Properties of SiC-Si made via binder jet 3D printing of SiC powder, carbon addition, and silicon melt infiltration
Corresponding Author
Corson L. Cramer
Manufacuting Science Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Correspondence
Corson L. Cramer, Manufacuting Science Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA.
Email: [email protected]
Search for more papers by this authorAmy M. Elliott
Manufacuting Science Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorEdgar Lara-Curzio
Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorAlexis Flores-Betancourt
Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorMichael J. Lance
Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorLu Han
Chemical Sciences Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorArtem A. Trofimov
Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorHsin Wang
Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorErcan Cakmak
Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorKashif Nawaz
Buildings and Transportation Science Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorCorresponding Author
Corson L. Cramer
Manufacuting Science Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Correspondence
Corson L. Cramer, Manufacuting Science Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA.
Email: [email protected]
Search for more papers by this authorAmy M. Elliott
Manufacuting Science Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorEdgar Lara-Curzio
Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorAlexis Flores-Betancourt
Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorMichael J. Lance
Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorLu Han
Chemical Sciences Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorArtem A. Trofimov
Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorHsin Wang
Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorErcan Cakmak
Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorKashif Nawaz
Buildings and Transportation Science Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA
Search for more papers by this authorAbstract
We report the physical and mechanical properties of ceramic composite materials fabricated by binder jet 3D printing (BJ3DP) with silicon carbide (SiC) powders, followed by phenolic resin infiltration and pyrolysis (IP) to generate carbon, and a final reactive silicon melt infiltration step. After two phenolic resin infiltration and pyrolysis cycles; porosity was less than 2%, Young's modulus was close to 300 GPa, and the flexural strength was 517.6 ± 24.8 MPa. However, diminishing returns were obtained after more than two phenolic resin infiltration and pyrolysis cycles as surface pores in carbon were closed upon the formation of SiC, resulting in reaction choking and residual-free carbon and porosity. The instantaneous coefficient of thermal expansion of the composite was found to be independent of the number of phenolic IP cycles and had values of between 4.2 and 5.0 ppm/°C between 300 and 1000℃, whereas the thermal conductivity was found to have a weak dependence on the number of phenolic IP cycles. While the manufacturing procedures described here yielded highly dense, gas impermeable, siliconized SiC composites with properties comparable to those of bulk siliconized silicon carbide processed according to conventional techniques, BJ3DP enables the manufacture of objects with complex shape, unlike conventional techniques.
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