Recent Advances in 3D Printing and Densification of SiC Ceramics

doi:10.15541/jim20240344

Abstract

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

CLC Number:

TQ174

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.

Figures/Tables 11

References 60

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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

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

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]

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]