Fabrication of SiC ceramic architectures using stereolithography combined with precursor infiltration and pyrolysis

Additive Manufacturing (AM) is the significantly progressing field in terms of methods, materials, and performance of fabricated parts. Periodical evaluation on the understanding of AM processes and its evolution is needed since the field is growing rapidly. To address this requirement, this paper presents a detailed review of the Additive Manufacturing (AM) methods, materials used, and challenges associated with them. A critical review of the state of art materials in the categories such as metals and alloys, polymers, ceramics, and biomaterials are presented along with their applications, benefits, and the problems associated with the formation of microstructures, mechanical properties, and controlling process parameters. The perspectives and the status of different materials on the fabrication of thin-walled structures using AM techniques have also been discussed. Additionally, the main challenges with AM techniques such as inaccuracy, surface quality, reinforcement distribution, and other common problems identified from the literature are presented. On the whole, this paper provides a comprehensive outlook on AM techniques, challenges, and future research directions.

Methods and materials for additive manufacturing: A critical review on advancements and challenges

Silicon carbide (SiC) ceramic and related materials are widely used in various military and engineering fields. The emergence of additive manufacturing (AM) technologies provides a new approach for the fabrication of SiC ceramic products. This article systematically reviews the additive manufacturing technologies of SiC ceramic developed in recent years, including Indirect Additive Manufacturing (Indirect AM) and Direct Additive Manufacturing (Direct AM) technologies. This review also summarizes the key scientific and technological challenges for the additive manufacturing of SiC ceramic, and also forecasts its possible future opportunities. This paper aims to provide a helpful guidance for the additive manufacturing of SiC ceramic and other structural ceramics.

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Progress and challenges towards additive manufacturing of SiC ceramic

Three-dimensional (3D) printing technology is becoming a promising method for fabricating highly complex ceramics owing to the arbitrary design and the infinite combination of materials Insufficient density is one of the main problems with 3D printed ceramics, but concentrated descriptions of making dense ceramics are scarce This review specifically introduces the principles of the four 3D printing technologies and focuses on the parameters of each technology that affect the densification of 3D printed ceramics, such as the performance of raw materials and the interaction between energy and materials The technical challenges and suggestions about how to achieve higher ceramic density are presented subsequently The goal of the presented work is to comprehend the roles of critical parameters in the subsequent 3D printing process to prepare dense ceramics that can meet the practical applications

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Dense ceramics with complex shape fabricated by 3D printing: A review

A heat shield called the thermal protection system (TPS) is an important structure in hypersonic vehicles as it prevents hot air from entering vehicles and potential impacts from space debris. With the increase in demand for low-cost reusable launch vehicles as well as for searching and exploration of new planets in both unmanned and manned missions, the need for developing an effective TPS has increased across many countries. The structural design of TPSs has become more prominent in the early stage of hypersonic vehicle development. Sandwich structures that have the advantages of low density and high performance are integrated into the structural design of an effective TPS. This paper provides a comprehensive review of recent research efforts on sandwich structures for TPSs. The topics discussed in this paper include aspects of structural and material design, mechanical and thermomechanical performances, and manufacturing methods. In particular, we review and discuss the structural design as well as the material design of sandwich structures for different TPS types with various configurations, including corrugated cores, lattice cores, multilayer cores, foams, honeycomb cores, bio-inspired cores. The materials used for the sandwich structures, such as various types of laminated composite, ceramic matrix composite, and metals, are included. We also discuss the performance of the TPS sandwich structures in terms of temperature gradients, deformation limits, and mechanical strengths and provide a discussion on the manufacturing methods of TPS sandwich structures for hypersonic vehicles. Finally, further research directions and challenges of sandwich structures for TPSs are presented.

Advanced sandwich structures for thermal protection systems in hypersonic vehicles: A review

The fabrication and mechanical properties of SiC/SiC composites prepared by SLS combined with PIP

High-temperature flexural strength of SiC ceramics prepared by additive manufacturing

Fabrication process and mechanical properties of C/SiC corrugated core sandwich panel

The invention discloses a preparation method for a 3D forming SiCp/Al complex structure, relates to the preparation method for the SiCp/Al complex structure (a lattice structure), in particular to a method for preparing the SiCp/Al lattice structure through a 3D forming technology and aims to solve the problem that a traditional machining method cannot be used for manufacturing the SiCp/Al complexstructure. The preparation method comprises the steps that firstly, mixed powder is prepared; secondly, parameters are set; thirdly, prefabricated members are prepared; fourthly, thermocuring is carried out; fifthly, adhesive impregnation is carried out; sixthly, degreasing is carried out; and seventhly, the SiCp/Al complex structure is obtained through sintering. The preparation method has the beneficial effects that an SLS forming machine is used, a laser sintering technology is selected for 3D forming, a mold is not needed, digitalized forming of the complex structure SiCp/Al prefabricatedmember is achieved, secondary processing forming of the SiCp/Al composite is avoided, and the problem that the SiCp/Al complex structure is difficult to form is solved. The preparation method is mainly used for preparing the SiCp/Al complex structure.

Preparation method for 3D forming SiCp/Al complex structure

The invention discloses a preparation method of a SiCf/SiC ceramic composite material through 3D moulding, relates to a preparation method of a SiCf/SiC ceramic composite material, and aims to solve the problem that in the prior art, a SiCf/SiC ceramic member is difficult to mould and process. The method comprises following steps: step one, mixing powder; step two, setting parameters; step three,preparing a ceramic blank; step four, curing; step five, sintering; step six, impregnating and cracking; and step seven, repeating the step six until the weight gain is less than 1% during the cracking process to obtain the SiCf/SiC ceramic composite material. The method has the advantages that (1) the problems of large porosity and bad mechanical properties of ceramic prepared by an SLS technology are solved; and (2) the technology is simple and stable, the preparation time is short, and the repeatability is good. The method is mainly used to prepare the SiCf/SiC ceramic composite material through 3D moulding.

Jin Laizhen

Papers

The fabrication and mechanical properties of SiC/SiC composites prepared by SLS combined with PIP

High-temperature flexural strength of SiC ceramics prepared by additive manufacturing

Fabrication process and mechanical properties of C/SiC corrugated core sandwich panel

Preparation method for 3D forming SiCp/Al complex structure

Preparation method of SiCf/SiC ceramic composite material through 3D moulding