Direct Additive Manufacturing of Al2O3-TiCp Composite Ceramics by Laser Directed Energy Deposition

doi:10.15541/jim20230013

Abstract

Abstract:

Al₂O₃-TiC_p (AT) composites are frequently used as materials for metal cutting tools due to their superior mechanical properties. However, conventional sintering methods for AT materials have limitations in terms of energy consumption and cycle time. Therefore, in this study, direct additive manufacturing of AT composite ceramic materials was investigated using laser directed energy deposition technology. Effects of different TiC_pratios on the microstructure and mechanical properties of composite ceramic materials were explored. The results demonstrate that TiC_p particles are uniformly distributed throughout the matrix of the fabricated samples, leading to refinement of Al₂O₃ grains. Stress induced by mismatch between the thermal expansion coefficients of TiC_p and the Al₂O₃ matrix causes cracks to deflect and penetrates the particles, which consumes the crack extension energy and effectively suppresses the cracks in AT materials. Additionally, doping TiC_p particles affects the molten pool by increasing the gas escape rate and improving the material density. However, high TiC_p content aggravates the reaction with Al₂O₃ at high temperature, resulting in generation of gas and large pores in the composite material, which reduces the mechanical properties. Composites with TiC_p mass fraction of 30% exhibit the best mechanical properties, with a relative density of 96.64%, microhardness and fracture toughness of 21.07 GPa and 4.29 MPa·m^1/2.

Key words: composite ceramic, additive manufacturing, laser directed energy deposition, microstructure, mechanical property

CLC Number:

TQ174

WU Dongjiang, ZHAO Ziyuan, YU Xuexin, MA Guangyi, YOU Zhulin, REN Guanhui, NIU Fangyong. Direct Additive Manufacturing of Al₂O₃-TiC_p Composite Ceramics by Laser Directed Energy Deposition[J]. Journal of Inorganic Materials, 2023, 38(10): 1183-1192.

Figures/Tables 16

Fig. 1 SEM morphologies of raw materials for different samples (a) AT10; (b) AT30; (c) AT50

Table 1 Composition and mass fraction of two raw materials powder

Al₂O₃	Composition	Al₂O₃	SiO₂	Fe₂O₃	Na₂O	CaO
Al₂O₃	Content/%	>99.9	0.0041	0.0021	0.0014	<0.001
TiC_p	Composition	TiC_p	Si/Ca	K/Na	Fe	Al
TiC_p	Content/%	>99.1	<0.01	<0.005	<0.09	<0.01

Fig. 2 Statistical diagram of stomatal rate

Fig. 3 Vickers indentation and fracture toughness calculation diagram

Fig. 4 Appearances and enlarged images of the samples (a) AT10; (b) AT30; (c) AT50

Fig. 5 Full cross-sections and particle distributions of samples (a-c) Full views of (a) AT10, (b) AT30 and (c) AT50;(d-f) Particle distributions of (d) AT10, (e) AT30 and (f) AT50

Fig. 6 Marangoni convection and secondary flow diagram

Fig. 7 Microstructures of the sample (a-c) Cross-sectional images of (a) AT10, (b) AT30 and (c) AT50; (d-f) Longitudinal section images of (d) AT10, (e) AT30 and (f)AT50

Fig. 8 EDS analysis of cross section of sample (a) Schematic diagram of EDS test area; (b) EDS surface scan; (c) Point scan results

Fig. 9 XRD patterns of three kinds of samples

Fig. 10 Diagram of crack growth and matrix stress

Fig. 11 Deflection and obstruction effects of TiC particles on crack growth (a) Pinning and micro crack; (b) Through particles and crack deflection

Fig. 12 Compactness of the samples (a) Relative density; (b) Porosity

Fig. 13 Mechanical properties of AT-samples of different proportions (a) Microhardness of particles; (b) Matrix microhardness; (c) Fracture toughness

Fig. 14 Cracks along the intergranular precipitates

Fig. 15 Fracture strength of different TiCp proportions AT samples

References 51

[1]	申仲琳, 苏海军, 刘海方, 等. 超高温氧化物陶瓷激光增材制造技术与缺陷控制研究进展. 复合材料学报, 2021, 38(3): 668.
[2]	GOLDSTEIN A, SINGURINDI A. Al₂O₃/TiC based metal cutting tools by microwave sintering followed by hot isostatic pressing. Journal of the American Ceramic Society, 2010, 83(6): 1530. DOI URL
[3]	赵喆, 龚江宏, 苗赫濯, 等. TiC颗粒弥散Al₂O₃复合材料的阻力曲线行为. 硅酸盐学报, 2000, 28(4): 371.
[4]	EVANS A G, CANNON R M. Toughening of brittle solids by martensitic transformations. Acta Metallurgica, 1986, 34(5): 761. DOI URL
[5]	CAI K F, MCLACHLAN D S, AXEN N, et al. Preparation, microstructures and properties of Al₂O₃-TiC composites. Ceramics International, 2002, 28(2): 217. DOI URL
[6]	GEVORKYAN E, RUCKI M, PANCHENKO S, et al. Effect of SiC addition to Al₂O₃ ceramics used in cutting tools. Materials, 2020, 13(22): 5195. DOI URL
[7]	程寓, 孙士帅. 一种氧化铝-碳化钛微米复合陶瓷刀具材料及其微波烧结方法. CN104131208A. 2014-11-05.
[8]	高纪明, 陈松年. 氧化铝/碳化钛复合材料的无压烧结. 湖南大学学报:自然科学版, 1996, 23(4): 46.
[9]	XIA T, MUNIR Z, TANG Y, et al. Structure formation in the combustion synthesis of Al₂O₃/TiC composites. Journal of the American Ceramic Society, 2000, 83(3): 507. DOI URL
[10]	苏海军, 王恩缘, 任群, 等. 超高温氧化物共晶复合陶瓷研究进展. 中国材料进展, 2018, 37(6): 437.
[11]	吴甲民. 方兴未艾的陶瓷增材制造. 硅酸盐学报, 2021, 49(09): 1785.
[12]	刘雨, 陈张伟. 陶瓷光固化3D打印技术研究进展. 材料工程, 2020, 48(9): 1.
[13]	WU D, YU X, ZHAO Z. Direct additive manufacturing of TiC_p reinforced Al₂O₃-ZrO₂ eutectic functionally graded ceramics by laser directed energy deposition. Journal of the European Ceramic Society, 2023, 43(6): 2718. DOI URL
[14]	LIU H, SU H, SHEN Z, et al. Research progress on ultrahigh temperature oxide eutectic ceramics by laser additive manufacturing. Journal of Inorganic Materials, 2022, 37(3): 255. DOI
[15]	WU D, YU C, WANG Q, et al. Synchronous-hammer-forging- assisted laser directed energy deposition additive manufacturing of high-performance 316L samples. Journal of Materials Processing Technology, 2022, 307: 117695.
[16]	苏海军, 尉凯晨, 郭伟, 等. 激光快速成形技术新进展及其在高性能材料加工中的应用. 中国有色金属学报, 2013, 23(6): 1567.
[17]	吴甲民, 陈敬炎, 陈安南, 等. 陶瓷零件增材制造技术及在航空航天领域的潜在应用. 航空制造技术, 2017, 11(10): 40.
[18]	WU D, SHI J, NIU F, et al. Direct additive manufacturing of melt growth Al₂O₃-ZrO₂ functionally graded ceramics by laser directed energy deposition. Journal of the European Ceramic Society, 2022, 42(6): 2957. DOI URL
[19]	HUANG Y, WU D, ZHAO D, et al. Process optimization of melt growth alumina/aluminum titanate composites directed energy deposition: effects of scanning speed. Additive Manufacturing, 2020, 35: 101210.
[20]	WU D, ZHAO D, HUANG Y, et al. Shaping quality, microstructure, and mechanical properties of melt-grown mullite ceramics by directed laser deposition. Journal of Alloys and Compounds, 2021, 871: 159609.
[21]	SU H, ZHANG J, LIU L, et al. Rapid growth and formation mechanism of ultrafine structural oxide eutectic ceramics by laser direct forming. Applied Physics Letters, 2011, 99(22): 1174.
[22]	ZHAO D, WU D, NIU F, et al. Heat treatment of melt-grown alumina ceramics with trace glass fabricated by laser directed energy deposition. Materials Characterization, 2023, 196: 112639.
[23]	HUANG Y, WU D, ZHAO D, et al. Investigation of melt-growth alumina/aluminum titanate composite ceramics prepared by directed energy deposition. International Journal of Extreme Manufacturing, 2021, 3: 035101.
[24]	WEI X, JIN M, YANG H, et al. Advances in 3D printing of magnetic materials: fabrication, properties, and their applications. Journal of Advanced Ceramics, 2022, 11(5): 665. DOI
[25]	刘安丽, 隋长有, 李发智, 等. 陶瓷激光增材制造等离子体特征与成形缺陷的相关性研究. 中国激光, 2020, 47(6): 146.
[26]	中国建筑材料工业协会. 精细陶瓷弯曲强度试验方法: GB/T 6569-2006. 中国标准出版社, 2006.
[27]	龚江宏. 陶瓷材料断裂力学. 北京: 清华大学出版社, 2001: 101- 117.
[28]	VOIGT W. Ueber die beziehung zwischen den beiden elasticitätsconstanten isotroper körper. Annalen Der Physik, 1889, 274(12): 573. DOI URL
[29]	REUSS A. Berechnung der fleissgrenze von mischkristallen auf grund der plastizitats bedingung für einkrisalle. Zeitschrift für Angewandte Mathematik und Mechanik, 1929, 9(1): 49. DOI URL
[30]	YUAN P, GU D. Molten pool behaviour and its physical mechanism during selective laser melting of TiC/AlSi₁₀Mg nanocomposites: simulation and experiments. Journal of Physics D: Applied Physics, 2015, 48(3): 035303. DOI URL
[31]	YUAN P, GU D, DAI D. Particulate migration behavior and its mechanism during selective laser melting of TiC reinforced Al matrix nanocomposites. Materials and Design, 2015, 82(5): 46. DOI URL
[32]	张进, 黄云涛, 岳新艳, 等. TiC含量对无压烧结TiC-Al₂O₃导电陶瓷复合材料微观结构与性能的影响. 机械工程材料, 2023, 47(1): 70. DOI
[33]	GOINS P E, FRAZIER W E. A model of grain boundary complexion transitions and grain growth in yttria-doped alumina. Acta Materialia, 2020, 188: 79.
[34]	胡晓清, 曾照强. Al₂O₃/TiC陶瓷中Al₂O₃与TiC化学反应抑制的研究. 硅酸盐通报, 1998, 17(5): 45.
[35]	KIM Y W, LEE J G. Pressureless sintering of alumina-titanium carbide composites. Journal of the American Ceramic Society, 1989, 72(8): 1333. DOI URL
[36]	ISHIDA K. Effect of grain size on grain boundary segregation. Journal of Alloys and Compounds, 1996, 235(2): 244. DOI URL
[37]	TERWILLIGER C D, CHIANG Y M. Size-dependent solute segregation and total solubility in ultrafine polycrystals: Ca in TiO₂. Acta Metallurgica Et Materialia, 1995, 43(1): 319. DOI URL
[38]	NIU F, WU D, YAN S, et al. Process optimization for suppressing cracks in laser engineered net shaping of Al₂O₃ ceramics. The Journal of The Minerals, Metals & Materials Society, 2016, 69(3): 557.
[39]	LAWN B R, WILSHAW T R. Fracture of brittle solids. Cambridge: Cambridge University Press, 1975: 47.
[40]	WU D, YU X, ZHAO Z, et al. One-step additive manufacturing of TiC_p reinforced Al₂O₃-ZrO₂ eutectic ceramics composites by laser directed energy deposition. Ceramics International, 49(8): 12758. DOI URL
[41]	LANGE F F, Fracture mechanics of ceramics. Ceramurgia International, 1978, 4(3): 142.
[42]	GUO J K. The Exploration on new approach of strengthening and toughening of ceramic materials. Journal of Inorganic Materials, 1998, 13(1): 23.
[43]	AHSAN M N, BRADLEY R, PINKERTON A J. Microcomputed tomography analysis of intralayer porosity generation in laser direct metal deposition and its causes. Journal of Laser Applications, 2011, 23(2): 807.
[44]	KOBRYN P A, MOORE E H. The effect of laser power and traverse speed on microstructure, porosity, and build height in laser-deposited Ti₆A1₄V. Scripta materialia, 2000. 43(4): 299. DOI URL
[45]	SUSAN D F, PUSKAR J D, BROOKS J A, et al. Quantitative characterization of porosity in stainless steel LENS powders and deposits. Materials Characterization, 2006. 57(1): 36. DOI URL
[46]	NIU F, WU D, LU F, et al. Microstructure and macro properties of Al₂O₃ ceramics prepared by laser engineered net shaping. Ceramics International, 2018, 44(12): 14303. DOI URL
[47]	FRANCISCO I D, MERINO R I, ORERA V M, et al. Growth of Al₂O₃/ZrO₂(Y₂O₃) eutectic rods by the laser floating zone technique: effect of the rotation. Journal of the European Ceramic Society, 2005, 25(8): 1341. DOI URL
[48]	WU D, HUANG Y, NIU F, et al. Effects of TiO₂ doping on microstructure and properties of directed laser deposition alumina/ aluminum titanate composites. Virtual and Physical Prototyping, 2019, 14(4): 371. DOI URL
[49]	ZHAO D, WU D, SHI J, et al. Microstructure and mechanical properties of melt-grown alumina-mullite/glass composites fabricated by directed laser deposition. Journal of Advanced Ceramics, 2022, 11(1): 75. DOI
[50]	PETCH N J. The cleavage strength of polycrystals. Journal of the Iron and Steel Institute, 1953, 174(1): 25.
[51]	HALL E O. The deformation and ageing of mild steel: III discussion of results. Proceedings of the Physical Society of London, 1951, 64(381): 747.

Direct Additive Manufacturing of Al₂O₃-TiC_p Composite Ceramics by Laser Directed Energy Deposition

RichHTML

PDF (PC)

Knowledge

Abstract

Cite this article

share this article

Figures/Tables 16

References 51

Related Articles 15

Recommended Articles

Metrics

Comments

[1]	WEI Xiangxia, ZHANG Xiaofei, XU Kailong, CHEN Zhangwei. Current Status and Prospects of Additive Manufacturing of Flexible Piezoelectric Materials [J]. Journal of Inorganic Materials, 2024, 39(9): 965-978.
[2]	FAN Wugang, CAO Xiong, ZHOU Xiang, LI Ling, ZHAO Guannan, ZHANG Zhaoquan. Anticorrosion Performance of 8YSZ Ceramics in Simulated Aqueous Environment of Pressurized Water Reactor [J]. Journal of Inorganic Materials, 2024, 39(7): 803-809.
[3]	CHEN Qian, SU Haijun, JIANG Hao, SHEN Zhonglin, YU Minghui, ZHANG Zhuo. Progress of Ultra-high Temperature Oxide Ceramics: Laser Additive Manufacturing and Microstructure Evolution [J]. Journal of Inorganic Materials, 2024, 39(7): 741-753.
[4]	WU Xiangquan, TENG Jiachen, JI Xiangxu, HAO Yubo, ZHANG Zhongming, XU Chunjie. Textured Porous Al₂O₃-SiO₂ Composite Ceramic Platelet-sphere Slurry: Characteristics and Simulation of Light Intensity Distribution [J]. Journal of Inorganic Materials, 2024, 39(7): 769-778.
[5]	JIANG Lingyi, PANG Shengyang, YANG Chao, ZHANG Yue, HU Chenglong, TANG Sufang. Preparation and Oxidation Behaviors of C/SiC-BN Composites [J]. Journal of Inorganic Materials, 2024, 39(7): 779-786.
[6]	WU Yuhao, PENG Renci, CHENG Chunyu, YANG Li, ZHOU Yichun. First-principles Study on Mechanical Properties and Melting Curve of Hf_xTa_1-_xC System [J]. Journal of Inorganic Materials, 2024, 39(7): 761-768.
[7]	WANG Weiming, WANG Weide, SU Yi, MA Qingsong, YAO Dongxu, ZENG Yuping. Research Progress of High Thermal Conductivity Silicon Nitride Ceramics Prepared by Non-oxide Sintering Additives [J]. Journal of Inorganic Materials, 2024, 39(6): 634-646.
[8]	SUN Haiyang, JI Wei, WANG Weimin, FU Zhengyi. Design, Fabrication and Properties of Periodic Ordered Structural Composites with TiB-Ti Units [J]. Journal of Inorganic Materials, 2024, 39(6): 662-670.
[9]	CAI Feiyan, NI Dewei, DONG Shaoming. Research Progress of High-entropy Carbide Ultra-high Temperature Ceramics [J]. Journal of Inorganic Materials, 2024, 39(6): 591-608.
[10]	LIU Guoang, WANG Hailong, FANG Cheng, HUANG Feilong, YANG Huan. Effect of B₄C Content on Mechanical Properties and Oxidation Resistance of (Ti_0.25Zr_0.25Hf_0.25Ta_0.25)B₂-B₄C Ceramics [J]. Journal of Inorganic Materials, 2024, 39(6): 697-706.
[11]	SU Yi, SHI Yangfan, JIA Chenglan, CHI Pengtao, GAO Yang, MA Qingsong, CHEN Sian. Microstructure and Properties of C/HfC-SiC Composites Prepared by Slurry Impregnation Assisted Precursor Infiltration Pyrolysis [J]. Journal of Inorganic Materials, 2024, 39(6): 726-732.
[12]	ZHANG Rui, ZHANG Kan, YUAN Mengya, GU Xinlei, ZHENG Weitao. Nitrogen Vacancy Regulated Lattice Distortion on Improvement of (NbMoTaW)N_x Thin Films: Mechanical Properties and Wear Resistance [J]. Journal of Inorganic Materials, 2024, 39(6): 715-725.
[13]	ZHENG Yawen, ZHANG Cuiping, ZHANG Ruijie, XIA Qian, RU Hongqiang. Fabrication of Boron Carbide Ceramic Composites by Boronic Acid Carbothermal Reduction and Silicon Infiltration Reaction Sintering [J]. Journal of Inorganic Materials, 2024, 39(6): 707-714.
[14]	XUE Yifan, LI Weijie, ZHANG Zhongwei, PANG Xu, LIU Yu. Process Control of PyC Interphases Microstructure and Uniformity in Carbon Fiber Cloth [J]. Journal of Inorganic Materials, 2024, 39(4): 399-408.
[15]	SUN Chuan, HE Pengfei, HU Zhenfeng, WANG Rong, XING Yue, ZHANG Zhibin, LI Jinglong, WAN Chunlei, LIANG Xiubing. SiC-based Ceramic Materials Incorporating GNPs Array: Preparation and Mechanical Characterization [J]. Journal of Inorganic Materials, 2024, 39(3): 267-273.