CN107973607B - Selective laser melting/sintering forming method for ceramic slurry without binder - Google Patents
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Abstract
The invention discloses a selective laser melting/sintering forming method of ceramic slurry without a binder, which comprises the steps of firstly mixing ceramic powder and water in proportion to form suspension slurry, presetting a slurry layer with the thickness of 30-150 mu m on the surface of a forming substrate, heating and evaporating to remove most of water, scanning a powder layer with partial water removed by using a continuous fiber laser according to cutting data by adopting an SLM/SLS forming technology, repeating the process from presetting of the powder layer to printing for multiple times, and overlapping layer by layer to obtain a ceramic forming part. Compared with powder, the evaporated ceramic slurry has higher original density and more uniform powder distribution, and meanwhile, the preset slurry powder layer is not easy to splash under the impact of laser due to the action of residual moisture. By adopting the selective laser melting/sintering forming method for ceramic slurry, ceramic parts with relative density of more than 93 percent and Vickers hardness of more than 1500MPa can be obtained.
Description
Technical Field
The invention belongs to the technical field of Selective Laser Melting/sintering (SLM/SLS) forming, and relates to a binder-free SLM/SLS forming method for ceramic slurry.
Background
The ceramic material has the advantages of high strength, high hardness, corrosion resistance, wear resistance, high temperature resistance, good heat insulation and the like, and shows increasingly wide application prospects in the fields of energy, mechano-electronics, aerospace, computers, bioengineering and the like. However, the difficulty of processing and forming complex ceramic parts is always a great difficulty in restricting the application of ceramics.
The existing ceramic parts are formed by hot-pressing sintering. In the hot-pressing sintering, a certain external force (generally, the pressure is between 10 and 40Mpa, and depends on the strength which can be borne by the material of the die) is applied at the same time in the sintering process, so that the material is accelerated to flow, rearrange and densify. The density of the product obtained by hot-pressing sintering is higher and can reach more than 99% of the theoretical density, the growth of crystal grains is inhibited due to the sintering at lower temperature, and the obtained sintered crystal grains are finer and have higher strength. However, the hot-pressing sintering has the disadvantages of complex process and equipment, strict production control requirement, high requirement on die materials, high energy consumption, low production efficiency and high production cost.
The SLM/SLS is an additive manufacturing technology developed in recent years, and based on the basic principle of additive manufacturing, a part with a specific geometric shape is directly formed by utilizing a mode of stacking 'growing' discrete materials layer by layer and has the advantages of high precision, high material utilization rate, good part compactness, simple process and the like. Ceramic powders and binder-added ceramic slurries are common forming materials. The powder forming ceramic part has the problems of difficult powder laying, low density of a preset powder layer and the like. When ceramic parts are formed by using the ceramic slurry with the binder, complicated post-treatments such as degreasing are required, and the steps are complicated. Chen Sihan et al used SLS technique to add SiO2SiO of sol2Sintering the slurry to prepare the three-dimensional SiO2The ceramic nozzle green body is actually used, but it is necessary to carry out post-treatments such as grinding, infiltration and sintering (Chenshin et al, research on ceramic original production by selective laser sintering technique [ J]Journal of the university of west ampere, 2011,45(11). Hsiao-Chuan Yen proposes a method for preparing SiO by adding silica sol and polyvinyl alcohol as binders2Slurry, then forming ceramic piece by laser scanning, but the formed original piece needs to be treated with 1200 ℃ heat to remove the polyvinyl alcohol material (Hsiao-Chuan Yen. A new slurry-based drying process for manufacturing ceramic piece green layer [ J-J].Journal of theEuropean Ceramic Society,2012,32(12):3123-3128)。
Disclosure of Invention
The invention aims to provide a selective laser melting/sintering forming method of ceramic slurry without a binder, which is characterized in that ceramic powder is dispersed in water to prepare ceramic slurry without the binder, most of water in a powder layer is removed by evaporation to obtain a densified ceramic powder layer, and a ceramic part is formed by adopting an SLM/SLS technology.
A selective laser melting/sintering forming method of ceramic slurry without a binder comprises the following specific steps:
step 1, dispersing ceramic material powder in water, stirring and mixing uniformly to prepare ceramic suspension slurry with the mass concentration of 30-70%;
step 2, presetting a slurry layer with the thickness of 30-150 microns on the surface of a formed substrate by the prepared ceramic suspension slurry, heating the preset ceramic slurry layer at 80-120 ℃, and evaporating to remove 80-95% of water;
step 3, scanning the powder layer with partial moisture removed by using laser according to the layer cutting data by adopting an SLM/SLS forming method, and cooling the temperature of a melting or sintering area to 50-130 ℃ after scanning is finished;
and 4, taking the surface of the processing layer formed in the step 3 as a slurry preset surface, repeating the step 2 and the step 3, and stacking layer by layer to obtain the ceramic forming part.
In step 1, the ceramic material may be a single or composite ceramic material, and may be selected from Al2O3、ZrO2、Y2O3、Na2O、Nb2O5、La2O3、CaO、SrO、CeO2、MgO、SiO2、TiO2、Cr2O3、CuO、Eu2O3、Er2O3、CoO、Gd2O3One or more of them.
Wherein the ceramic material is Al2O3And ZrO2When composed of a composite ceramic material, Al2O3And ZrO2The proportion of the active ingredients is 50-80 percent and 20-50 percent respectively.
The present invention obtains a uniform binder-free ceramic suspension slurry by dispersing a single or composite ceramic powder in water. The slurry is then laid on a substrate, and the presence of water in the slurry wets the surface of the ceramic material particles, and the particles are adsorbed together by a water film. In the process of evaporation at the temperature of 80-120 ℃, most of water is evaporated, but a small part of water exists as water molecules and film water due to the huge binding force between the water molecules and the ceramic particles. Due to the surface tension of water, the particles are mutually close and polymerized, so that the powder layer is gradually densified, and a dense and uniform powder layer is obtained. According to the SLM/SLS forming principle, the relationship between the density of the preset powder layer and the final density of the formed part is large, and the ceramic slurry can effectively improve the density of the powder layer so as to effectively improve the final density of the ceramic test piece. Moreover, when ceramic powder is used as a raw material preset powder layer, the powder is loosely stacked, pores are filled among particles, the adhesion force between the particles and a substrate is small, and the impact force during laser scanning cannot be resisted sufficiently, so that a large amount of powder splashes, and a ceramic test piece is difficult to form. The ceramic slurry of the invention is agglomerated together during the evaporation process, the contact area is increased, the adhesion force is strong, and the ceramic slurry can bear the laser impact.
Compared with ceramic slurry or ceramic powder added with a binder, the ceramic slurry added with water only is used for preparing the ceramic parts, the water plays a role in binding before and during the forming process, the problems that powder is difficult to spread and the powder is easy to splash during the forming process are solved, and the density of the preset powder layer is improved to a great extent; after the ceramic slurry is formed, the water is completely evaporated, and complicated subsequent treatment steps are not needed, the ceramic part with a certain shape and higher density and hardness compared with the traditional processing mode can be obtained by adopting the ceramic slurry prepared by the process through an SLM/SLS forming technology, wherein the micro Vickers hardness of the ceramic formed part is at least 1500MPa, which can reach 1750MPa, the relative density is at least 93 percent, and the highest density reaches 99 percent.
Drawings
FIG. 1 shows Al prepared in example 12O3And (3) a final preset powder layer effect diagram of the ceramic slurry.
FIG. 2 shows Al prepared in example 12O3Scanning electron micrographs of a pre-set powder layer of ceramic slurry.
FIG. 3 shows Al prepared in example 12O3Ceramic slurry is used as a raw material to prepare ceramic part pictures through an SLM forming process.
FIG. 4 shows Al prepared in example 12O3And (3) taking the ceramic slurry as a raw material, and preparing a scanning electron microscope picture of the ceramic part by using an SLM (selective laser melting) forming process.
Detailed Description
The present invention will be described in more detail with reference to the following examples and the accompanying drawings.
The Vickers hardness in examples and comparative examples was measured using a Vickers hardness tester model HV-50, manufactured by Shanghai dinning optical instruments Co., Ltd, using a square pyramid diamond indenter, pressed into the surface of a test piece under a test force, and after a prescribed time, the test force was removed and the length of the diagonal line of the indentation in the surface of the test piece was measured. The vickers hardness value is the quotient of the test force divided by the surface area of the indentation.
The relative density tests in the examples and the comparative examples adopt a drainage method for testing, the weight of a test piece immersed in air and liquid is measured according to the Archimedes principle, the buoyancy force of the material in the liquid can be calculated, so that the volume of the test piece is calculated, then the weight of the test piece is weighed, the weight and the volume of the test piece are divided to obtain the density of the material, and then the measured density is divided by the theoretical density to obtain the relative density of the test piece.
Example 1
According to the mass ratio of 1: 1 proportion of Al with an average particle size of 0.62 μm2O3And pure distilled water, stirring for 10min with an electromagnetic stirring rod to prepare ceramic slurry; then, using the ceramic slurry to preset a slurry powder layer with the thickness of 50 microns on a ceramic substrate; preheating the preset slurry powder layer to 110 ℃ by using an induction heating system, keeping the temperature for 2min until the water in the preset slurry layer is evaporated by 80-95%, as shown in figure 1, the powder layer is flat and smooth and has certain viscosity, can bear the impact of laser energy and is not easy to splash, as shown in figure 2, a scanning electron microscope high-power picture of the preset slurry layer in figure 1 is shown, and it can be seen that the surface of the preset powder layer has no gap and the density is very high; then, scanning and printing the layer by using a laser according to the three-dimensional data; the layer after scanning and printing is cooled to 50 toAbout 130 ℃; the process from the preset powder layer to the printing is repeated for a plurality of times to obtain the final ceramic forming part, as shown in fig. 3, the forming ceramic part is a square block with the thickness of 10 multiplied by 10mm and the height of 2mm, the surface is smooth, and fig. 4 shows a high-power scanning electron microscope photo of the surface of the ceramic part in fig. 3, so that the surface of the ceramic part formed by the ceramic slurry is completely melted, flat and crack-free, and the forming quality is good.
The average value of the micro Vickers hardness of the ceramic part prepared by the ceramic slurry prepared by the process through the SLM forming process is about 1500MPa, and the relative density is about 95%.
Example 2
According to the mass ratio of 7: 3 weighing Al with average particle size of 2 μm2O3And pure distilled water, stirring for 10min with an electromagnetic stirring rod to prepare ceramic slurry; then, using the ceramic slurry to preset a slurry powder layer with the thickness of 50 microns on a ceramic substrate; preheating the preset slurry powder layer to 110 ℃ by using an induction heating system, and keeping the temperature for 2min until the moisture in the preset slurry layer is evaporated by 80-95%; then, scanning and printing the layer by using a laser according to the three-dimensional data; cooling the layer after scanning and printing to about 50-130 ℃; and repeating the process from the preset powder layer to printing for multiple times to obtain the final ceramic forming part.
The average value of the micro Vickers hardness of the ceramic part prepared by the ceramic slurry prepared by the process through the SLM forming process is about 1550MPa, and the relative compactness is about 94%.
Example 3
According to the mass ratio of 80%: 20% by weight of Al having an average particle diameter of 0.62 μm2O3And ZrO2Ceramic powder, and then mixing the ceramic powder and pure distilled water according to the mass ratio of 1: 1, weighing pure distilled water according to the proportion; mixing in a glass container and stirring for 10min by using an electromagnetic stirring rod to prepare ceramic slurry; then, using the ceramic slurry to preset a slurry powder layer with the thickness of 30 microns on a ceramic substrate; preheating the preset slurry powder layer to 110 ℃ by using an induction heating system, and keeping the temperature for 2min until the moisture in the preset slurry layer is evaporated by 80-95%; then using the laser based on the three-dimensional dataScanning and printing the layer by an optical device; cooling the layer after scanning and printing to about 50-130 ℃; and repeating the process from the preset powder layer to printing for multiple times to obtain the final ceramic forming part.
The average value of the micro Vickers hardness of the ceramic part prepared by the ceramic slurry prepared by the process through the SLM forming process is about 1540MPa, and the relative compactness is about 95%.
Example 4
According to the mass ratio of 50%: 50% by weight of Al having an average particle diameter of 0.62 μm2O3And ZrO2Ceramic powder, and then mixing the ceramic powder and pure distilled water according to the mass ratio of 3: 7, weighing pure distilled water according to the proportion; mixing in a glass container and stirring for 10min by using an electromagnetic stirring rod to prepare ceramic slurry; then, using the ceramic slurry to preset a slurry powder layer with the thickness of 30 microns on a ceramic substrate; preheating the preset slurry powder layer to 110 ℃ by using an induction heating system, and keeping the temperature for 2min until the moisture in the preset slurry layer is evaporated by 80-95%; then, scanning and printing the layer by using a laser according to the three-dimensional data; cooling the layer after scanning and printing to about 50-130 ℃; and repeating the process from the preset powder layer to printing for multiple times to obtain the final ceramic forming part.
The average value of the micro Vickers hardness of the ceramic part prepared by the ceramic slurry prepared by the process through the SLM forming process is about 1580MPa, and the relative density is about 98%.
Claims (2)
1. A selective laser melting/sintering forming method of ceramic slurry without a binder is characterized by comprising the following specific steps:
step 1, dispersing ceramic material powder in water, stirring and mixing uniformly to prepare ceramic suspension slurry with the mass concentration of 30-70%;
step 2, presetting a slurry layer with the thickness of 30-150 microns on the formed substrate by the prepared ceramic suspension slurry, heating the preset ceramic slurry layer at 80-120 ℃, and evaporating to remove 80-95% of water;
step 3, scanning the powder layer with partial moisture removed by using laser according to the layer cutting data by adopting an SLM/SLS forming method, and cooling the temperature of a melting or sintering area to 50-130 ℃ after scanning is finished;
step 4, taking the surface of the processing layer formed in the step 3 as a slurry preset surface, repeating the step 2 and the step 3, and stacking layer by layer to obtain a ceramic forming part;
wherein the ceramic material is Al2O3、ZrO2At least one of (1).
2. The selective laser melting/sintering method of binderless ceramic slurry of claim 1 wherein said ceramic material is Al2O3And ZrO2Composite ceramic material of composition, Al2O3And ZrO2The proportion of the water-soluble organic acid is 50-80% and 20-50% respectively.
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CN109111233A (en) * | 2018-06-19 | 2019-01-01 | 广东工业大学 | A kind of TiB2Ceramics increase the manufacturing method of material |
CN109734425B (en) * | 2019-02-20 | 2020-10-02 | 华中科技大学 | Laser selective rapid forming method of complex phase ceramic casting mold and product thereof |
CN112521139B (en) * | 2019-09-03 | 2022-09-23 | 南京优登科技有限公司 | Cross-scale porous ceramic and preparation method thereof |
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CN111689764B (en) * | 2020-07-06 | 2022-05-31 | 南京理工大学 | Low-cost preparation of ceramic powder for selective laser melting and defocusing forming method thereof |
CN114409388A (en) * | 2022-01-27 | 2022-04-29 | 兰州文理学院 | Material for 3D printing of brick carving in summer and manufacturing method thereof |
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