Microstructure evolution and mechanical properties of Al2O3 foams via laser powder bed fusion from Al particles

Ye Dong; Annan Chen; Ting Yang; Shuai Gao; Shuning Liu; Bingjian Guo; Hongyi Jiang; Yusheng Shi; Chunze Yan

Advanced Powder Materials (Oct 2023)

Microstructure evolution and mechanical properties of Al2O3 foams via laser powder bed fusion from Al particles

Ye Dong,
Annan Chen,
Ting Yang,
Shuai Gao,
Shuning Liu,
Bingjian Guo,
Hongyi Jiang,
Yusheng Shi,
Chunze Yan

Affiliations

Ye Dong: School of Materials Science and Engineering, Wuhan University of Technology, Wuhan 430070, China; State Key Laboratory of New Ceramics and Fine Processing, School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China
Annan Chen: State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China; Engineering Research Center of Ceramic Materials for Additive Manufacturing, Ministry of Education, Wuhan 430074, China; Centre for Advanced Structural Materials, Department of Mechanical Engineering, City University of Hong Kong, Hong Kong, China; Corresponding author. State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China.
Ting Yang: School of Materials Science and Engineering, Wuhan University of Technology, Wuhan 430070, China
Shuai Gao: School of Materials Science and Engineering, Wuhan University of Technology, Wuhan 430070, China
Shuning Liu: School of Materials Science and Engineering, Wuhan University of Technology, Wuhan 430070, China
Bingjian Guo: School of Materials Science and Engineering, Wuhan University of Technology, Wuhan 430070, China
Hongyi Jiang: School of Materials Science and Engineering, Wuhan University of Technology, Wuhan 430070, China; Corresponding author. School of Materials Science and Engineering, Wuhan University of Technology, Wuhan 430070, China.
Yusheng Shi: State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China; Engineering Research Center of Ceramic Materials for Additive Manufacturing, Ministry of Education, Wuhan 430074, China
Chunze Yan: State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China; Engineering Research Center of Ceramic Materials for Additive Manufacturing, Ministry of Education, Wuhan 430074, China

Journal volume & issue: Vol. 2, no. 4
p. 100135

Abstract

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Laser powder bed fusion (LPBF) combined with reaction bonding (RB) of Al particles is an effective method for preparing high-performance 3D Al2O3 ceramic foams. However, the indistinct microstructure evolution hinders the regulation of pore features and the improvement of synthetic properties. Herein, the microstructure evolution of the Al2O3 ceramic foams during the LPBF/RB process is clarified by various characterization methods, and the corresponding mechanical property modulation is realized by optimizing LPBF parameters, organic binder (E12 epoxy resin) content, heating rate, sintering time, and coral-like Al2O3 content. The expansion from Al2O3 outward growth and Al granule precipitation counteracts the shrinkage from E12 decomposition and Al2O3 sintering, resulting in an ultra-low shrinkage of 0.94%–3.01%. The pore structures of particle packing pores, hollow spheres, and microporous structures allow a tunable porosity of 52.6%–73.7%. The in-situ formation of multi-scale features including hollow spheres, flaky grains, whiskers, nanofibers, and bond bridges brings about a remarkably high bending strength of 6.5–38.3 MPa. Our findings reveal the relationship between microstructure evolution and property optimization of high-performance ceramic foams, with potential significance for microstructure design and practical application.

Published in Advanced Powder Materials

ISSN: 2772-834X (Online)
Publisher: KeAi Communications Co. Ltd.
Country of publisher: China
LCC subjects: Technology: Mining engineering. Metallurgy
Website: https://www.keaipublishing.com/en/journals/advanced-powder-materials/

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