Ceramic AM Powder Composition for Low-Loss Void-Free Sintering
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Solution Overview
Problem
Existing additive manufacturing technologies struggle to produce ceramic structures with low dielectric loss tangent due to the formation of voids and cracks, which are not adequately addressed by existing methods that mix materials with different thermal conductivities, leading to increased dielectric loss.
Innovation Solution
A raw material powder comprising particles A and B with specific thermal conductivity ratios, particle size relationships, and the addition of absorber particles to ensure uniform melting and minimize voids, using a powder bed fusion method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If materials with different thermal conductivities are mixed to reduce melting point, then fabrication precision is improved, but dielectric loss tangent increases due to nonuniform melting and void formation
Solution Approach 1:
The patent changes the thermal conductivity parameter by introducing particles with higher thermal conductivity than the base ceramic material. These high thermal conductivity particles act as heat transfer mediators, ensuring uniform heat distribution throughout the powder bed during laser irradiation, which prevents nonuniform melting and void formation while maintaining the benefits of multi-material mixing for lowered melting point
Solution Approach 2:
The patent uses particles with higher thermal conductivity as intermediary substances that facilitate heat transfer between the laser source and the ceramic particles. These intermediary particles bridge the thermal conductivity gap between materials with different thermal properties, enabling uniform melting without creating voids or cracks that would increase dielectric loss
2Use of energy by moving object
If absorber particles are added to enhance laser light absorption, then heating efficiency is improved, but thermal conductivity becomes nonuniform causing voids and increased dielectric loss
Solution Approach 1:
The patent applies local quality by distributing particles with different thermal conductivity properties throughout the powder bed in specific concentrations. The absorber particles are strategically present to enhance local heat absorption where needed, while high thermal conductivity particles are distributed to ensure uniform heat propagation, creating a balanced thermal field that prevents void formation
Solution Approach 2:
The patent modifies the thermal conductivity parameter by incorporating particles with higher thermal conductivity than the base material. This parameter change ensures that even though absorber particles create localized heating, the overall thermal field remains uniform, preventing the formation of voids and cracks that would increase dielectric loss
3Strength
If small voids are present in ceramic structure, then mechanical strength is reduced, but dielectric loss tangent increases significantly
Solution Approach 1:
The patent converts the potential harm of thermal conductivity differences into a benefit by using particles with higher thermal conductivity as heat transfer mediators. These particles, which would normally create thermal nonuniformity, are instead utilized to distribute heat evenly throughout the powder bed, eliminating voids and cracks while maintaining the lowered melting point benefits of multi-material composition
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 solution results in ceramic structures with reduced voids and low dielectric loss tangent, enhancing mechanical strength and fabrication precision.
Implementation Method 1
absorber particles exhibiting higher absorptive capacity for light with wavelengths present in the laser light than particles A and particles B
Implementation Method 2
heat from laser irradiation may not be transferred to the particles with the lower conductivity because their thermal conductivities are different
Implementation Method 3
fabrication is performed by irradiation with laser light
Implementation Method 4
The presence of absorber particles in the raw material powder reduces the diffusion of laser light within the powder to achieve locale heating and melting
Data Source
AI summary
A powder, used in an additive manufacturing method in which fabrication is performed by irradiation with laser light, contains particles A of an inorganic compound, particles B of another inorganic compound with a lower thermal conductivity than particles A, and absorber particles exhibiting higher absorptive capacity for light with wavelengths present in the laser light than particles A and particles B. The powder satisfies the following relationships (1) to (4):5.≤W(A);(1)5.≤W(B);(2)60.≤W(A)+W(B);and(3)1.2≤D(A)/D(B)≤400.,(4)wherein D(A) represents the average particle size in μm of particles A, D(B) represents the average particle size in μm of particles B, W(A) represents the mass percent of particles A in % by weight in the powder, and W(B) represents the mass percent of particles B in % by weight.