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RuiHuang_PhD_Dissertation_2022.pdf (7.65 MB)

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Material Extrusion Additive Manufacturing of Binder-Coated Zirconia: Process, Comprehensive Characterizations, and Applications

Huang, Rui
http://rave.ohiolink.edu/etdc/view?acc_num=akron1649681128201288

Abstract Details

2022, Doctor of Philosophy, University of Akron, Mechanical Engineering.
Material extrusion processes have been increasingly employed in the fabrication of advanced ceramics in the aerospace, automotive, and biomedical fields. Such processes—which involve printing compositions containing ceramic powders and sacrificial binders, debinding the binders, and sintering the parts to obtain pure ceramics—can be used to produce more complex structures than traditional ceramic manufacturing techniques. In this study, a rod-shaped feedstock comprised of binder-coated zirconia containing 87 wt% zirconia was supplied to a motorized piston extruder in a customized 3D printer to fabricate green ceramic structures, and the structures were then subjected to debinding and sintering. A comprehensive set of characteristics were examined: the thermal and rheological properties of the feedstock, the printability of the feedstock, the influence of the layer thickness and raster angle on the surface roughness and flexural/tensile/compressive strengths of the sintered zirconia, Vickers hardness, relative density and porosity, shrinkage behavior, and the micro/macro structure of green and sintered 3D-printed zirconia structures. The comprehensive characteristics of 3D printed green and sintered zirconia that were obtained in this study can facilitate the successful 3D printing of ceramics. Next, for extending the functionality and applications of parts produced by additive manufacturing, an inductive proximity sensor with a 3D-printed ceramic housing and embedded sensing elements was designed and produced using a hybrid manufacturing process in which the printing process is paused, and a sensing element is embedded into the printed structure. In the developed process, binder-coated zirconia was used to fabricate the ceramic housing for the sensor, and platinum wire was used in the sensing element. The subsequent debinding and sintering processes achieved a nearly fully dense ceramic housing that protects the sensor in harsh environments. Furthermore, zirconia feedstock was additively manufactured on a freeform surface with a conformal printing algorithm to overcome the conventional additive manufacturing limitations. A conformal slicing algorithm that uses the substrate’s surface as the slicing surface to slice the 3D model was used to generate the tool path. A series of filaments were fabricated on freeform surfaces with a different slope and their cross sections were measured for evaluating the printing quality and surface finish.
Jae-Won Choi (Advisor)
Gregory N Morscher (Committee Member)
Jiang Zhe (Committee Member)
Kwek-Tze Tan (Committee Member)
Kye-Shin Lee (Committee Member)
Sadhan C Jana (Committee Member)
188 p.
Mechanical Engineering
additive manufacturing; material extrusion; binder-coated zirconia; mechanical properties; inductive sensor; ceramic 3D printing; conformal additive manufacturing

Recommended Citations

Citations

  • Huang, R. (2022). Material Extrusion Additive Manufacturing of Binder-Coated Zirconia: Process, Comprehensive Characterizations, and Applications [Doctoral dissertation, University of Akron]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=akron1649681128201288

    APA Style (7th edition)

  • Huang, Rui. Material Extrusion Additive Manufacturing of Binder-Coated Zirconia: Process, Comprehensive Characterizations, and Applications. 2022. University of Akron, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=akron1649681128201288.

    MLA Style (8th edition)

  • Huang, Rui. "Material Extrusion Additive Manufacturing of Binder-Coated Zirconia: Process, Comprehensive Characterizations, and Applications." Doctoral dissertation, University of Akron, 2022. http://rave.ohiolink.edu/etdc/view?acc_num=akron1649681128201288

    Chicago Manual of Style (17th edition)

akron1649681128201288
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This open access ETD is published by University of Akron and OhioLINK.