Advanced Laminated Object Manufacturing (LOM) of SiSiC Ceramics

Carbon sheets were used as a starting material for fabrication of SiSiC composites by advanced LOM. This approach consists of three steps: First a preform was fabricated form phenolic resin coated carbon paper with a LOM-device. Second the preform was turned into a carbon preform by pyrolysis in N2-atmosphere. Third pressureless reactive melt infiltration of silicon into the as fabricated carbon preform, which finally yielded a dense SiSiC composite. SEM analysis revealed a microstructure consisting of uniformly dispersed β-SiC grains in a matrix of silicon. The LOM fabricated material exhibited an average four point bending strength and Youngs modulus of 115 MPa and 165 GPa, respectively.Mechanical Engineerin

Model of layers bonding during LOM-process

The model of LOM-process with chemical reaction in intermediate layer is suggested in this paper. Maximal stress in contact zone and half-thickness of contact area are given from contact problem of mechanics. It was shown that this problem is similar to the problem of different material conjugation using synthesis in solid phase. Dimensionless variables and dimensionless criteria are identical for these processes. The qualitative examples of temperature field evolution for self-sustaining mode are demonstrated

Novel hybrid method to additively manufacture denser graphite structures using Binder Jetting.

This study introduces two hybrid processes integrating an additive manufacturing technique with post-processing treatments namely (i) Binder Jetting Printing (BJP) + Cold Isostatic Pressing (CIP) + cycle and (ii) BJP + cycle where cycle refers to a sequence of Impregnation-Drying-Pyrolysis. These two new processes yielded additively manufactured parts with higher density and reduced defects/porosities. As a testbed, we used these new processes to fabricate graphite structures. The samples produced by both methods were compared with each other and benchmarked to the samples produced by (a) BJP alone and (b) Traditional uniaxial pressing like compaction moulding. Various characterisation methods were used to investigate the microstructure and mechanical properties which showed that the porosity of hybrid manufactured samples reduces from 55% to a record 7%. This technological pathway is expected to create a new avalanche of industrial applications that are hitherto unexplored in the arena of hybrid additive manufacturing with BJP method

Metallized ceramic substrate with mesa structure for voltage ramp-up of power modules

International audienceAs the available wide bandgap semiconductors continuingly increase their operating voltages, the electrical insulation used in their packaging is increasingly constrained. More precisely the ceramic substrate, used in demanding applications, represents a key multi-functional element is being in charge of the mechanical support of the metallic track that interconnects the semiconductor chips with the rest of the power system, as well as of electrical insulation and of thermal conduction. In this complex assembly, the electric field enhancement at the triple junction between the ceramic, the metallic track borders and the insulating environment is usually a critical point. When the electrical field at the triple point exceeds the critical value allowed by the insulation system, this hampers the device performance and limits the voltage rating for future systems. The solution proposed here is based on the shape modification of the ceramic substrate by creating a mesa structure (plateau) that holds the metallic tracks in the assembly. A numerical simulation approach is used to optimize the structure. After the elaboration of the structures by ultrasonic machining we observed a significant increase (30%) in the partial discharge detection voltages, at 10 pC sensitivity, in a substrate with a mesa structure when comparing to a conventional metallized ceramic substrate

Microstructural Analysis of Novel Preceramic Paper-Derived SiCf/SiC Composites

This paper presents the results of microstructural analysis of novel preceramic paper-derived SiCf/SiC composites fabricated by spark plasma sintering. The sintering temperature and pressure were 2100/2200 °C and 60/100 MPa, respectively. The content of fibers in the composites was approx. 10 wt %. The SiCf/SiC composites were analyzed by positron annihilation methods, X-ray diffraction technology, scanning electron microscopy, and Raman spectroscopy. Longer sintering time causes the proportion of the 6H-SiC composition to increase to ~80%. The increase in sintering temperature from 2100 °C to 2200 °C leads to partial transition of 4H-SiC to 6H-SiC during the sintering process, and the long-life component of positrons indicates the formation of Si vacancies. The Raman characteristic peaks of turbostratic graphite appear in the Raman spectrum of SiC fibers, this is caused by the diffusion of carbon from the surface of the SiC fiber and the preceramic paper during the high-temperature sintering process

Reorientation of Suspended Ceramic Particles in Robocasted Green Filaments during Drying

This work considers the fabrication of ceramic parts with the help of an additive manufacturing process, robocasting, in which a paste with suspended particles is robotically extruded. Within the final part, the material properties depend on the orientation of the particles. A prediction of the particle orientation is challenging as the part usually undergoes multiple processing steps with varying contributions to the orientation. As the main contribution to the final particle orientation arises from the extrusion process, many corresponding prediction models have been suggested. Robocasting involves, however, further processing steps that are less studied as they have a smaller influence on the orientation. One of the processing steps is drying by natural convection, which follows directly after the extrusion process. A quantification of the reorientation that occurs during drying is mostly unknown and usually neglected in the models. Therefore, we studied the amount of reorientation of suspended particles in robocasted green filaments during drying in detail. For our study, we applied the discrete element method, as it meets various requirements: The exact particle geometry can be resolved precisely; particle–particle interactions can be described; the paste composition is reproduced exactly; the initial particle orientation can be set in accordance with the prediction from the analytical models for the extrusion part; macroscopic force laws exist to represent capillary forces due to the remaining fluid phase that remains during drying. From our study, we concluded that the magnitude of particle reorientation during drying is small compared to the orientation occurring during the extrusion process itself. Consequently, reorientation during drying might further be neglected within analytical orientation prediction models

Ultrasonic tomography of SiC-based materials synthesized by spark plasma sintering of preceramic paper

This paper is devoted to study a structure of SiC-based materials using ultrasonic tomography method. The SiC-based materials were fabricated from preceramic paper using spark plasma sintering (SPS) method. Also as part of the study the Young's modulus and density of sintered materials were determined and the effect of sintering pressure changing to this parameters value was investigated. The preceramic paper is a composite material including a matrix of organic cellulose fibers and inorganic powder filler (SiC). The sintering temperature and pressure were 2373 K and 20-40 MPa, respectively. The holding time for the sintering process was 10 min. The density of sintered materials was investigated by the hydrostatic weighing method. Ultrasonic tomography was implemented using of single-channel sensor at 10 MHz frequency. © Published under licence by IOP Publishing Ltd.Russian Science Foundation, RSF: 19-19-00192The research was supported by the Russian Science Foundation (grant No. 19-19-00192) as well as b

Microstructure and Hydrogen Permeability of Nb-Ni-Ti-Zr-Co High Entropy Alloys

Hydrogen separation membranes are one of the most promising technologies for hydrogen purification. The development of high-entropy alloys (HEAs) for hydrogen separation membranes is driven by a “cocktail effect” of elements with different hydrogen affinities to prevent hydride formation and retain high permeability due to the single-phase BCC structure. In this paper, equimolar and non-equimolar Nb-Ni-Ti-Zr-Co high entropy alloys were fabricated by arc melting. The microstructure and phase composition of the alloys were analyzed by scanning electron microscopy and X-ray diffraction, respectively. The hydrogen permeation experiments were performed at 300–500 °C and a hydrogen pressure of 4 bar. In order to estimate the effect of composition and lattice structure on hydrogen location and diffusivity in Nb-Ni-Ti-Zr-Co alloy, ab initio calculations of hydrogen binding energy were performed using virtual crystal approximation. It was found that Nb-enriched and near equimolar BCC phases were formed in Nb20Ni20Ti20Zr20Co20 HEA while Nb-enriched BCC and B2-Ni(Ti, Zr) were formed in Nb40Ni25Ti18Zr12Co5 alloy. Hydrogen permeability tests showed that Nb20Ni20Ti20Zr20Co20 HEA shows lower activation energy and higher permeability at lower temperatures as well as higher resistance to hydrogen embrittlement compared to Nb40Ni25Ti18Zr12Co5 alloy. The effect of composition, microstructure and hydrogen binding energies on permeability of the fabricated alloys was discussed

Formation of gradient porous composites from preceramic papers with Ti3SiC2 powder filler

This article is devoted to fabrication of gradient Ti3SiC2-based composites using preceramic papers as a feedstock. The initial raw material is a stack of preceramic paper with a Ti3SiC2 powder filler, the content of which varies from 60 to 90% every three layers. The composites were obtained by spark plasma sintering (SPS) method at 10 MPa pressure for 10 min holding time. The sintering temperature was 1250 °C. The microstructure and phase composition of the obtained gradient composites were analyzed

Crystallisation Kinetics of a β

LZSA (Li2O-ZrO2-SiO2-Al2O3) glass ceramic system has shown high potential to obtain LTCC laminate tapes at low sintering temperature (<1000°C) for several applications, such as screen-printed electronic components. Furthermore, LZSA glass ceramics offer interesting mechanical, chemical, and thermal properties, which make LZSA also a potential candidate for fabricating multilayered structures processed by Laminated Objects Manufacturing (LOM) technology. The crystallization kinetics of an LZSA glass ceramic with a composition of 16.9Li2O⋅5.0ZrO2⋅65.1SiO2⋅8.6Al2O3 was investigated using nonisothermal methods by differential thermal analysis and scanning electronic microscopy. Apparent activation energy for crystallization was found to be in the 274–292 kJ⋅mol−1 range, and an Avrami parameter n of 1 was obtained that is compared very favorably with SEM observations