Aqueous-based freeze-form extrusion fabrication of alumina components

Purpose - The purpose of this paper is to develop an inexpensive and environmentally friendly solid freeform fabrication technique, called the freeze-form extrusion fabrication (FEF), and use this technique in advanced ceramic fabrication. Design/methodology/approach - FEF uses a highly loaded aqueous ceramic paste (>= 50 vol.% solids loading) with a small quantity (similar to 2 vol.%) of organic binder to fabricate a ceramic green part layer by layer with a computer-controlled 3D gantry machine at a temperature below the freezing point of the paste. Further, a freeze-drying technique is used for preventing deformation and the formation of cracks during the green part drying process. Following the freeze-drying, the ceramic green part undergoes binder removal and is sintered to near full density. Findings - Extrudable, alumina pastes of high solids loading and process parameters for FEF processing of these pastes have been developed. Paste theological properties and stability, extrusion rate, 3D gantry motion speed and other process parameters strongly affect the quality of the final ceramic parts. The minimum deposition angle, which reflects the maximum amount of extrusion offset to produce components with overhanging features without using support materials, is strongly related to the fabrication (environment) temperature. The lower the fabrication temperature, the lower the minimum deposition angle that could be achieved. Four point bending flexure strengths of the FEF processed Al2O3 test samples were 219 and 198 MPa for longitudinally deposited and transversely deposited samples, respectively. Major defects, which limited the strength of the materials, were due to under-filling during the extrusion. Originality/value - Successful development of the FEF technique will introduce a new approach to manufacturing ceramic materials into useful, complex shapes and components. The significant advantages of this technique include the use of environmentally friendly processing medium (water), inexpensive method of medium removal (freeze-drying), and a much smaller quantity of organic binder to remove by pyrolysis techniques. The products can be sintered to near full density.