Additive manufacturing and joining double processes of ceramic-resin green bodies using a single- or double-phase photocuring slurry

Abstract

The present work focuses on a double process involving additive manufacturing and joining of ceramic-resin green bodies, aiming to overcome the challenges of printing long-span and large-size ceramic specimens. Through partitioned 3D printing, individual green bodies were built and then joined together using either a single-phase slurry (Al2O3) or a double-phase slurry (Al2O3 and ZrO2). The impact of sintered temperature, photocuring duration time, and sandwich layer thickness on the three-point bending strength of the joined specimens was investigated. The analysis of photocuring depth, thermogravimetry, and composition structure characteristics reveals two significant joining mechanisms, namely initial polymer network joining and ultimate grain bonding and growth joining, which play a crucial role in holding the connection shapes and enhancing the connection strength. Furthermore, the bending strength analysis indicates a positive correlation between sintering temperature and bending strength, while a negative correlation is observed between sandwich layer thickness and bending strength. The photocuring duration time has no significant impact on the bending strength. Finally, the double-phase slurry demonstrates superior connection performance, but the joining strength is decreased to 44.53 % of the sintered substrate specimens due to the presence of joining defects such as flow channel pores and lamellar gaps. These defects have prompted the development of lamellar structures, flow channel pores, and intercrystalline fracture regions, consequently reducing the overall strength.