Microstructure and mechanical properties of 3D printed porous Al2O3–ZrO2 laminated ceramics with tailored porosity

Abstract

A 3D printing technique was proposed to fabricate porous Al2O3–ZrO2 laminated ceramics by controlling the content of polymethyl methacrylate (PMMA) microspheres. The flexural performance of the 3D printed porous laminated ceramics was assessed through three-point bending tests and compared with theoretical predictions. The experimental results agree with analytical projections. The present study investigated the influence of porosity and its distribution on the microstructure and flexural properties of porous Al2O3–ZrO2 laminated ceramics. The findings reveal that an increase in PMMA microsphere content in the outer layer leads to a decrease in both flexural modulus and strength for the type A ceramics. Among all type B samples, TB1 exhibits the highest flexural strength while TB3 displays the lowest. Furthermore, the crack deflection in the laminated ceramics was examined to elucidate the underlying mechanism of failure. It was determined that both type A and type B Al2O3–ZrO2 porous laminated ceramics exhibit brittle behavior under bending. The orientation of the maximum principal stress at the interface between the lower and inner layers being not align with the axis of the beam leads to the crack deflection. Overall, this study provides valuable guidance for designing and additively manufacturing porous Al2O3–ZrO2 laminated ceramics.