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Selective laser reaction synthesis of SiC, Si3N4 and HfC/SiC composites for additive manufacturing.

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Title: Selective laser reaction synthesis of SiC, Si3N4 and HfC/SiC composites for additive manufacturing.
Authors: Peters, Adam B.1 (AUTHOR) apeter57@alumni.jh.edu, Zhang, Dajie1,2 (AUTHOR), Hernandez, Alberto1 (AUTHOR), Wang, Chuhong1 (AUTHOR), Nagle, Dennis C.1,2 (AUTHOR), Mueller, Tim1 (AUTHOR), Spicer, James B.1,2 (AUTHOR)
Source: Journal of the European Ceramic Society. Apr2023, Vol. 43 Issue 4, p1270-1283. 14p.
Subjects: Ceramics, Selective laser sintering, Metal powders, Manufacturing processes, Vapor pressure, Chemical precursors
Abstract: Selective laser reaction sintering techniques (SLRS) techniques were investigated for the production of near net-shape non-oxide ceramics including SiC, Si 3 N 4 , and HfC/SiC composites that might be compatible with prevailing powder bed fusion additive manufacturing processes. Reaction bonded layers of covalent ceramics were produced using in-situ reactions that occur during selective laser processing and layer formation. During SLRS, precursor materials composed of metal and/or metal oxide powders were fashioned into powder beds for conversion to non-oxide ceramic layers. Laser-processing was used to initiate simultaneous chemical conversion and local interparticle bonding of precursor particles in 100 vol% CH 4 or NH 3 gases. Several factors related to the reaction synthesis process—precursor chemistry, gas-solid and gas-liquid synthesis mechanisms, precursor vapor pressures—were investigated in relation to resulting microstructures and non-oxide yields. Results indicated that the volumetric changes which occurred during in-situ conversion of single component precursors negatively impacted the surface layer microstructure. To circumvent the internal stresses and cracking that accompanied the conversion of Si or Hf (that expands upon conversion) or SiO x (that contracts during conversion), optimized ratios of the precursor constituents were used to produce near isovolumetric conversion to the product phase. Phase characterization indicated that precipitation of SiC from the Si/SiO 2 melt formed continuous, crack-free, and dense layers of 93.7 wt% SiC that were approximately 35 µm thick , while sintered HfC/SiC composites (84.2 wt% yield) were produced from the laser-processing of Hf/SiO 2 in CH 4. By contrast, the SLRS of Si/SiO x precursor materials used to produce Si 3 N 4 resulted in whisker formation and materials vaporization due to the high temperatures required for conversion. The results demonstrate that under appropriate processing conditions and precursor selection, the formation of near net-shape SiC and SiC composites might be achieved through single-step AM-compatible techniques. [Display omitted] [ABSTRACT FROM AUTHOR]
Copyright of Journal of the European Ceramic Society is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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DbLabel: Engineering Source
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  Data: Selective laser reaction synthesis of SiC, Si3N4 and HfC/SiC composites for additive manufacturing.
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  Data: <searchLink fieldCode="AR" term="%22Peters%2C+Adam+B%2E%22">Peters, Adam B.</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> apeter57@alumni.jh.edu</i><br /><searchLink fieldCode="AR" term="%22Zhang%2C+Dajie%22">Zhang, Dajie</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Hernandez%2C+Alberto%22">Hernandez, Alberto</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wang%2C+Chuhong%22">Wang, Chuhong</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Nagle%2C+Dennis+C%2E%22">Nagle, Dennis C.</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Mueller%2C+Tim%22">Mueller, Tim</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Spicer%2C+James+B%2E%22">Spicer, James B.</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Journal+of+the+European+Ceramic+Society%22">Journal of the European Ceramic Society</searchLink>. Apr2023, Vol. 43 Issue 4, p1270-1283. 14p.
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  Data: <searchLink fieldCode="DE" term="%22Ceramics%22">Ceramics</searchLink><br /><searchLink fieldCode="DE" term="%22Selective+laser+sintering%22">Selective laser sintering</searchLink><br /><searchLink fieldCode="DE" term="%22Metal+powders%22">Metal powders</searchLink><br /><searchLink fieldCode="DE" term="%22Manufacturing+processes%22">Manufacturing processes</searchLink><br /><searchLink fieldCode="DE" term="%22Vapor+pressure%22">Vapor pressure</searchLink><br /><searchLink fieldCode="DE" term="%22Chemical+precursors%22">Chemical precursors</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Selective laser reaction sintering techniques (SLRS) techniques were investigated for the production of near net-shape non-oxide ceramics including SiC, Si 3 N 4 , and HfC/SiC composites that might be compatible with prevailing powder bed fusion additive manufacturing processes. Reaction bonded layers of covalent ceramics were produced using in-situ reactions that occur during selective laser processing and layer formation. During SLRS, precursor materials composed of metal and/or metal oxide powders were fashioned into powder beds for conversion to non-oxide ceramic layers. Laser-processing was used to initiate simultaneous chemical conversion and local interparticle bonding of precursor particles in 100 vol% CH 4 or NH 3 gases. Several factors related to the reaction synthesis process—precursor chemistry, gas-solid and gas-liquid synthesis mechanisms, precursor vapor pressures—were investigated in relation to resulting microstructures and non-oxide yields. Results indicated that the volumetric changes which occurred during in-situ conversion of single component precursors negatively impacted the surface layer microstructure. To circumvent the internal stresses and cracking that accompanied the conversion of Si or Hf (that expands upon conversion) or SiO x (that contracts during conversion), optimized ratios of the precursor constituents were used to produce near isovolumetric conversion to the product phase. Phase characterization indicated that precipitation of SiC from the Si/SiO 2 melt formed continuous, crack-free, and dense layers of 93.7 wt% SiC that were approximately 35 µm thick , while sintered HfC/SiC composites (84.2 wt% yield) were produced from the laser-processing of Hf/SiO 2 in CH 4. By contrast, the SLRS of Si/SiO x precursor materials used to produce Si 3 N 4 resulted in whisker formation and materials vaporization due to the high temperatures required for conversion. The results demonstrate that under appropriate processing conditions and precursor selection, the formation of near net-shape SiC and SiC composites might be achieved through single-step AM-compatible techniques. [Display omitted] [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Journal of the European Ceramic Society is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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RecordInfo BibRecord:
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      – Type: doi
        Value: 10.1016/j.jeurceramsoc.2022.11.015
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      – Code: eng
        Text: English
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      Pagination:
        PageCount: 14
        StartPage: 1270
    Subjects:
      – SubjectFull: Ceramics
        Type: general
      – SubjectFull: Selective laser sintering
        Type: general
      – SubjectFull: Metal powders
        Type: general
      – SubjectFull: Manufacturing processes
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      – SubjectFull: Vapor pressure
        Type: general
      – SubjectFull: Chemical precursors
        Type: general
    Titles:
      – TitleFull: Selective laser reaction synthesis of SiC, Si3N4 and HfC/SiC composites for additive manufacturing.
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            – D: 01
              M: 04
              Text: Apr2023
              Type: published
              Y: 2023
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