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Materials
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Design and Additive Manufacturing of Innovative Components with Hybrid Ceramics
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Design and Additive Manufacturing of Innovative Components with Hybrid Ceramics

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (10 July 2022) | Viewed by 7651

Special Issue Editor

Prof. Dr. Alberto Ortona

E-Mail Website
Guest Editor
Mechanical Engineering and Materials Technology Institute (MEMTi), University of Applied Sciences (SUPSI-DTI), Polo Universitario Lugano, 6962 Lugano, Switzerland
Interests: additive manufacturing; ceramic matrix composites; porous ceramics

Special Issue Information

Dear Colleagues,

Hybrid ceramic materials are combinations of materials or a particular distribution of them in space. In modern engineering, they are designed and brought together to exploit their properties according to the function of the final component. Ceramic matrix composites, foams, lattice structures, sandwich structures, and more are examples of this material’s concepts. This Special Issue will broadcast the potential of hybrid ceramics, emphasizing the choice of the components, their topology, and the relative volume fraction. In particular, for complex ceramic architectures such as lattice structures or triply periodical minimal surfaces (TPMS) we are targeting design efforts that are currently trying to realize multi-functional components. The huge growth of applications with hybrid ceramic materials started when ceramic additive manufacturing techniques became available. There are several ceramic AM techniques; each one is better suited for specific applications. This Special Issue is intended for researchers who want to publish their work on designing high-performance components in combination with the appropriate AM technique. Some examples of these components are CMC parts, porous burners, catalysts support, ceramic sandwich structures, heat exchangers, complex chemical reactors, electronic devices, medical implants, and high-performance filters for water, air, and molten metals casting.

Prof. Dr. Alberto Ortona
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

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Keywords

  • selective laser melting/sintering (SLM/SLS)
  • fused deposition modeling (FDM)
  • binder jetting and powder bed fusion processes
  • stereolithography
  • direct writing and inkjet printing technologies
  • multi-material and hybrid printing techniques
  • design for additive manufacturing
  • applications of am materials and components

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Published Papers (3 papers)

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Research

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13 pages, 5253 KiB  
Article
Investigation on Flaw Evolution of Additively Manufactured Al2O3 Ceramic by In Situ X-ray Computed Tomography
by Naijia Cai, Qiaoyu Meng, Keqiang Zhang, Luchao Geng, Rujie He and Zhaoliang Qu
Materials 2022, 15(7), 2547; https://doi.org/10.3390/ma15072547 - 30 Mar 2022
Cited by 2 | Viewed by 1809
Abstract
The additive manufacturing process may create flaws inside ceramic materials. The flaws have a significant influence on the macroscopic mechanical behavior of ceramic materials. In order to reveal the influence of flaws on the mechanical behavior of additively manufactured ceramic, flaw evolution under [...] Read more.
The additive manufacturing process may create flaws inside ceramic materials. The flaws have a significant influence on the macroscopic mechanical behavior of ceramic materials. In order to reveal the influence of flaws on the mechanical behavior of additively manufactured ceramic, flaw evolution under mechanical loads was studied by in situ X-ray computed tomography (XCT) in this work. In situ compression XCT tests were conducted on stereolithographic additively manufactured Al2O3 ceramic. The three-dimensional full-field morphologies at different compressive loads were obtained. The evolution of flaws, including pores, transverse cracks, and vertical cracks, during compressive loading was observed. The number and volume of pores, transverse cracks, and vertical cracks were extracted. It was found that most pores and transverse cracks tend to be compacted. However, high compressive loads cause vertical cracks near the upper surface to expand, leading to the failure of the specimen. Real flaws with morphological and positional information were introduced into the finite element models. The influence of different types of flaws on the mechanical behavior is discussed. It was found that vertical cracks have a greater influence on mechanical behavior than do transverse cracks under compression. The presence of transverse cracks contributes to the evolution of vertical cracks. This study may be helpful for process optimization and performance enhancement of additively manufactured ceramic materials. Full article
(This article belongs to the Special Issue Design and Additive Manufacturing of Innovative Components with Hybrid Ceramics)
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19 pages, 4202 KiB  
Article
Application of Ceramic Lattice Structures to Design Compact, High Temperature Heat Exchangers: Material and Architecture Selection
by Marco Pelanconi, Simone Zavattoni, Luca Cornolti, Riccardo Puragliesi, Edoardo Arrivabeni, Luca Ferrari, Sandro Gianella, Maurizio Barbato and Alberto Ortona
Materials 2021, 14(12), 3225; https://doi.org/10.3390/ma14123225 - 11 Jun 2021
Cited by 26 | Viewed by 5493
Abstract
In this work, we report the design of ceramic lattices produced via additive manufacturing (AM) used to improve the overall performances of compact, high temperature heat exchangers (HXs). The lattice architecture was designed using a Kelvin cell, which provided the best compromise among [...] Read more.
In this work, we report the design of ceramic lattices produced via additive manufacturing (AM) used to improve the overall performances of compact, high temperature heat exchangers (HXs). The lattice architecture was designed using a Kelvin cell, which provided the best compromise among effective thermal conductivity, specific surface area, dispersion coefficient and pressure loss, compared to other cell geometries. A material selection was performed considering the specific composition of the fluids and the operating temperatures of the HX, and Silicon Carbide (SiC) was identified as promising materials for the application. The 3D printing of a polymeric template combined with the replica method was chosen as the best manufacturing approach to produce SiC lattices. The heat transfer behaviour of various lattice configurations, based on the Kelvin cell, was determined through computational fluid dynamics (CFD). The results are used to discuss the application of such structures to compact high temperature HXs. Full article
(This article belongs to the Special Issue Design and Additive Manufacturing of Innovative Components with Hybrid Ceramics)
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Review

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12 pages, 4653 KiB  
Review
Systematic Compounding of Ceramic Pastes in Stereolithographic Additive Manufacturing
by Soshu Kirihara
Materials 2021, 14(22), 7090; https://doi.org/10.3390/ma14227090 - 22 Nov 2021
Cited by 6 | Viewed by 2700
Abstract
In this paper, stereolithographic additive manufacturing of ceramic dental crowns is discussed and reviewed. The accuracy of parts in ceramic processing were optimized through smart computer-aided design, manufacturing, and evaluation. Then, viscous acrylic resin, including alumina particles, were successfully compounded. The closed packing [...] Read more.
In this paper, stereolithographic additive manufacturing of ceramic dental crowns is discussed and reviewed. The accuracy of parts in ceramic processing were optimized through smart computer-aided design, manufacturing, and evaluation. Then, viscous acrylic resin, including alumina particles, were successfully compounded. The closed packing of alumina particles in acrylic pastes was virtually simulated using the distinct element method. Multimodal distributions of particle diameters were systematically optimized at an 80% volume fraction, and an ultraviolet laser beam was scanned sterically. Fine spots were continuously joined by photochemical polymerization. The optical intensity distributions from focal spots were spatially simulated using the ray tracing method. Consequently, the lithographic conditions of the curing depths and dimensional tolerances were experimentally measured and effectively improved, where solid objects were freely processed by layer stacking and interlayer bonding. The composite precursors were dewaxed and sintered along effective heat treatment patterns. The results show that linear shrinkages were reduced as the particle volume fractions were increased. Anisotropic deformations in the horizontal and vertical directions were recursively resolved along numerical feedback for graphical design. Accordingly, dense microstructures without microcracks or pores were obtained. The mechanical properties were measured as practical levels for dental applications. Full article
(This article belongs to the Special Issue Design and Additive Manufacturing of Innovative Components with Hybrid Ceramics)
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