Abstract
ABSTRACT Additive manufacturing (AM) has provided huge versatility in geometry and materials, allowing new products and processes in several areas to be created. Laser Engineered Net Shaping (LENS) is an additive manufacturing process created in 1995 that allows building high-density metals and ceramics parts with no need for further operation. This manuscript aims to study the scientific literature about the process of Laser Engineered Net Shaping related to ceramics. After a systematic review, the articles were grouped into three categories: ceramic coating and AM of ceramics and AM of composites with ceramic reinforcement. Raw materials, substrates, applications, process parameters, and the obtained properties were analyzed and summarized for each group. Most of the additive manufacturing of ceramic parts are related to alumina, which present similar properties when compared to the traditionally manufactured ones. Recent works have the aid of an ultrasonic vibration to homogenize the in-process material, reduce cracks and improve mechanical properties. The additive manufacturing of composites with ceramic reinforcement has been used to create functionally graded composites materials with increased hardness, while the ceramic coating has been employed to manufacture biocompatible coating with increased hardness and low wear rate. Moreover, an additive manufacturing timeline including Laser Engineered Net Shaping landmarks is presented.
Highlights
In the last four decades, scientific and industrial researches have enabled considerable advances in additive manufacturing, allowing the manufacture of several products to be made of polymers, metals, ceramics, and composites with unviable or even impossible geometries by other processes [1–4]
3.1 Additive Manufacturing of Ceramics 3.1.1 Raw materials and substrate: Alumina was used as the raw material in 15 of the 16 employed articles related to Additive manufacturing (AM) of ceramics
A systematic review about Laser Engineered Net Shaping (LENS) of ceramics was made based on articles written in English published until August 2018 available in SCOPUS and Web of Science databases, where an analysis was made and divided into three major groups: AM of ceramics, AM of composites with ceramic reinforcement and coating of ceramics
Summary
In the last four decades, scientific and industrial researches have enabled considerable advances in additive manufacturing, allowing the manufacture of several products to be made of polymers, metals, ceramics, and composites with unviable or even impossible geometries by other processes [1–4]. The additive manufacturing allows fabricating complex ceramic products in small quantities, without the costs of preparing new tools each time. Such a process has been used mainly in biomedical, aerospace, automotive and chemical industries to manufacture scaffolds, filters, and lightweight structures. The direct methods, in which pure ceramic powder is directly melted and solidified to create parts, include Laser Engineered Net Shaping (LENS) and Selective Laser Sintering (SLS). The Sandia Corporation published the first articles related to Laser engineered net shaping around 1995 [15,16], while its patent was filled in 1996 [17] and it was licensed to Optomec Inc. in 1997 [18] Even though this technique was first created to fabricate metal parts, studies indicate that some laboratories were studying the use of LENS applied to ceramics already in 1999 [19].
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