SiC陶瓷的3D打印成形与致密化新进展

doi:10.15541/jim20240344

无机材料学报 ›› 2025, Vol. 40 ›› Issue (3): 245-255.DOI: 10.15541/jim20240344 CSTR: 32189.14.10.15541/jim20240344

SiC陶瓷的3D打印成形与致密化新进展

殷杰¹^,²(), 耿佳毅¹^,², 王康龙¹, 陈忠明¹, 刘学建¹^,², 黄政仁¹^,²^,³()

1.中国科学院上海硅酸盐研究所, 上海 200050
2.中国科学院大学光电学院, 北京 101408
3.中国科学院宁波材料技术与工程研究所, 宁波 315201

收稿日期:2024-07-19 修回日期:2024-10-05 出版日期:2025-03-20 网络出版日期:2025-03-12
通讯作者: 黄政仁, 研究员. E-mail:zhrhuang@mail.sic.ac.cn
作者简介:殷杰(1986-), 男, 研究员. E-mail:jieyin@mail.sic.ac.cn
基金资助:
国家自然科学基金(U23A20563);国家自然科学基金(52073299);国家自然科学基金(52172077);国家重点研发计划(2022YFB3706300)

Recent Advances in 3D Printing and Densification of SiC Ceramics

YIN Jie¹^,²(), GENG Jiayi¹^,², WANG Kanglong¹, CHEN Zhongming¹, LIU Xuejian¹^,², HUANG Zhengren¹^,²^,³()

1. Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, China
2. School of Optoelectronics, University of Chinese Academy of Sciences, Beijing 101408, China
3. Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo 315201, China

Received:2024-07-19 Revised:2024-10-05 Published:2025-03-20 Online:2025-03-12
Contact: HUANG Zhengren, professor. E-mail: zhrhuang@mail.sic.ac.cn
About author:YIN Jie (1986-), male, professor. E-mail: jieyin@mail.sic.ac.cn
Supported by:
National Natural Science Foundation of China(U23A20563);National Natural Science Foundation of China(52073299);National Natural Science Foundation of China(52172077);National Key R&D Program of China(2022YFB3706300)

摘要/Abstract

摘要：

SiC陶瓷具有高强度和良好的热稳定性, 在航空航天、热端部件等领域有着广泛的应用前景。随着对大尺寸和复杂形状SiC陶瓷需求的日益增长, 3D打印技术在制造周期、成本及可靠性等诸多方面明显优于传统减材、等材制造方法, 越来越受到重视。3D打印方法众多, 各具特点: 立体光刻(Stereolithography, SLA)技术可以实现高精度和优良的表面质量, 但实际操作中往往需要设计支撑结构, 再加上残余应力和低固含量等问题, 极大限制了其发展; 激光选区烧结(Selective laser sintering, SLS)技术具有较强的材料普适性, 适用于高分子、金属和陶瓷等多种材料, 可实现大尺寸快速成形, 且制造成本较低, 但其成形素坯表面质量较低, 需进行后续加工; 熔融沉积(Fused deposition modeling, FDM)技术制备的SiC陶瓷材料可借助反应烧结实现致密化, 但成形素坯存在层间结合强度低、表面有较明显条纹等缺陷, 并且成形速度相对较慢, 不适合构建大型零件, 因此在实际生产中受到限制。本文综述了近五年来3D打印SiC陶瓷的最新研究进展, 讨论了成形素坯的后续高温致密化处理方法及其基本物理性能, 并展望了3D打印SiC陶瓷材料的未来前景。新型3D打印技术及其与多种打印方式的融合将在陶瓷宏微观结构的精细化中发挥重要作用, 或将成为未来的重要发展趋势。

关键词: SiC陶瓷, 3D打印, 激光选区烧结, 致密化, 综述

Abstract:

SiC ceramics exhibit high strength and thermal stability, rendering them highly suitable for applications in space and thermal components. However, the growing demand for large-sized and complex-shaped SiC ceramics necessitates advanced manufacturing techniques. In comparison to traditional reduction and equal material manufacturing methods, 3D printing technology offers significant advantages in various aspects, such as manufacturing cycle, effective cost, and reliability. There are many 3D printing methods, each with distinct characteristics. Stereolithography (SLA) is capable of achieving high precision and superior surface quality. However, its practical applications often necessitate special design of support structures. Additionally, issues such as residual stress and low solid content significantly hinder its further development. Selective laser sintering (SLS) exhibits strong material compatibility, which is suitable for a wide range of materials, including polymers, metals and ceramics. This technology enables large-scale rapid prototyping at low manufacturing costs. But its surface quality of the formed billet is typically insufficient, which needs additional post-processing. Fused deposition modeling (FDM) though facilitates the preparation of SiC ceramics via reaction sintering, proves unsuitable for constructing large components which restricts its applicability in actual production contexts, due to its inadequate interlayer bonding strength coupled with pronounced surface striations and slower forming speeds. This paper reviews the latest research progresses of 3D-printed SiC ceramics and analyzes the subsequent high-temperature densification treatments of green bodies, along with their fundamental physical properties. Finally, it proposes some prospects of 3D printing of SiC ceramic materials, and strengthens integration of new 3D printing technologies and various printing methods for fine regulation of ceramics’ macro- and micro-structures.

Key words: SiC ceramic, 3D printing, selective laser sintering, densification, review

中图分类号:

TQ174

殷杰, 耿佳毅, 王康龙, 陈忠明, 刘学建, 黄政仁. SiC陶瓷的3D打印成形与致密化新进展[J]. 无机材料学报, 2025, 40(3): 245-255.

YIN Jie, GENG Jiayi, WANG Kanglong, CHEN Zhongming, LIU Xuejian, HUANG Zhengren. Recent Advances in 3D Printing and Densification of SiC Ceramics[J]. Journal of Inorganic Materials, 2025, 40(3): 245-255.

图/表 11

图1 典型陶瓷3D打印成形技术示意图[13]

Fig. 1 Schematic diagrams of typical 3D printing technology for ceramics[13] (a) Fused deposition modeling; (b) Direct ink writing; (c) Stereolithography; (d) Selective laser sintering

图2 SiC反射镜制备工艺示意图[15]

Fig. 2 Schematic diagram of SiC mirror preparation process[15]

图3 聚碳硅烷(PCS)基凝胶制备3D-SiC陶瓷示意图[17]

Fig. 3 Schematic illustration of the fabrication process of 3D-SiC using PCS-based gels[17]

图4 基于SLA和RMI的SiC陶瓷制备工艺[24]

Fig. 4 Fabrication process of SiC ceramic based on SLA and RMI[24] (a) Preparation of SiC slurry; (b) SLA; (c) Pyrolysis and impregnation; (d) RMI

图5 SLS技术制备Si/SiC点阵结构流程示意图[30]

Fig. 5 Schematic illustration of the procedure for fabricating Si/SiC lattice structures by SLS technology[30]

图6 SiC复合材料的制备原理图(SLS+RMI)[12]

Fig. 6 Schematic diagram of the fabrication principles of SiC composites (SLS+RMI)[12]

图7 碳密度对SLS+RMI工艺制备的SiC陶瓷的密度和抗弯强度的影响[40]

Fig. 7 Effects of carbon density on densities and flexure strengths of SiC ceramics fabricated by SLS+RMI[40]

图8 SLS结合7次PIP制备SiC陶瓷[41]

Fig. 8 Preparation of SiC ceramics by SLS combined with 7 PIPs[41]

表1 固相烧结和液相烧结SiC陶瓷对比[50]

Table 1 Characteristics of solid-phase sintered and liquid-phase sintered SiC ceramics[50]

Sintering method	Sintering temperature/℃	Mechanical property	Fracture mechanism	Mass transfer
Solid-phase sintering	2000-2200	High flexure strength, low fracture toughness, and being sensitive to cracks	Transgranular fracture	Diffusion
Liquid-phase sintering	1850-2000	High flexure strength and fracture toughness	Intergranular fracture	Viscous flow

图9 液相烧结过程的微观结构变化示意图[52]

Fig. 9 Schematic diagram of the microstructural changes in the liquid-phase sintering process[52]

表2 3D打印制备SiC陶瓷的力学性能、优势以及面临的挑战[16,23,39,60]

Table 2 Mechanical properties, advantages and challenges of SiC ceramics by 3D printing techniques[16,23,39,60]

Additive manufacturing process	Mechanical property	Advantage	Challenge	Ref.
FDM	Bulk density: 3.12 g/cm³ Flexure strength: 465 MPa	Being simple, efficient preparation process and low requirements for equipment	Poor surface roughness, additional support for complex structures, and obvious step effect of layered structure	[60]
DIW	Bulk density: 3 g/cm³ Flexure strength: 406.1 MPa	High adaptability of raw materials, simple preparation process, and low manufacturing cost	Dimensional restrictions, and low precision	[16]
SLA	Bulk density: 2.85 g/cm³ Flexure strength: 234.8 MPa	High printing accuracy and surface finish, enabling design of macro- and micro-structures	Low green body strength, additional support structures required for complex structures, and toxic photosensitive resins	[23]
SLS	Bulk density: 3.1 g/cm³ Flexure strength: 794 MPa	High molding efficiency, and recoverable powder	High thermal stress, and being prone to defects	[39]

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SiC陶瓷的3D打印成形与致密化新进展

Recent Advances in 3D Printing and Densification of SiC Ceramics

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