Technical reports and Deliverables

Deliverable title: Bibliography report on eutectic systems

The present Deliverable focuses on the definition of a feasible design for 3D printed Al2O3-based ceramics. The process parameters and the material properties are briefly reviewed, with particular attention to critical aspects from the granulate preparation of oxide powders to the printing process parameters (spot size, laser power, scan speed, ……). 

Based on the identified target properties, in the present Deliverable printing process parameters and materials properties are also reviewed.

The results of this bibliographic research have led to the writing of a review paper titled: “Laser additive manufacturing of Al2O3 and /ZrO2-based Eutectic Ceramic Oxide: an overview” submitted to the Journal of the European Ceramic Society the 24th of September 2024.

Deliverable title: Report on the optimization process to obtain feedstock for AM and feedstock characterization

Executive Summary

Based on the collected data reported in Deliverable D.1.1, the production of ceramic eutectic systems by AM, which presents unique challenges due to the low thermal shock resistance of ceramics that can lead to delamination and cracking during AM production, requires careful optimisation of several steps starting with the choice of the powders used. Therefore, several powder properties, including particle size distribution (PSD), morphology and chemical composition, must be carefully characterised and optimised.

To obtain spherical particles two different ways were chosen: spray-drying process and sol-gel synthesis. For these reasons, this Deliverable focuses on:

1. Spray drying process optimization:
2. identification of raw materials suitable for the process through comprehensive characterisation;
3. preparation of engineered batches for LAM processes;
4. characterisation of powders after the spray-drying process.
5. Sol-gel powders characterisation

Finally in order to evaluate the use of CO₂ laser instead of fiber laser, two other alumina powders, furnished by Italian company, were characterised.

Since one of the main factors influencing the process is the powder properties, and since there is a lack of quantified and widely accepted requirements for powders, it is crucial to study both the extrinsic (particle size distribution and morphology) and intrinsic (chemical composition and microstructure) properties of powders.

SEM micrographs of Al₂O₃-ZrO₂ eutectic granules prepared with graphene ​