Zirconia Ceramic Powder Composition for Additive Manufacturing
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Solution Overview
Problem
Current powders for additive manufacturing of ceramic objects using zirconium oxide lack sufficient strength, particularly in thermal shock resistance and mechanical strength, limiting the production of high-strength ceramic components.
Innovation Solution
A powder composition for ceramic shaping involving oxide particles with a specific ratio of Zr, Y, Si, and optionally Al, where the content of Zr is converted into ZrO2, Y into Y2O3, and Si into SiO2, with mass percentages within specific ranges, is used in an additive manufacturing method involving laser irradiation, followed by heat treatment to enhance mechanical strength and self-repair of cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If zirconium oxide powder is used for additive manufacturing, then thermal characteristics such as thermal shock resistance and low thermal expansion coefficient are improved, but the strength of the shaped object is insufficient
Solution Approach 1:
The patent uses a composite powder composition containing zirconium oxide (ZrO2), silicon oxide (SiO2), and yttrium oxide (Y2O3) in specific ratios. This composite material approach combines the thermal resistance properties of ZrO2 with the strength-enhancing effects of SiO2 and Y2O3, resolving the contradiction between thermal characteristics and mechanical strength. The specific composition ranges (ZrO2: 77.64-93.06%, SiO2: 0.72-17.29%, Y2O3: 4.42-6.49%) are optimized to achieve both thermal shock resistance and high flexural strength.
Solution Approach 2:
The patent optimizes the compositional parameters of the powder mixture, specifically controlling the mass percentages of ZrO2, SiO2, and Y2O3 within defined ranges. By adjusting these parameters, the material achieves optimal balance between thermal properties and mechanical strength. The specific parameter ranges are designed to ensure both thermal shock resistance and high strength characteristics in the final shaped object.
2Ease of manufacture
If conventional zirconium oxide powder is used, then manufacturing process is simple, but the mechanical strength and thermal shock resistance are insufficient
Solution Approach 1:
The patent employs a composite powder system that maintains ease of additive manufacturing while significantly improving mechanical strength. The multi-component composition (ZrO2, SiO2, Y2O3) is designed to be processed using conventional additive manufacturing techniques, yet produces parts with superior flexural strength and thermal shock resistance compared to pure zirconium oxide.
Solution Approach 2:
By optimizing the compositional parameters within specific ranges, the patent enhances mechanical strength without complicating the manufacturing process. The defined parameter ranges ensure that the material remains suitable for standard additive manufacturing processes while achieving the desired performance improvements in mechanical properties.
3Reliability
If zirconium oxide powder is used, then thermal resistance is maintained, but self-repair capability and flexural strength are insufficient
Solution Approach 1:
The patent creates a composite material system where ZrO2 provides thermal resistance, while SiO2 and Y2O3 contribute to self-repair capability and flexural strength. The synergistic interaction of these components in specific ratios enables the material to simultaneously achieve high thermal resistance and enhanced mechanical properties, including self-repair characteristics.
Solution Approach 2:
The patent incorporates components (SiO2 and Y2O3) that enable self-repair capability in the zirconium oxide matrix. This self-service property allows the material to automatically repair microcracks and defects, thereby enhancing both flexural strength and reliability under thermal conditions without requiring external intervention.
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 achieves a ceramic shaped object with improved mechanical strength, including high three-point flexural strength and self-repairing capabilities, suitable for applications in components requiring thermal resistance and mechanical durability.
Implementation Method 1
irradiating part or a whole of the oxide particles with laser light to melt and solidify the oxide particles at a site irradiated with the laser light
Implementation Method 2
irradiating part or a whole of the oxide particles with laser light to melt and solidify the oxide particles
Implementation Method 3
a heating step of subjecting the intermediate shaped object to heat treatment
Implementation Method 4
subjecting the intermediate shaped object to heat treatment
Data Source
AI summary
Provided is a powder for ceramic shaping including oxide particles, wherein the oxide particles each contain a plurality of kinds of elements including at least Zr, Y, Si, and optionally Al, and contain at least silicon monoxide particles, and wherein when a content of the Zr is converted into a mass of ZrO2, a content of the Y is converted into a mass of Y2O3, a content of the Si is converted into a mass of SiO2, and a content of the Al is converted into a mass of Al2O3, the mass of ZrO2, the mass of Y2O3, and the mass of SiO2 with respect to a total amount of the mass of ZrO2, the mass of Y2O3, the mass of SiO2, and the mass of Al2O3 are represented by α (mass %), β (mass %), and γ (mass %), respectively, α, β, and γ satisfy the following expressions.77.64≤α≤93.064.42≤β≤6.490.72≤γ<¯17.29