, high specific surface area, and low thermal conductivity. They show great potential in various applications, such as thermal insulation, bone tissue engineering, filtration and pollutants removal, and electronic components. However, there still exist some challenges for shaping complex geometries on the macro- scale and adjusting pore morphologies on the micro- and nano-scale through the conventional preparation strategy of ceramic-based porous structures. In recent decades, researchers have been devoting themselves to developing novel manufacturing techniques for ceramic-based porous structures. The direct-ink-writing 3D printing, as one of the representative additive manufacturing technologies, has become a current research hotspot, rapidly developing a series of mature theories and innovative methodologies for fabricating porous structures. In this work, the conventional strategies and additive manufacturing strategies for obtaining porous structures were firstly summarized. The direct-write assembly processes of pore structures were further introduced in detail, mainly including pseudoplastic ink formulation, solidification strategy, drying, and post-treatment. Meanwhile, the feasibility of direct-ink-writing 3D printing technologies combined with conventional manufacturing strategies in constructing ceramic-based hierarchical pore structures was analyzed emphatically. The new perspectives, developments, and discoveries of direct-ink-writing 3D printing technologies were further summarized in the field of manufacturing complex ceramic-based porous structures. In addition, the developments and challenges in the future were prospected according to the actual application status.

Key words: additive manufacturing, direct-ink-writing 3D printing, ceramic, porous material, functional application, review

中图分类号:

TQ174

王鲁凯, 冯军宗, 姜勇刚, 李良军, 冯坚. 直写3D打印陶瓷基多孔结构的研究进展[J]. 无机材料学报, 2023, 38(10): 1133-1148.

WANG Lukai, FENG Junzong, JIANG Yonggang, LI Liangjun, FENG Jian. Direct-ink-writing 3D Printing of Ceramic-based Porous Structures: a Review[J]. Journal of Inorganic Materials, 2023, 38(10): 1133-1148.

图/表 13

图1 增材制造技术与传统制造技术互补制备多孔结构[4]

Fig. 1 Complementarity of additive manufacturing and traditional processing for fabricating porous structures[4]

图2 直写3D打印技术

Fig. 2 Direct-ink-writing 3D printing technology (a) Schematic illustration of the ink extrusion process[29]; (b, c) Rheological behavior of pseudoplastic inks[28]

表1 代表性陶瓷基多孔结构的孔结构特征和墨水配方的流变性能及其打印参数

Table 1 Pore structure characteristics of representative ceramic-based porous structures and rheological properties and printing parameters of ink formulations

图3 陶瓷基墨水的固化方法

Fig. 3 Solidification strategies of ceramic-based inks (a) Solution-assisted solidification[61,63]; (b) Temperature-induced solidification[42,50]; (c) Light-based solidification[79]

图4 不同干燥技术的温度和压力变化[28]

Fig. 4 Parameter variation of temperature and pressure for different drying processes[28]

图5 组合直接发泡法的直写3D打印技术

Fig. 5 Direct-ink-writing 3D printing technology integrated with direct foaming methods (a, b) Process schematic diagram of direct foam writing for porous ceramic-based structures[40]; (c-h) Morphologies of honeycomb ceramic with hierarchical pore structures[95]

图6 组合冷冻浇筑法的直写3D打印技术及其所制备的多级孔氧化铝支架[70]

Fig. 6 Direct-ink-writing 3D printing technology integrated with freezing casting method and its hierarchical porous alumina scaffold[70] (a) Schematic illustration of the printing process; (b) Microscopic morphology of hierarchical pore structures

图7 组合牺牲模板法的直写3D打印技术

Fig. 7 Direct-ink-writing 3D printing technology integrated with sacrificial template method (a, b) Flow chart of preparation of hierarchical porous SiOC ceramic structures[53]; (c) Three sacrificial template methods for 3D-printed ceramics[104]

图8 组合溶胶-凝胶法的直写3D打印技术

Fig. 8 Direct-ink-writing 3D printing technology integrated with Sol-Gel method (a) Morphologies of hierarchical pore structures of SiO2 aerogels[105]; (b) TiO2 aerogel scaffolds with different hierarchical pore structures[61]

图9 3D打印纳米孔陶瓷基气凝胶的隔热应用

Fig. 9 3D-printed nanoporous ceramic-based aerogels for thermal insulation applications (a, b) Thermal shielding demonstration of 3D-printed Al2O3-SiO2 aerogels[42]; (c, d) 3D-printed SiO2 aerogels for miniaturized thermal insulation applications[105]

图10 3D打印生物陶瓷支架及其骨修复过程的植入图[112]

Fig. 10 3D-printed bioceramic scaffold and its implantation photographs of bone repair processes[112]

图11 3D打印多级孔结构过滤器用于污水净化[115]

Fig. 11 3D-printed filters with hierarchical pore structures for sewage purification[115] (a) Direct-write assembly process; (b) Pollutant decomposition mechanism

图12 3D打印多孔压电陶瓷的结构、性能及其应用

Fig. 12 Structures, performances, and applications of 3D-printed porous piezoelectric ceramics (a-f) Printed structures and performance characterizations [51]; (g) Direct-ink-writing 3D printing processes of lead zirconate titanate piezoelectric ceramics[121]

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直写3D打印陶瓷基多孔结构的研究进展

Direct-ink-writing 3D Printing of Ceramic-based Porous Structures: a Review

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