Abstract:
In order to improve the efficiency of precision casting and shorten the manufacturing cycle of ceramic molds, Al2O3, ZrO2 and MgO molds suitable for casting special material parts were prepared by digital light processing (DLP) 3D printing technology based on surface exposure. The ceramic slurry mixed with photosensitive resin and nano-scale ceramic powder was cured by ultraviolet light to form a ceramic green body. After drying, degreasing and sintering, the required ceramic sample was obtained. The process of DLP 3D printing ceramics includes ceramic slurry preparation, 3D modeling, model slicing, 3D printing green body, green body degreasing and sintering. The DLP ceramic slurry is composed of nano-ceramic powder and organic resin, in which the organic resin is composed of monomer, oligomer, photoinitiator, dispersant and defoaming agent. The monomer is 1,6-hexanediol diacrylate (HDDA), and the additive amount is 47.5% of the powder mass. The oligomer is aliphatic polyacrylate (E8210), the additive amount is 47.5% of the powder mass, the photoinitiator is TPO, and the dispersant is BYK11. The microstructure of the ceramics before and after sintering was characterized by SEM, and the mechanical properties (compression and bending) and thermal shock resistance of the 3D printing ceramic samples were tested. Al
2O
3, ZrO
2 and MgO ceramic bodies were prepared by using 50% (volume fraction) ceramic slurry with light intensity of 25-32 mW/cm
2, exposure time of 2-10 s and layer thickness of 30 μm. The microstructure of Al
2O
3, ZrO
2 and MgO ceramic bodies is changed from porous to dense by heating in stages. Compared with the printed green bodies, the shrinkage rate of ceramic sintered body in three directions is in the range of 20%-23%. The compression strength and bending strength of photocured 3D printing ceramics can reach the level of isostatic pressing process, among which 3D printing ZrO
2 ceramics have the highest strength. After the thermal shock resistance test, the three kinds of photocured 3D printing ceramics have more than 15 thermal shocks at 800 ℃, among which ZrO
2 ceramics have the best thermal shock resistance at 800 ℃ and 1 300 ℃. The results show that the microstructure of the ceramic green body becomes densified from porous structure after sintering at appropriate temperature. Through the thermal shock resistance test, DLP 3D printing ceramics show good thermal shock resistance. DLP 3D printing technology shows great advantages in the preparation of ceramic components with complex structures and functions, which can greatly reduce the manufacturing cycle and cost, and provide important technical support for the manufacture of high-precision products in the field of nuclear energy.