Ceramic Material Laser Sintering Defect Reduction
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Solution Overview
Problem
Existing methods for preparing ceramic materials often result in defects such as pores and unexpected second phases, affecting their thermal conductivity, ionic conductivity, and optical properties due to complex reactions and volume expansion during the calcining process.
Innovation Solution
A method involving mixing oxides of specific elements (Sc, Y, La, Nd, Eu, Gd, Dy, Er, Yb, Lu, Ti, Zr, Ce, and Hf), followed by ball-milling to achieve particle sizes under 1 μm, drying at 60-80°C, and sintering with laser irradiation at 980 nm wavelength, power ranging from 50 to 1500 W, and a spot diameter of 10 to 15 mm to produce ceramic materials with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional calcining method is used to prepare ceramic material, then the ceramic material can be obtained, but complex reactions occur causing unexpected second phases and volume expansion creating pores and defects
Solution Approach 1:
The patent changes the heating parameters by using laser irradiation with specific wavelength (980 nm), power density, and heating rate to achieve precise temperature control during sintering, preventing unwanted phase formation and volume expansion that cause pores and defects
Solution Approach 2:
The patent replaces the traditional furnace calcining method with laser irradiation technology, substituting a thermal field-based mechanical system with a targeted electromagnetic field approach that enables localized and controlled heating, thereby eliminating the harmful effects of uniform high-temperature calcining
2Reliability
If traditional calcining method is used, then ceramic material is produced, but thermal conductivity and optical properties are degraded due to pores and defects
Solution Approach 1:
The patent performs preliminary ball-milling of raw materials to achieve uniform particle size distribution and intimate mixing before sintering, which ensures homogeneous densification during laser sintering and eliminates pores that would degrade thermal conductivity and optical properties
Solution Approach 2:
By replacing traditional furnace calcining with laser irradiation, the patent achieves controlled heating that prevents excessive volume expansion and pore formation, thereby maintaining high material density and improving thermal conductivity and optical properties
3Productivity
If traditional mixing and calcining method is used, then ceramic material can be obtained, but raw material utilization is low due to complex reactions
Solution Approach 1:
The patent optimizes the chemical composition parameters of the raw material mixture and controls the laser sintering parameters (wavelength, power, heating rate) to promote complete reaction of intended phases while suppressing formation of unexpected second phases, thereby improving raw material utilization
Solution Approach 2:
The substitution of furnace calcining with laser irradiation enables more controlled and efficient reactions, reducing material waste and improving productivity by minimizing the formation of unwanted second phases that would reduce raw material utilization
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces ceramic materials with enhanced thermal conductivity, optical properties, and ionic conductivity, suitable for applications like thermal barrier coatings and transparent materials, with reduced complexity, environmental impact, and increased raw material utilization.
Implementation Method 1
sintering the powder with a laser irradiation having a laser wavelength of 980 nm
Implementation Method 2
sintering the powder with a laser irradiation having a laser wavelength of 980 nm, an irradiation power ranging from 50 to 1500 W
Implementation Method 3
ball-milling the mixture until a particle size of the mixture is not greater than 1 μm
Data Source
AI summary
Disclosed are a method for preparing a ceramic material including a compound of a formula of A2BxOy and a ceramic material prepared by the method. The method includes: mixing a first oxide of AOm and a second oxide of BOn to obtain a mixture, ball-milling the mixture until a particle size of the mixture is not greater than 1 μm with a medium selected from a group consisting of ethanol, acetone, deionized water and a combination thereof, to obtain a powder, drying the powder at a temperature in a range of 60 to 80° C., and sintering the powder with a laser irradiation having a laser wavelength of 980 nm, an irradiation power ranging from 50 to 1500 W and an irradiation period of 3 s to 8 min to obtain the ceramic material.