Silica strengthened alumina ceramic cores prepared by 3D printing

Preparation and characterization of starch-based binders for binder jetting

In recent years, binder jetting technology has made significant advances across industries, expanding the range of material options to meet diverse needs. Commonly used binders may leave residues during the sintering process, affecting surface quality and performance, and some may contain harmful substances. Therefore, there is a high demand for binders that are environmentally friendly and easy to remove. This study proposes to use sodium alginate and polyvinylpyrrolidone as additives to prepare starch-based inks that are both environmentally friendly and safe. The effects of additive composition, starch content, dispersant content, and dispersant ratio on the viscosity and stability of starch-based inks were studied. Through performance testing, the particle size, surface tension, rheological properties, and printability of inks with different components were demonstrated. The optimal ink formulation consists of 1 wt% starch and 0.3 wt% additives (30 wt% sodium alginate and 70 wt% PVP). The viscosity reaches 23 mPa s and the stability is excellent. The surface tension of the ink is 69.5 mN m-1, which is slightly higher than the surface tension requirements for the printhead. This article provides a new process route for binder jetting technology and lays the foundation for its application in green and environmental protection.

Structural Electromagnetic Absorber Based on MoS2 /PyC-Al2 O3 Ceramic Metamaterials

Limited by the types of suitable absorbents as well as the challenges in engineering the nanostructures (e.g., defects, dipoles, and hetero-interface) using state-of-the-art additive manufacturing (AM) techniques, the electromagnetic (EM) wave absorption performance of the current ceramic-based materials is still not satisfying. Moreover, because of the high residual porosity and the possible formation of cracks during sintering or pyrolysis, AM-formed ceramic components may in many cases exhibit low mechanical strength. In this work, semiconductive MoS2 and conductive PyC modified Al2 O3 (MoS2 /PyC-Al2 O3 ) ceramic-based structural EM metamaterials are developed by innovatively harnessing AM, precursor infiltration and pyrolysis (PIP), and hydrothermal methods. Three different meta-structures are successfully created, and the ceramic-based nanocomposite benefit from its optimization of EM parameters. Ultra-broad effective absorption bandwidth (EAB) of 35 GHz is achieved by establishment of multi-loss mechanism via nanostructure engineering and fabrication of meta-structures via AM. Due to the strengthening by the PyC phase, the bending strength of the resulting ceramics can reach ≈327 MPa, which is the highest value measured on 3D-printed ceramics of this type that has been reported so far. For the first time, the positive effect deriving from the engineering of the microscopic nano/microstructure and of the macroscopic meta-structure of the absorber on the permittivity and EM absorption performance is proposed. Integration of outstanding mechanical strength and ultra-broad EAB is innovatively realized through a multi-scale design route. This work provides new insights for the design of advanced ceramic-based metamaterials with outstanding performance under extreme environment.

SiC Nanoparticles Strengthened Alumina Ceramics Prepared by Extrusion Printing

Extrusion-free-form printing of alumina ceramics has the advantages of low cost, short cycle time, and high customization. However, some problems exist, such as the low solid content of ceramic paste and the unsatisfactory mechanical properties of pure alumina ceramics. In this study, SiC nanoparticles were used as a reinforcement phase added to the alumina ceramic matrix. Methylcellulose is used as the binder in the raw material system. Ammonium polyacrylate is used as a dispersant to change the rheological properties of the slurry and increase the solid content of ceramics. SiC nanoparticle-strengthened alumina ceramics were successfully prepared by the extrusion process. The relative settling height and viscosity of ceramic slurries were characterized. The sintering shrinkage of composite ceramics was tested. The flexural strength, fracture toughness, and hardness of the ceramics were characterized. The strengthening and toughening mechanisms of the composite ceramics were further explained by microscopic morphology analysis. Experimental results show that when the content of the dispersant is 1 wt.%, the rheological properties of the slurry are the best. Maximum measured bending strength (227 MPa) and fracture toughness (5.35 MPa·m^1/2) were reached by adding 8 wt% SiC nanoparticles; compared with pure alumina ceramics, flexural strength and fracture toughness increased by 42% and 41%, respectively. This study provides a low-cost and effective method for preparing ceramic composite parts.

Microstructure and Crystallization Kinetics of Silica-Based Ceramic Cores with Enhanced High-Temperature Property

Silica-based ceramic cores play key roles in the casting of aeroengine blades, but they are highly limited by the poor high-temperature mechanical property. Here, fused mullite (FM) and sintered mullite (SM) powders were modified in silica-based ceramic cores, and the microstructure evolution and crystallization kinetics of ceramic cores depending on mullite types were studied. The ceramic cores with FM showed a dense microstructure and superior mechanical properties compared to those with SM. The ceramic cores with 10 wt.% of FM showed a crystallization activation energy of 1119.5 kJ/mol and a crystallization exponent of 1.74, and the values of 938.4 kJ/mol and 1.86 as SM were employed; the decreased crystallization activation energy and the elevated crystallization exponent by SM suggested that the excess impurities of alkali oxides and alkaline-earth oxides significantly promoted the crystallization of cristobalite. Even though the ceramic cores with mullite powders decreased slightly in the room-temperature mechanical property, their high-temperature flexure strength and creep deformation resistance were enhanced. The ceramic cores with 10 wt.% of FM showed excellent comprehensive performance, with linear shrinkage of 0.69%, room-temperature strength of 18.9 MPa, and high-temperature strength of 15.5 MPa, which satisfied the demands for hollow-blade casting.

Rice husk waste into various template-engineered mesoporous silica materials for different applications: A comprehensive review on recent developments

Following the discovery of Stöber silica, the realm of morphology-controlled mesoporous silica nanomaterials like MCM-41, SBA-15, and KCC-1 has been expanded. Due to their high BET surface area, tunable pores, easiness of functionalization, and excellent thermal and chemical stability, these materials take part a vital role in the advancement of techniques and technologies for tackling the world's largest challenges in the area of water and the environment, energy storage, and biotechnology. Synthesizing these materials with excellent physicochemical properties from cost-efficient biomass wastes is a foremost model of sustainability. Particularly, SiO₂ with a purity >98% can be obtained from rice husk (RH), one of the most abundant biomass wastes, and can be template engineered into various forms of mesoporous silica materials in an economic and eco-friendly way. Hence, this review initially gives insight into why to valorize RH into value-added silica materials. Then the thermal, chemical, hydrothermal, and biological methods of high-quality silica extraction from RH and the principles of synthesis of mesoporous and fibrous mesoporous silica materials like SBA-15, MCM-41, MSNs, and KCC-1 are comprehensively discussed. The potential applications of rice husk-derived mesoporous silica materials in catalysis, drug delivery, energy, adsorption, and environmental remediation are explored. Finally, the conclusion and the future outlook are briefly highlighted.