Stereolithography (SL) is a process that uses photosensitive polymer solutions to create 3D parts in a layer by layer approach. Sandia National Labs is interested in using SL for the printing of ceramic loaded resins, namely alumina, that we are formulating here at the labs. One of the most important aspects for SL printing of ceramics is the properties of the slurry itself. The work presented here will focus on the use of a novel commercially available low viscosity resin provided by Colorado Photopolymer Solutions, CPS 2030, and a Hypermer KD1 dispersant from Croda. Two types of a commercially available alumina powder, Almatis A16 SG and Almatis A15 SG, are compared to determine the effects that the size and the distribution of the powder have on the loading of the solution using rheology. The choice of a low viscosity resin allows for a high particle loading, which is necessary for the printing of high density parts using a commercial SL printer. The Krieger-Dougherty equation was used to evaluate the maximum particle loading for the system. This study found that a bimodal distribution of micron sized powder (A15 SG) reduced the shear thickening effects caused by hydroclusters, and allows for the highest alumina powder loading. A final sintered density of 90% of the theoretical density of alumina was achieved based on the optimized formulation and printing conditions.
Additive Manufacturing (AM) can create novel and complex engineered material structures. Features such as controlled porosity, micro-fibers and/or nano-particles, transitions in materials and integral robust coatings can be important in developing solutions for fusion subcomponents. A realistic understanding of this capability would be particularly valuable in identifying development paths. Major concerns for using AM processes with lasers or electron beams that melt powder to make refractory parts are the power required and residual stresses arising in fabrication. A related issue is the required combination of lasers or e-beams to continue heating of deposited material (to reduce stresses) and to deposit new material at a reasonable built rate while providing adequate surface finish and resolution for meso-scale features. Some Direct Write processes that can make suitable preforms and be cured to an acceptable density may offer another approach for PFCs.
Processing of the low workability Fe-Co-1.5V (Hiperco ® equivalent) alloy is demonstrated using the Laser Engineered Net Shaping (LENS) metals additive manufacturing technique. As an innovative and highly localized solidification process, LENS is shown to overcome workability issues that arise during conventional thermomechanical processing, enabling the production of bulk, near net-shape forms of the Fe-Co alloy. Bulk LENS structures appeared to be ductile with no significant macroscopic defects. Atomic ordering was evaluated and significantly reduced in as-built LENS specimens relative to an annealed condition, tailorable through selection of processing parameters. Fine equiaxed grain structures were observed in as-built specimens following solidification, which then evolved toward a highly heterogeneous bimodal grain structure after annealing. The microstructure evolution in Fe-Co is discussed in the context of classical solidification theory and selective grain boundary pinning processes. Magnetic properties were also assessed and shown to fall within the extremes of conventionally processed Hiperco ® alloys. Hiperco ® is a registered trademark of Carpenter Technologies, Readings, PA.