Numerical Simulation of Sintering of DLP Printed Alumina Ceramics
Digital Light Processing (DLP) technology exhibits the capability of producing components with complex structures for a variety of technical applications. Postprocessing of additively printed ceramic components has been shown to be an important step in determining the final product resolution and me...
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-06-01
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| Series: | Aerospace |
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| Online Access: | https://www.mdpi.com/2226-4310/9/7/336 |
| _version_ | 1797434019877486592 |
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| author | Michele De Lisi Nikolina Kovacev Usama M. Attia Khamis Essa |
| author_facet | Michele De Lisi Nikolina Kovacev Usama M. Attia Khamis Essa |
| author_sort | Michele De Lisi |
| collection | DOAJ |
| description | Digital Light Processing (DLP) technology exhibits the capability of producing components with complex structures for a variety of technical applications. Postprocessing of additively printed ceramic components has been shown to be an important step in determining the final product resolution and mechanical qualities, particularly with regard to distortions and resultant density. The goal of this research is to study the sintering process parameters to create a nearly fully dense, defect-free, ceramic component. A high-solid-loading alumina slurry with suitable rheological and photopolymerisable characteristics for DLP was created. TGA/DSC analysis was used to estimate thermal debinding parameters. The sintering process of the debound parts was studied by employing a numerical model based on thermo-viscoelasticity theory to describe the sintering process. The validated Finite Element Modelling (FEM) code was capable of predicting shrinkage and relative density changes during the sintering cycle, as well as providing meaningful information on the final shape. Archimedes’ principle and scanning electron microscope (SEM) were used to characterise the sintered parts and validate the numerical model. Samples with high relative density (>98.5%) were produced and numerical data showed close matches for predicted shrinkages and relative densities, with less than 2% mismatch between experimental results and simulations. The current model may allow to effectively predict the properties of alumina ceramics produced via DLP and tailor them for specific applications. |
| first_indexed | 2024-03-09T10:24:18Z |
| format | Article |
| id | doaj.art-7e41c37c56944dc58ebd13b85d7a0cb0 |
| institution | Directory Open Access Journal |
| issn | 2226-4310 |
| language | English |
| last_indexed | 2024-03-09T10:24:18Z |
| publishDate | 2022-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Aerospace |
| spelling | doaj.art-7e41c37c56944dc58ebd13b85d7a0cb02023-12-01T21:45:13ZengMDPI AGAerospace2226-43102022-06-019733610.3390/aerospace9070336Numerical Simulation of Sintering of DLP Printed Alumina CeramicsMichele De Lisi0Nikolina Kovacev1Usama M. Attia2Khamis Essa3Department of Mechanical Engineering, University of Birmingham, Edgbaston, Birmingham B15 2TT, UKDepartment of Mechanical Engineering, University of Birmingham, Edgbaston, Birmingham B15 2TT, UKManufacturing Technology Centre, Ansty Park, Coventry CV7 9JU, UKDepartment of Mechanical Engineering, University of Birmingham, Edgbaston, Birmingham B15 2TT, UKDigital Light Processing (DLP) technology exhibits the capability of producing components with complex structures for a variety of technical applications. Postprocessing of additively printed ceramic components has been shown to be an important step in determining the final product resolution and mechanical qualities, particularly with regard to distortions and resultant density. The goal of this research is to study the sintering process parameters to create a nearly fully dense, defect-free, ceramic component. A high-solid-loading alumina slurry with suitable rheological and photopolymerisable characteristics for DLP was created. TGA/DSC analysis was used to estimate thermal debinding parameters. The sintering process of the debound parts was studied by employing a numerical model based on thermo-viscoelasticity theory to describe the sintering process. The validated Finite Element Modelling (FEM) code was capable of predicting shrinkage and relative density changes during the sintering cycle, as well as providing meaningful information on the final shape. Archimedes’ principle and scanning electron microscope (SEM) were used to characterise the sintered parts and validate the numerical model. Samples with high relative density (>98.5%) were produced and numerical data showed close matches for predicted shrinkages and relative densities, with less than 2% mismatch between experimental results and simulations. The current model may allow to effectively predict the properties of alumina ceramics produced via DLP and tailor them for specific applications.https://www.mdpi.com/2226-4310/9/7/336additive manufacturingDLPaluminasinteringnumerical modelling |
| spellingShingle | Michele De Lisi Nikolina Kovacev Usama M. Attia Khamis Essa Numerical Simulation of Sintering of DLP Printed Alumina Ceramics Aerospace additive manufacturing DLP alumina sintering numerical modelling |
| title | Numerical Simulation of Sintering of DLP Printed Alumina Ceramics |
| title_full | Numerical Simulation of Sintering of DLP Printed Alumina Ceramics |
| title_fullStr | Numerical Simulation of Sintering of DLP Printed Alumina Ceramics |
| title_full_unstemmed | Numerical Simulation of Sintering of DLP Printed Alumina Ceramics |
| title_short | Numerical Simulation of Sintering of DLP Printed Alumina Ceramics |
| title_sort | numerical simulation of sintering of dlp printed alumina ceramics |
| topic | additive manufacturing DLP alumina sintering numerical modelling |
| url | https://www.mdpi.com/2226-4310/9/7/336 |
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