Effect of Particle Grading on Properties of Silicon Carbide Ceramics by Binder Jetting Printing

doi:10.15541/jim20230216

Abstract

Abstract:

Silicon carbide (SiC) ceramics, as a high-performance structural-functional integrated material, are widely used in aerospace, nuclear industry and braking system. However, the conventional fabrication methods can not meet the increasing demands for large-scale and complex-structured SiC ceramics, such as engine nozzles, flaps and turbine blades. Binder jetting (BJ) 3D printing technology can overcome the traditional obstacle and provide a novel manufacturing roadmap. Here, we adopted this technique via SiC particle grading, optimized the particle size ratio based on gradation theory, and studied the influence of BJ printing on properties of SiC green body and as-sintered ceramic. For the particle-graded green body after BJ printing, SiC ceramics with a maximum flexural strength of (16.70±0.53) MPa was obtained after one precursor impregnation and pyrolysis (PIP) treatment, whose flexural strength was improved by 116% as compared with that BJ printed from a median diameter of 20 μm. SiC ceramics were further densified using liquid phase siliconization, with the density, flexural strength, elastic modulus, and fracture toughness reaching (2.655±0.001) g/cm³, (285±30) MPa, (243±12) GPa, and (2.54±0.02) MPa·m^1/2, respectively. XRD results demonstrated that the sintered SiC ceramics were mainly composed of 3C structured-β-SiC. All results show that high-performance SiC ceramic materials are innovatively prepared by an efficient and reliable method, based on the combined techniques of particle grading, BJ printing, PIP and liquid silicon infiltration.

Key words: silicon carbide, particle grading, binder jetting printing, precursor impregnation and pyrolysis

CLC Number:

TQ174

GU Xuesu, YIN Jie, WANG Kanglong, CUI Chong, MEI Hui, CHEN Zhongming, LIU Xuejian, HUANG Zhengren. Effect of Particle Grading on Properties of Silicon Carbide Ceramics by Binder Jetting Printing[J]. Journal of Inorganic Materials, 2023, 38(12): 1373-1378.

Figures/Tables 9

Table 1 Mass ratios and flowability indexes of SiC powders with different median diameters

Group	Fraction	Carr index/%
G0	20 μm (non-grading)	37.11
G1	5 μm:10 μm:20 μm:50 μm:80 μm =5:6:15:5:5	27.80
G2	5 μm:10 μm:20 μm:50 μm:80 μm =6:6:15:5:4	30.05
G3	5 μm:10 μm:20 μm:50 μm:80 μm =6:5:15:4:6	34.94

Fig. 1 Flow chart of SiC ceramics by BJ process

Table 2 Bulk densities and open porosities of BJ-printed SiC green body before and after PIP treatment

Group	Bulk density/(g•cm^-3)		Open porosity/%
Group	Before PIP	After PIP	Before PIP	After PIP
G0	1.236±0.008	1.533±0.005	61.12±0.47	47.48±0.84
G1	1.470±0.006	1.718±0.009	53.19±0.46	40.63±0.57
G2	1.313±0.007	1.598±0.003	59.72±0.20	46.44±0.63
G3	1.284±0.004	1.572±0.007	59.04±0.13	45.85±0.77

Fig. 2 Flexual strength of BJ-printed green body after one PIP

Fig. 3 Fracture morphologies (a-d), and pore size distributions (e) of green bodies after PIP (a) G0; (b) G1; (c) G2; (d) G3

Fig. 4 Bulk densities and open porosities of BJ-printed SiC ceramics

Fig. 5 Mechanical properties of BJ-printed SiC ceramics (a) Flexural strength; (b) Elastic modulus; (c) Fracture toughness

Fig. 6 Polished surface morphologies of BJ-printed SiC ceramics (a) G0; (b) G1; (c) G2; (d) G3

Fig. 7 XRD patterns of BJ-printed SiC ceramics

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