Preparation and characteristics of honeycomb mullite ceramics with controllable structure by stereolithography 3D printing and in-situ synthesis

Abstract

Porous honeycomb mullite ceramics were controllably fabricated in-situ using stereolithography 3D printing. The effects of the dispersant type and content on the rheological behavior of the mullite precursor slurry were investigated. Additionally, the influence of the debinding atmosphere (air and argon) on the quality of the samples and formation of cracks was also studied. The results indicated that oleic acid (OA), 3-glycidoxypropylthrimethoxysilane (KH560), and disperbyk (BYK111) displayed the capability to create low-viscosity and highly stable slurries. Among these KH560 was proved to be the most effective. The mullite precursor slurry containing 4 wt% KH560 dispersants exhibited a shear thinning behavior. It displayed a viscosity of 0.26 Pa·s at a shear rate of 30 s−1. The mullite ceramic parts displayed good a dimensional resolution at an exposure dose of 5.47 mJ/cm2. During the debinding process, the printed parts were susceptible to cracking and deformation in air, but remained devoid of defects in argon. When the samples were sintered at 1600 °C, the corundum phase transformed almost completely into the mullite phase. The linear shrinkage values were 5.81%, 6.33%, and 10.26% in the O-X, O–Y and O-Z directions, respectively.