CN108033802A - 基于凝胶注模3d打印的纤维增强陶瓷异型件成型方法 - Google Patents
基于凝胶注模3d打印的纤维增强陶瓷异型件成型方法 Download PDFInfo
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- ROOXNKNUYICQNP-UHFFFAOYSA-N ammonium persulfate Chemical compound [NH4+].[NH4+].[O-]S(=O)(=O)OOS([O-])(=O)=O ROOXNKNUYICQNP-UHFFFAOYSA-N 0.000 claims abstract description 40
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- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 claims description 17
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Abstract
一种基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法，包括：将陶瓷粉体、纤维材料、和助烧剂和聚丙烯酰胺交联剂溶液充分混合；将陶瓷粉体、纤维材料、和助烧剂和过硫酸铵引发剂溶液充分混合；将上述含有交联剂和引发剂的陶瓷泥料分别由两条管路供给混流管充分混合，由3D打印机的打印头挤出；打印头按照异型件的截面数据运动，在交联剂和引发剂的聚合反应作用下，陶瓷浆料凝固成型，获得陶瓷异型件坯体；在数控加工中心上对陶瓷异型件坯体进行表面修整；进行脱脂和烧结，获得纤维增强陶瓷异型件。使用该方法可以避免3D打印技术中的光固化或加热等复杂的复杂工艺，实现表面质量优良，近净尺寸的纤维增强陶瓷异型件的快速制造。
Description
技术领域
本发明涉及一种纤维增强陶瓷异型件成型方法。特别是涉及一种基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法。
背景技术
工程陶瓷材料由于其优秀的机械性能、透波性能以及生物相容性等，在国防、空天、智能终端以及医疗等领域得到了广泛应用。然而由于其脆性较大，抗机械和热冲击性能不佳，工程陶瓷在上述领域的应用还有待进一步扩展。通过向陶瓷基体中添加纤维，增强陶瓷的强度和韧性，受到了研究人员的广泛关注。目前，纤维编织体增强陶瓷应用较多，在一定程度上改善了工程陶瓷的抗冲击性能，然而其纤维编织工艺复杂，制备周期偏长，导致其成本极高。短纤维增强陶瓷无需复杂的纤维编织工艺，制备相对简单，可望取代纤维编织体增强陶瓷。不仅如此，上述领域应用的工程陶瓷零件外形多为不规则曲面，常规方法制备的陶瓷工件还需要进行去除量很大的磨削修形工作，对工程陶瓷材料造成了很大的浪费。
3D打印技术又称增材制造技术，是一种新兴先进制造技术。3D打印技术以金属、陶瓷和塑料等为材料，通过材料的逐层打印，可以实现快速成型，无需设计开发模具，因此可以缩短产品的设计和生产周期，大幅降低研制成本。3D打印技术收到世界范围内的广泛重视，但是目前打印材料种类有待进一步丰富，并且常规3D打印成型的材料性能较差，打印质量有待进一步提高。陶瓷材料的直接成型技术是3D打印技术的研究热点和重要发展方向。光固化或熔融沉积成型可以将增强纤维和陶瓷泥料进行打印并制备成陶瓷坯体，但是需要额外的光固化或者加热装置，工艺较为复杂。此外，对于工程陶瓷而言，其特定的陶瓷粉体属于瘠性材料，粘度、塑性和分散性较差，导致其无法直接用于3D打印。
发明内容
本发明所要解决的技术问题是，提供一种无需额外光固化或者加热工艺的基于凝胶注模 3D打印的纤维增强陶瓷异型件成型方法。
本发明所采用的技术方案是：一种基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法，包括如下步骤：
1)将陶瓷粉体材料和增强纤维材料混合后，在球磨机中搅拌混合均匀，得到纤维增强陶瓷材料；
2)配制聚丙烯酰胺溶液，并向聚丙烯酰胺溶液中分别加入润湿分散剂和消泡剂，然后将获得的纤维增强陶瓷材料以及助烧剂加入所述的溶液中，在分散机中混合均匀，获得纤维增强陶瓷交联剂泥料；
3)配制过硫酸铵溶液，并向过硫酸铵溶液中加入润湿分散剂和消泡剂，然后将获得的纤维增强陶瓷材料以及助烧剂加入所述的溶液中，在分散机中混合均匀，获得纤维增强陶瓷引发剂泥料；
4)使用三维建模软件设计异型件的3D模型，并将3D模型转换为分层路径文件，导入 3D打印机；
5)将步骤2)和步骤3)获得的纤维增强陶瓷交联剂泥料和纤维增强陶瓷引发剂泥料由两条管路供给混流管充分混合，混合后的陶瓷泥料供给打印头，气泵通入压缩气体，提供均匀压强，打印头将混合后的陶瓷泥料均匀挤出；
6)打印头根据分层路径文件按照异型件的3D模型当前层的轮廓数据进行平面二维运动，陶瓷泥料在聚丙烯酰胺和过硫酸铵的聚合反应作用下凝固，形成当前轮廓截面；
7)完成异型件的3D模型当前层的轮廓数据后，打印头上升一个分层的厚度；
8)重复步骤5)至步骤7)，直至异型件坯体打印完成；
9)将打印完成的异型件坯体置于烘箱内，保持温度在40-60℃，保温24-48小时；
10)在数控加工中心上对陶瓷异型件坯体进行表面修整，改善表面质量；
11)将步骤10)获得的异型件坯体进行脱脂和烧结，获得纤维增强陶瓷异型件。
步骤1)中所述的陶瓷粉体的粒径为0.5-2μm；纤维材料的直径为2-4μm，长度为20-40μm。
步骤1)中所述的纤维增强陶瓷材料中陶瓷粉体材料和增强纤维材料的质量比为4-9：1。
步骤2)中所述的聚丙烯酰胺溶液的质量分数为1％；。
步骤2)中所述的润湿分散剂和消泡剂的加入质量分别为聚丙烯酰胺溶液质量的1％。
步骤3)中所述的过硫酸铵溶液的质量分数为1％；润湿分散剂和消泡剂的加入质量分别为过硫酸铵溶液质量的1％。
步骤2)和步骤3)中所述的助烧剂是氧化铝、氧化钾和氧化硼中的一种以上，所述的助烧剂的质量分数为纤维增强陶瓷材料的0.5％。
所述的纤维增强陶瓷交联剂泥料和纤维增强陶瓷引发剂泥料的固含量均为70-75％。
步骤6)中由纤维增强陶瓷交联剂泥料和纤维增强陶瓷引发剂泥料混合的陶瓷泥料发生聚合反应凝固的时间为1-5分钟。
步骤1)中所述的陶瓷粉体材料为石英、氧化锆、氧化铝、氮化硼和氮化硅中的一种或多种；所述的增强纤维材料为石英纤维、高硅氧纤维、氮化硅纤维和氮化硼纤维中的一种或多种。
本发明的基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法，避免了3D打印技术中常用的光固化和加热等复杂工艺，将带有交联剂和引发剂的陶瓷泥料快速充分混合后挤出打印，利用交联聚合反应实现陶瓷泥料的快速凝固，从而获得具有良好韧性和高强度的纤维增强陶瓷异型件坯体，明显简化了3D打印工艺，促进3D打印技术在陶瓷异型天线罩成型中的应用。本发明采用无毒的聚丙烯酰胺为交联剂，明显提高了凝胶注模工艺的安全性。本发明适用于多种成分的纤维增强陶瓷异型件的快速成型，脱脂烧结后可获得具有良好强度、韧性和表面质量的异型天线罩工件，无需开发模具，避免了常规纤维增强陶瓷异型件制备周期长，加工去除余量大的问题，可以显著降低生产成本。
具体实施方式
下面结合实施例对本发明的基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法做出详细说明。
本发明的基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法，包括如下步骤：
1)将陶瓷粉体材料和增强纤维材料混合后，在球磨机中搅拌混合均匀，得到纤维增强陶瓷材料；其中，
所述的陶瓷粉体材料为石英、氧化锆、氧化铝、氮化硼和氮化硅中的一种或多种；所述的增强纤维材料为石英纤维、高硅氧纤维、氮化硅纤维和氮化硼纤维中的一种或多种；
所述的陶瓷粉体的粒径为0.5-2μm；纤维材料的直径为2-4μm，长度为20-40μm；
所述的纤维增强陶瓷材料中陶瓷粉体材料和增强纤维材料的质量比为4-9：1。
2)配制聚丙烯酰胺溶液，并向聚丙烯酰胺溶液中分别加入润湿分散剂和消泡剂，然后将获得的纤维增强陶瓷材料以及助烧剂加入所述的溶液中，在分散机中混合均匀，获得纤维增强陶瓷交联剂泥料；其中，
所述的聚丙烯酰胺溶液的质量分数为1％；
所述的润湿分散剂和消泡剂的加入质量分别为聚丙烯酰胺溶液质量的1％。
纤维增强陶瓷交联剂泥料的固含量均为70-75％。
3)配制过硫酸铵溶液，并向过硫酸铵溶液中加入润湿分散剂和消泡剂，然后将获得的纤维增强陶瓷材料以及助烧剂加入所述的溶液中，在分散机中混合均匀，获得纤维增强陶瓷引发剂泥料；其中，
所述的过硫酸铵溶液的质量分数为1％；所述的润湿分散剂和消泡剂的加入质量分别为过硫酸铵溶液质量的1％。
所述的纤维增强陶瓷引发剂泥料的固含量为70-75％。
在上述步骤2)和步骤3)中所述的助烧剂是氧化铝、氧化钾和氧化硼中的一种以上，所述的助烧剂的质量分数为纤维增强陶瓷材料的0.5％。
4)使用三维建模软件设计异型件的3D模型，并将3D模型转换为分层路径文件，导入 3D打印机；所述的三维建模软件是CAD或UG或Solidworks等。
5)将步骤2)和步骤3)获得的纤维增强陶瓷交联剂泥料和纤维增强陶瓷引发剂泥料由两条管路供给混流管充分混合，混合后的陶瓷泥料供给打印头，气泵通入压缩气体，提供均匀压强，打印头将混合后的陶瓷泥料均匀挤出；
6)打印头根据分层路径文件按照异型件的3D模型当前层的轮廓数据进行平面二维运动，陶瓷泥料在聚丙烯酰胺和过硫酸铵的聚合反应作用下凝固，形成当前轮廓截面；由纤维增强陶瓷交联剂泥料和纤维增强陶瓷引发剂泥料混合的陶瓷泥料发生聚合反应凝固的时间为1-5 分钟。
7)完成异型件的3D模型当前层的轮廓数据后，打印头上升一个分层的厚度；
8)重复步骤5)至步骤7)，直至异型件坯体打印完成；
9)将打印完成的异型件坯体置于烘箱内，保持温度在40-60℃，保温24-48小时；
10)在数控加工中心上对陶瓷异型件坯体进行表面修整，改善表面质量；
11)将步骤10)获得的异型件坯体进行脱脂和烧结，获得纤维增强陶瓷异型件。
下面结合具体实施例对本发明进行详细说明。以下实施例将有助于本领域的技术人员进一步理解本发明，但不以任何形式限制本发明。应当指出的是，对本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变形和改进。这些都属于本发明的保护范围。
实施例1
1)使用Solidworks软件设计异型件的3D模型，并将3D模型转换为分层路径文件，导入3D打印机；
2)将粒径为2μm的石英陶瓷粉体和直径4μm，长40μm的石英纤维按质量比9:1倒入球磨机中，再加入质量分数1％的氧化硼作为助烧剂，搅拌混合均匀，得到石英纤维增强石英陶瓷材料；
3)配制质量分数1％的聚丙烯酰胺溶液，并向聚丙烯酰胺溶液中分别加入质量分数分别为1％的润湿分散剂和消泡剂，将石英纤维增强石英陶瓷材料按照固液质量比7:3加入上述溶液，在分散机中混合均匀，获得固含量为70％的石英纤维增强石英陶瓷交联剂泥料；
4)配制质量分数1％的聚丙烯酰胺溶液，并向过硫酸铵溶液中加入质量分数分别为1％的润湿分散剂和消泡剂，将石英纤维增强石英陶瓷材料按照固液质量比7:3加入上述溶液，在分散机中混合均匀，获得固含量为70％的石英纤维增强石英陶瓷引发剂泥料；
5)将步骤3)和步骤4)获得的石英纤维增强石英陶瓷交联剂泥料和石英纤维增强石英陶瓷引发剂泥料由两条管路供给混流管充分混合，混合后的陶瓷泥料供给打印头，气泵通入压缩气体，提供均匀压强，打印头将混合后的陶瓷泥料均匀挤出；
6)打印头根据分层路径文件按照异型件的3D模型当前层的轮廓数据进行平面二维运动，陶瓷泥料在聚丙烯酰胺和过硫酸铵的聚合反应作用下凝固，形成当前轮廓截面；由石英纤维增强石英陶瓷交联剂泥料和石英纤维增强石英陶瓷引发剂泥料混合的陶瓷泥料发生聚合反应凝固的时间为5分钟；
7)完成异型件的3D模型当前层的轮廓数据后，打印头上升一个分层的厚度；
8)重复步骤5)至步骤7)，直至异型件坯体打印完成；
9)将打印完成的异型件坯体置于烘箱内，保持温度在40℃，保温24小时；
10)在数控加工中心上对陶瓷异型件坯体进行表面修整，改善表面质量；
11)将步骤10)获得的异型件坯体进行脱脂和烧结，获得石英纤维增强石英陶瓷异型件。
实施例2
1)使用Solidworks软件设计异型件的3D模型，并将3D模型转换为分层路径文件，导入3D打印机；
2)、将粒径为0.5μm的氮化硼陶瓷粉体和直径2μm，长20μm的氮化硅纤维按质量比4:1 倒入球磨机中，再加入质量分数1％的氧化铝作为助烧剂，搅拌混合均匀，得到氮化硅纤维增强氮化硼陶瓷材料；
3)配制质量分数1％的聚丙烯酰胺溶液，并向聚丙烯酰胺溶液中分别加入质量分数分别为1％的润湿分散剂和消泡剂，将氮化硅纤维增强氮化硼陶瓷材料按照固液质量比7:3加入上述溶液，在分散机中混合均匀，获得固含量为70％的氮化硅纤维增强氮化硼陶瓷交联剂泥料；
4)配制质量分数1％的聚丙烯酰胺溶液，并向过硫酸铵溶液中加入质量分数分别为1％的润湿分散剂和消泡剂，将氮化硅纤维增强氮化硼陶瓷材料按照固液质量比7:3加入上述溶液，在分散机中混合均匀，获得固含量为70％的氮化硅纤维增强氮化硼陶瓷引发剂泥料；
5)将步骤3)和步骤4)获得的氮化硅纤维增强氮化硼陶瓷交联剂泥料和氮化硅纤维增强氮化硼陶瓷引发剂泥料由两条管路供给混流管充分混合，混合后的陶瓷泥料供给打印头，气泵通入压缩气体，提供均匀压强，打印头将混合后的陶瓷泥料均匀挤出；
6)打印头根据分层路径文件按照异型件的3D模型当前层的轮廓数据进行平面二维运动，陶瓷泥料在聚丙烯酰胺和过硫酸铵的聚合反应作用下凝固，形成当前轮廓截面；由氮化硅纤维增强氮化硼陶瓷交联剂泥料和氮化硅纤维增强氮化硼陶瓷引发剂泥料混合的陶瓷泥料发生聚合反应凝固的时间为1分钟；
7)完成异型件的3D模型当前层的轮廓数据后，打印头上升一个分层的厚度；
8)重复步骤5)至步骤7)，直至异型件坯体打印完成；
9)将打印完成的异型件坯体置于烘箱内，保持温度在60℃，保温48小时；
10)在数控加工中心上对陶瓷异型件坯体进行表面修整，改善表面质量；
11)、将步骤10)获得的异型件坯体进行脱脂和烧结，获得氮化硅纤维增强氮化硼陶瓷异型件。
Claims (10)
1.一种基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法，其特征在于，包括如下步骤：
1)将陶瓷粉体材料和增强纤维材料混合后，在球磨机中搅拌混合均匀，得到纤维增强陶瓷材料；
2)配制聚丙烯酰胺溶液，并向聚丙烯酰胺溶液中分别加入润湿分散剂和消泡剂，然后将获得的纤维增强陶瓷材料以及助烧剂加入所述的溶液中，在分散机中混合均匀，获得纤维增强陶瓷交联剂泥料；
3)配制过硫酸铵溶液，并向过硫酸铵溶液中加入润湿分散剂和消泡剂，然后将获得的纤维增强陶瓷材料以及助烧剂加入所述的溶液中，在分散机中混合均匀，获得纤维增强陶瓷引发剂泥料；
4)使用三维建模软件设计异型件的3D模型，并将3D模型转换为分层路径文件，导入3D打印机；
5)将步骤2)和步骤3)获得的纤维增强陶瓷交联剂泥料和纤维增强陶瓷引发剂泥料由两条管路供给混流管充分混合，混合后的陶瓷泥料供给打印头，气泵通入压缩气体，提供均匀压强，打印头将混合后的陶瓷泥料均匀挤出；
6)打印头根据分层路径文件按照异型件的3D模型当前层的轮廓数据进行平面二维运动，陶瓷泥料在聚丙烯酰胺和过硫酸铵的聚合反应作用下凝固，形成当前轮廓截面；
7)完成异型件的3D模型当前层的轮廓数据后，打印头上升一个分层的厚度；
8)重复步骤5)至步骤7)，直至异型件坯体打印完成；
9)将打印完成的异型件坯体置于烘箱内，保持温度在40-60℃，保温24-48小时；
10)在数控加工中心上对陶瓷异型件坯体进行表面修整，改善表面质量；
11)将步骤10)获得的异型件坯体进行脱脂和烧结，获得纤维增强陶瓷异型件。
2.根据权利要求1所述的基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法，其特征在于，步骤1)中所述的陶瓷粉体的粒径为0.5-2μm；纤维材料的直径为2-4μm，长度为20-40μm。
3.根据权利要求1所述的基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法，其特征在于，步骤1)中所述的纤维增强陶瓷材料中陶瓷粉体材料和增强纤维材料的质量比为4-9：1。
4.根据权利要求1所述的基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法，其特征在于，步骤2)中所述的聚丙烯酰胺溶液的质量分数为1％；。
5.根据权利要求1所述的基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法，其特征在于，步骤2)中所述的润湿分散剂和消泡剂的加入质量分别为聚丙烯酰胺溶液质量的1％。
6.根据权利要求1所述的基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法，其特征在于，步骤3)中所述的过硫酸铵溶液的质量分数为1％；润湿分散剂和消泡剂的加入质量分别为过硫酸铵溶液质量的1％。
7.根据权利要求1所述的基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法，其特征在于，步骤2)和步骤3)中所述的助烧剂是氧化铝、氧化钾和氧化硼中的一种以上，所述的助烧剂的质量分数为纤维增强陶瓷材料的0.5％。
8.根据权利要求1所述的基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法，其特征在于，所述的纤维增强陶瓷交联剂泥料和纤维增强陶瓷引发剂泥料的固含量均为70-75％。
9.根据权利要求1所述的基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法，其特征在于，步骤6)中由纤维增强陶瓷交联剂泥料和纤维增强陶瓷引发剂泥料混合的陶瓷泥料发生聚合反应凝固的时间为1-5分钟。
10.根据权利要求1所述的基于凝胶注模3D打印的纤维增强陶瓷异型件成型方法，其特征在于，步骤1)中所述的陶瓷粉体材料为石英、氧化锆、氧化铝、氮化硼和氮化硅中的一种或多种；所述的增强纤维材料为石英纤维、高硅氧纤维、氮化硅纤维和氮化硼纤维中的一种或多种。
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