Method for manufacturing silicon carbide ceramic special-shaped part with complex shape by plastic fused deposition modeling (FDM)-3D printing based on water debinding

Patent metadata

Field	Value
Publication number	US-12403625-B1
Application number	US-202519027370-A
Country	US
Kind code	B1
Filing date	Jan 17, 2025
Priority date	Nov 19, 2024
Publication date	Sep 2, 2025
Grant date	Sep 2, 2025

Abstract

Disclosed is a method for manufacturing a silicon carbide ceramic special-shaped part with a complex shape by plastic fused deposition modeling (FDM)-3D printing based on water debinding. The method includes: mixing graphite, carbon black, silicon carbide, and a surface modifier, and subjecting a resulting mixture to modification to obtain a surface modifier-coated composite ceramic powder; subjecting the surface modifier-coated composite ceramic powder with a macromolecular binder to internal mixing with an internal mixer to obtain a ceramic 3D printing feed; and subjecting the ceramic 3D printing feed to 3D printing, debinding, and reaction sintering in sequence to obtain the silicon carbide ceramic special-shaped part with the complex shape.

First claim

What is claimed is:

1. A method for manufacturing a silicon carbide ceramic part by plastic fused deposition modeling (FDM)-3D printing based on water debinding, comprising:
mixing graphite, carbon black, silicon carbide, and a surface modifier, and subjecting a resulting mixture to modification to obtain a surface modifier-coated composite ceramic powder;
subjecting the surface modifier-coated composite ceramic powder, a macromolecular binder and a water-soluble binder to internal mixing, and then subjecting a resulting mixed material to crushing or granulation to obtain a ceramic 3D printing feed, wherein the macromolecular binder comprises a high-strength engineering plastic, a high-toughness engineering plastic, and a thermoplastic elastomer, and the water-soluble binder comprises a polyethylene glycol (PEG); the high-strength engineering plastic has a bending strength greater than or equal to 50 MPa, the high-toughness engineering plastic has a fracture toughness greater than or equal to 50 MPa·m 1/2 , and the PEG comprises a high-molecular-weight PEG and a low-molecular-weight PEG; and the low-molecular-weight PEG has a weight-average molecular weight less than or equal to 1,000, and the high-molecular-weight PEG has a weight-average molecular weight greater than 1,000; and
subjecting the ceramic 3D printing feed to FDM-3D printing, water debinding, and reaction sintering in sequence to obtain the silicon carbide ceramic part.

2. The method of claim 1 , wherein a mass ratio of the graphite, the carbon black, and the silicon carbide is in a range of (5-7):(1-2): 100.

3. The method of claim 1 , wherein the surface modifier comprises one or more selected from the group consisting of a fatty acid surface modifier, and a coupling agent surface modifier; the fatty acid surface modifier comprises one or more selected from the group consisting of stearic acid, oleic acid, and dodecyl stearic acid; and the coupling agent surface modifier comprises one or more selected from the group consisting of a silane coupling agent, a titanate coupling agent, and an aluminate coupling agent; and
a ratio of a mass of the surface modifier to a total mass of the graphite, the carbon black, and the silicon carbide is in a range of 0.5:100 to 3:100.

4. The method of claim 1 , wherein the modification is conducted under a condition of ball milling, and the ball milling is conducted by wet ball milling; and
the ball milling is conducted at a rotate speed of 500 rpm to 700 rpm with alcohol as a medium under a ball-to-material mass ratio of 2:1 to 3:1 for 12 h to 24 h, and the ball milling is conducted by using a zirconium oxide microbead as a grinding ball.

5. The method of claim 1 , wherein a ratio of a mass of the surface modifier-coated composite ceramic powder to a total mass of the macromolecular binder and the water-soluble binder is in a range of 4.6:1 to 8:1; and a mass ratio of the high-strength engineering plastic, the high-toughness engineering plastic, the PEG, and the thermoplastic elastomer is in a range of (15-20):(15-20):(50-60):(5-10).

6. The method of claim 1 , wherein the high-molecular-weight PEG comprises one or more selected from the group consisting of PEG2000 and PEG6000; and the low-molecular-weight PEG comprises one or more selected from the group consisting of PEG500 and PEG800; and
a mass ratio of the low-molecular-weight PEG to the high-molecular-weight PEG is in a range of 1:1 to 4:1.

7. The method of claim 1 , wherein the internal mixing is conducted in an internal mixer at a temperature of 170° C. to 190° C. for 1 h to 2 h.

8. The method of claim 1 , wherein the FDM-3D printing is conducted by a precision screw extrusion FDM printer; and
the FDM-3D printing is conducted under the following conditions: an extrusion pressure being 10 MPa to 40 MPa, and temperatures from a feed port to a nozzle of the screw extrusion FDM printer being 160° C., 170° C., 180° C., and 190° C. in sequence.

9. The method of claim 1 , wherein the water debinding is conducted at a temperature of 40° C. to 60° C. for 72 h to 120 h.

10. The method of claim 1 , wherein the reaction sintering is conducted at a temperature of 2,100° C. to 2,250° C. under a vacuum degree less than or equal to 10 Pa, and the reaction sintering is held at the temperature for 3 h to 7 h.

11. The method of claim 5 , wherein the high-molecular-weight PEG comprises one or more selected from the group consisting of PEG2000 and PEG6000; and the low-molecular-weight PEG comprises one or more selected from the group consisting of PEG500 and PEG800; and
a mass ratio of the low-molecular-weight PEG to the high-molecular-weight PEG is in a range of 1:1 to 4:1.

12. The method of claim 5 , wherein the internal mixing is conducted in an internal mixer at a temperature of 170° C. to 190° C. for 1 h to 2 h.

Assignees

• Univ Dongguan Technology

Inventors

• Liu Wei
• Luo Muqi
• Zeng Qi
• Hou Geng

Classifications

• C04B2111/00181

  Mixtures specially adapted for three-dimensional printing (3DP), stereo-lithography or prototyping · CPC title

• C04B38/0645

  Burnable, meltable, sublimable materials · CPC title

• C04B35/565 Primary

  based on silicon carbide · CPC title

• C04B35/6261

  Milling · CPC title

• C04B2235/6581

  Total pressure below 1 atmosphere, e.g. vacuum · CPC title