Additive Manufacturing of Novel Hybrid Monolithic Ceramic Substrates
Additive manufacturing (AM) can revolutionise engineering by taking advantage of unconstrained design and overcoming the limitations of traditional manufacturing capabilities. A promising application of AM is in catalyst substrate manufacturing, aimed at the enhancement of the catalytic efficiency a...
| Main Authors: | , , , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-05-01
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| Series: | Aerospace |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2226-4310/9/5/255 |
| _version_ | 1827671114122264576 |
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| author | Nikolina Kovacev Sheng Li Weining Li Soheil Zeraati-Rezaei Athanasios Tsolakis Khamis Essa |
| author_facet | Nikolina Kovacev Sheng Li Weining Li Soheil Zeraati-Rezaei Athanasios Tsolakis Khamis Essa |
| author_sort | Nikolina Kovacev |
| collection | DOAJ |
| description | Additive manufacturing (AM) can revolutionise engineering by taking advantage of unconstrained design and overcoming the limitations of traditional manufacturing capabilities. A promising application of AM is in catalyst substrate manufacturing, aimed at the enhancement of the catalytic efficiency and reduction in the volume and weight of the catalytic reactors in the exhaust gas aftertreatment systems. This work addresses the design and fabrication of innovative, hybrid monolithic ceramic substrates using AM technology based on Digital Light Processing (DLP). The designs are based on two individual substrates integrated into a single, dual-substrate monolith by various interlocking systems. These novel dual-substrate monoliths lay the foundation for the potential reduction in the complexity and expense of the aftertreatment system. Several examples of interlocking systems for dual substrates were designed, manufactured and thermally post-processed to illustrate the viability and versatility of the DLP manufacturing process. Based on the findings, the sintered parts displayed anisotropic sintering shrinkage of approximately 14% in the X–Y direction and 19% in the Z direction, with a sintered density of 97.88 ± 0.01%. Finally, mechanical tests revealed the mechanical integrity of the designed interlocks. U-lock and Thread configurations were found to sustain more load until complete failure. |
| first_indexed | 2024-03-10T03:32:39Z |
| format | Article |
| id | doaj.art-c14586259a204b379892b870248e2da1 |
| institution | Directory Open Access Journal |
| issn | 2226-4310 |
| language | English |
| last_indexed | 2024-03-10T03:32:39Z |
| publishDate | 2022-05-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Aerospace |
| spelling | doaj.art-c14586259a204b379892b870248e2da12023-11-23T09:37:56ZengMDPI AGAerospace2226-43102022-05-019525510.3390/aerospace9050255Additive Manufacturing of Novel Hybrid Monolithic Ceramic SubstratesNikolina Kovacev0Sheng Li1Weining Li2Soheil Zeraati-Rezaei3Athanasios Tsolakis4Khamis Essa5Department of Mechanical Engineering, University of Birmingham, Birmingham B15 2TT, UKSchool of Electromechanical Engineering, Guangdong University of Technology, Guangzhou 510006, ChinaDepartment of Mechanical Engineering, University of Birmingham, Birmingham B15 2TT, UKDepartment of Mechanical Engineering, University of Birmingham, Birmingham B15 2TT, UKDepartment of Mechanical Engineering, University of Birmingham, Birmingham B15 2TT, UKDepartment of Mechanical Engineering, University of Birmingham, Birmingham B15 2TT, UKAdditive manufacturing (AM) can revolutionise engineering by taking advantage of unconstrained design and overcoming the limitations of traditional manufacturing capabilities. A promising application of AM is in catalyst substrate manufacturing, aimed at the enhancement of the catalytic efficiency and reduction in the volume and weight of the catalytic reactors in the exhaust gas aftertreatment systems. This work addresses the design and fabrication of innovative, hybrid monolithic ceramic substrates using AM technology based on Digital Light Processing (DLP). The designs are based on two individual substrates integrated into a single, dual-substrate monolith by various interlocking systems. These novel dual-substrate monoliths lay the foundation for the potential reduction in the complexity and expense of the aftertreatment system. Several examples of interlocking systems for dual substrates were designed, manufactured and thermally post-processed to illustrate the viability and versatility of the DLP manufacturing process. Based on the findings, the sintered parts displayed anisotropic sintering shrinkage of approximately 14% in the X–Y direction and 19% in the Z direction, with a sintered density of 97.88 ± 0.01%. Finally, mechanical tests revealed the mechanical integrity of the designed interlocks. U-lock and Thread configurations were found to sustain more load until complete failure.https://www.mdpi.com/2226-4310/9/5/255additive manufacturingDLPmonolithic substratecatalystceramic |
| spellingShingle | Nikolina Kovacev Sheng Li Weining Li Soheil Zeraati-Rezaei Athanasios Tsolakis Khamis Essa Additive Manufacturing of Novel Hybrid Monolithic Ceramic Substrates Aerospace additive manufacturing DLP monolithic substrate catalyst ceramic |
| title | Additive Manufacturing of Novel Hybrid Monolithic Ceramic Substrates |
| title_full | Additive Manufacturing of Novel Hybrid Monolithic Ceramic Substrates |
| title_fullStr | Additive Manufacturing of Novel Hybrid Monolithic Ceramic Substrates |
| title_full_unstemmed | Additive Manufacturing of Novel Hybrid Monolithic Ceramic Substrates |
| title_short | Additive Manufacturing of Novel Hybrid Monolithic Ceramic Substrates |
| title_sort | additive manufacturing of novel hybrid monolithic ceramic substrates |
| topic | additive manufacturing DLP monolithic substrate catalyst ceramic |
| url | https://www.mdpi.com/2226-4310/9/5/255 |
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