Selective Laser Flash Sintering of Ceramics
Traditional additive manufacturing (AM) of ceramic parts is performed using indirect processes that require a polymeric binder to fuse ceramic powder particles layer by layer. Post processing consists of pyrolysis of the polymeric binder before sintering the parts to full density. The pyrolysis step can be extremely slow and and challenging for the production of large ceramic parts. Direct AM of ceramic parts without polymer binder has been attempted but is challenging because of the slow sintering kinetics, high melting temperatures, high Young’s modulus and poor fracture toughnesses of ceramics that leads to cracking.
Selective laser flash sintering (SLFS) is a recently invented process that utilizes a scanning laser combined with an electric field that lower the required temperatures and speeds the sintering kinetics significantly so that direct laser sintering may be possible. We are conducting research to understand the mechanisms that control SLFS.
Faculty Members
• Desiderio Kovar
• Joseph J. Beaman
Current Graduate Student Researchers
• Christina Nissen
• David Kahan
• Joey Zamora
• Kaya Bayazitoglu
This work is supported by the National Center for Defense Manufacturing and Machining through a grant from the Air Force Research Laboratory and Los Alamos National Laboratory.
Publications
K.J. Bayazitoglu, M. Cassoli, J.J. Beaman, and D. Kovar, “Spreading and Packing of Alumina Powder Using a Displacement-controlled Roller in SLFS,” Proceedings of the 34th Annual International Solid Freeform Fabrication Symposium, August 14-16, 2023. weblink
L.G. Matto, D. Hagen, J.J. Beaman, and Kovar, “The Onset of Selective Laser Flash Sintering in Undoped and Doped Lanthanum Chromite,” International Journal of Ceramic Engineering and Science, 5 [6] e10189 (16 pages), 2023. DOI: 10.1002/ces2.10189
D. Hagen, D., J.J. Beaman, and D. Kovar, “Mechanisms Responsible for the Onset of Selective Laser Flash Sintering of 8-YSZ, Journal of the American Ceramic Society, 106 [8] 4592-4604 (2023). DOI: 10.1111/jace.19138
D. Hagen, J.J. Beaman, and D. Kovar, “Effects of Inter-Particle Neck Development on the Initiation of Selective Laser Flash Sintering of 8-YSZ," Journal of the American Ceramic Society, 105 [10] 6023-6040 (2022). DOI: 10.1111/jace.18574
A. Gouws, D. Hagen, A. Chen, E. Kardoulaki, J.J. Beaman, and D. Kovar, “Onset of Selective Laser Flash Sintering of AlN, International Journal of Applied Ceramic Technology, 18 [6]1988-1998 (2021). DOI: 10.1111/ijac.13840
J.J. Beaman, D.B. Bourell, D. Kovar, D. Hagen, “Systems and Methods for Additive Manufacturing of Ceramics”, US Patent 10,611,694, April 7, 2020.
D. Hagen, J.J. Beaman, and D. Kovar, “Laser Flash Sintering of YSZ,” Journal of the American Ceramic Society, 103 [2] 800-808 (2020) DOI: 10.1111/jace.16771.
D. Hagen, A. Chen, J. Beaman, and D. Kovar, "Moisture Effects on Selective Laser Flash Sintering of Yttria-Stabilized Zirconia," Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium, pp 873-891, 2019. Link
D. Hagen, D. Kovar, J. Beaman, M. Gammage, “Laser Flash Sintering for Additive Manufacturing of Ceramics,” ARL-TR-8657, March 2019.
D. Hagen, D. Kovar and J.J. Beaman, “Effects of Electric Field on Selective Laser Sintering of Nano-Scale Ceramic Powder,” in Proceedings of the 29st Annual SFF Symposium, pp 909-915, 2018. Link