Using Layered Manufacturing to Create Textured Microstructures in Si3N4 Ceramics

Abstract

AbstractIn recent years, seeding has been shown to be an effective method to create textured microstructures in Si 3N4, Al2O3 and PZT ceramics. The objective of this research is to create anisotropic and textured Si3N4 parts using the Fused Deposition of Ceramics (FDC) process. This technique is currently being developed to fabricate high performance structural Si 3N4 based components. In order to create the textured microstructures, rod-like β-Si3N4 seed particles are introduced into the FDC feedstock filaments. In this study, anisometric β-Si3N4 seeds were introduced into the starting α-Si3N4 powder (Honeywell's AS800 grade) at a 10 vol.% loading. The effects of the seeds (aspect ratio ∼4) on the viscosity and resultant microstructure were evaluated using capillary rheology, scanning electron microscopy, coefficient of thermal expansion (CTE) measurements, and x-ray diffraction. It is observed that the seeds do align during filament extrusion and a significant texture has been detected by x-ray diffraction and CTE measurements in FDC feedstock filaments and sintered FDC parts.