A Study of Lithography-Based Additive Manufacturing of Ceria Ceramics

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New York State College of Ceramics at Alfred University. Inamori School of Engineering.
Additive manufacturing enables freedom of design and rapid prototyping which are valuable assets in every application and industry. Cerium oxide (ceria) is well-known for applications in various fields, including abrasives, electro ceramics, and medicine, and understanding the working mechanisms of lithography-based manufacturing of ceria will help advance the technology in these fields. This investigation was focused on the effects of modulating process parameters for additive manufacturing of ceria ceramics with a CeraFab 8500, lithography-based 3D printer. A 3 x 3 parametric study was designed with intentions of mapping the effects of process parameter alterations of 3D printed ceria parts. Characteristics such as grain size, porosity, stoichiometry, and density were used to compare printed samples with traditionally processed and sintered ceria. Main parameters varied were powder particle size, solid loading of the photocurable slurry, and sintering temperature, which each having a low, medium, and high value. Ceria powders with a particle size of 0.5 μm and slurry solid loading of 41.5 vol% produced high-density ceramics with complex structures and geometries. A maximum sintered density of 98.3% of theoretical was achieved with no apparent porosity. The optimal sintering temperature was found to be ~ 1450°C and x-ray photoelectron spectroscopy results showed no significant variation of Ce(III) concentration between the printed samples.
Thesis completed in partial fulfillment of the requirements for the degree of Master of Science in Materials Science and Engineering at the Inamori School of Engineering, New York State College of Ceramics at Alfred University
Three-dimensional printing, Cerium oxides, Additive manufacturing