Concentrated suspension-based additive manufacturing – viscosity, packing density, and segregation

Abstract

This paper describes the influence of particle size distribution (PSD) of refractory silica on the suspension viscosity, packing density, and segregation in layers solidified by ceramic stereolithography (CerSLA). Using bimodal PSD displays most significant decrease of suspension viscosity than suspension made of mono-modal PSD. Given the Krieger-Dougherty model and packing density experiment, the lower viscosity results from the higher maximum volume fraction, φm, reached through the closely packed particles. Furthermore, from the differential sedimentation of coarser or denser particles in suspensions, particle size segregation in layers is detected. To determine the distribution of particle size within each layer, a linear intercept method is used, which demonstrates the vertical changes in PSD. Mono–modal PSD case show severe segregations in solidified layers in which the population of larger or denser particles is greater near the bottom. However, much less segregation occurs with bimodal PSD due to suppressed segregation.