Vat Photopolymerization of Ceramic Parts: Effects of Carbon Fiber Additives on Microstructure and Mechanical Performance.

Vat photopolymerization (VPP), as an additive manufacturing (AM) technology, can conveniently produce ceramic parts with high resolution and excellent surface quality. However, due to the inherent brittleness and low toughness of ceramic materials, manufacturing defect-free ceramic parts remains a challenge. Many researchers have attempted to use carbon fibers as additives to enhance the performance of ceramic parts, but these methods are mostly applied in processes like fused deposition modeling and hot pressing. To date, no one has applied them to VPP-based AM technology. This is mainly because the black carbon fibers reduce laser penetration, making it difficult to cure the ceramic slurry and thus challenging to produce qualified ceramic parts. To address this issue, our study has strictly controlled the amount of carbon fibers by incorporating trace amounts of carbon fiber powder into the original ceramic slurry with the aim to investigate the impact of these additions on the performance of ceramic parts. In this study, ceramic slurries with three different carbon fiber contents (0 wt.%, 0.1 wt.%, 0.2 wt.%, and 0.3 wt.%) were used for additive manufacturing. A detailed comparative analysis of the microstructure, physical properties, and mechanical performance of the parts was conducted. The experimental results indicate that the 3D-printed alumina parts with added carbon fibers show varying degrees of improvement in multiple performance parameters. Notably, the samples prepared with 0.2 wt.% carbon fiber content exhibited the most significant performance enhancements.

Vat Photopolymerization of Sepiolite Fiber and 316L Stainless Steel-Reinforced Alumina with Functionally Graded Structures.

Alumina (Al2O3) ceramics are widely used in electronics, machinery, healthcare, and other fields due to their excellent hardness and high temperature stability. However, their high brittleness limits further applications, such as artificial ceramic implants and highly flexible protective gear. To address the limitations of single-phase toughening in Al2O3 ceramics, some researchers have introduced a second phase to enhance these ceramics. However, introducing a single phase still limits the range of performance improvement. Therefore, this study explores the printing of Al2O3 ceramics by adding two different phases. Additionally, a new gradient printing technique is proposed to overcome the limitations of single material homogeneity, such as uniform performance and the presence of large residual stresses. Unlike traditional vat photopolymerization printing technology, this study stands out by generating green bodies with varying second-phase particle ratios across different layers. This study investigated the effects of different contents of sepiolite fiber (SF) and 316L stainless steel (SS) on various aspects of microstructure, phase composition, physical properties, and mechanical properties of gradient-printed Al2O3. The experimental results demonstrate that compared to Al2O3 parts without added SF and 316L SS, the inclusion of these materials can significantly reduce porosity and water absorption, resulting in a denser structure. In addition, the substantial improvements, with an increase of 394.4% in flexural strength and an increase of 316.7% in toughness, of the Al2O3 components enhanced by incorporating SF and 316L SS have been obtained.