Solid Freeforming of Silicon Carbide by Inkjet Printing Using a Polymeric Precursor

Preceramic polymers can be dissolved in solvents to form low-viscosity fluids. This makes them suitable for solid freeforming by direct inkjet printing. Two ways of using polycarbosilane (pcs) were investigated. In the first, it was dissolved in n-heptane at up to 30 vol% and printed as a single-phase material. In the second, it was used as an organic binder for silicon carbide powder suspended in an homologous series of hydrocarbon solvents ranging from n-heptane to n-decane. Polyisobutene succinimide was used as a surfactant. In both cases, components could be rendered successfully but pyrolysis of the unfilled pcs resulted in cracking. Components printed with powder suspensions did not crack on pyrolysis, retained overall near net shape, and underwent low shrinkage (8.2 vol%). The molecular weight of the n-paraffin solvents influenced the viscosity and hence the maximum powder loading while the volatility, a property also related to molecular weight, influenced the quiescence time and the drying time needed between layers. Octane gave the best compromise between speed of printing, the quality and knitting of droplet relics, and the avoidance of nozzle blockage caused by too rapid drying.

[1]  Peter Greil,et al.  Near Net Shape Manufacturing of Polymer Derived Ceramics , 1997 .

[2]  S. Yajima.  Special heat-resisting materials from organometallic polymers , 1983 .

[3]  Julian R. G. Evans,et al.  The properties of a ceramic injection moulding suspension based on a preceramic polymer , 1991 .

[4]  D. Rowcliffe,et al.  Microstructural development in Si sub 3 N sub 4 /polysilazane bodies during heating , 1988 .

[5]  Young‐Wook Kim,et al.  Effect of polycarbosilane addition on mechanical properties of hot-pressed silicon carbide , 1992 .

[6]  D. Seyferth,et al.  Application of poly(methylsilane) and Nicalon® polycarbosilane precursors as binders for metal/ceramic powders in preparation of functionally graded materials , 1997 .

[7]  Michael J. Cima,et al.  New Process and Materials Developments in 3-Dimensional Printing, 3DP ™ , 1998 .

[8]  D. Tsai,et al.  Raising pyrolysis yield of preceramic polymers of silicon carbonitride , 1995 .

[9]  A. Oberlin,et al.  Conversion mechanisms of a polycarbosilane precursor into an SiC-based ceramic material , 1991, Journal of Materials Science.

[10]  V. Beltran,et al.  New method of assessing efflorescence , 1996 .

[11]  C. Pantano,et al.  Synthesis of Silicon Carbide Thin Films with Polycarbosilane (PCS) , 2005 .

[12]  Jean-Pierre Kruth,et al.  Material incress manufacturing by rapid prototyping techniques , 1991 .

[13]  Mamoru Omori,et al.  Synthesis of Continuous Sic Fibers with High Tensile Strength , 1976 .

[14]  Y. Hasegawa,et al.  Synthesis of continuous silicon carbide fibre , 1986 .

[15]  John W. Halloran,et al.  Freeform Fabrication of Ceramics via Stereolithography , 2005 .

[16]  Y. Hasegawa,et al.  Synthesis of continuous silicon carbide fibre , 1983 .

[17]  F. Wallenberger.  Rapid Prototyping Directly from the Vapor Phase , 1995, Science.

[18]  M. Swain,et al.  Preparation of ceramic coatings from pre-ceramic precursors , 1994, Journal of Materials Science.

[19]  John Evans,et al.  The computer aided manufacture of ceramics using multilayer jet printing , 1995 .

[20]  Noshir A. Langrana,et al.  FDC, rapid fabrication of structural components , 1996 .

[21]  David L. Bourell,et al.  Selective laser sintering of metals and ceramics , 1992 .

[22]  C. Blanchard,et al.  The influence of preceramic binders on the microstructural development of silicon nitride , 1994, Journal of Materials Science.

[23]  K. Kikuta,et al.  Processing of silicon carbide ceramics using chemically modified polycarbosilanes , 1999 .

[24]  A. Vrij,et al.  Preparation of sterically stabilized silica dispersions in nonaqueous media , 1981 .

[25]  R. Rice.  Ceramics from polymer pyrolysis, opportunities and needs. A materials perspective , 1983 .

[26]  Solid freeform fabrication of In situ SiC/C thermocouples in macrocomponents , 1999 .

[27]  G. Graff,et al.  Freeform fabrication of ceramics , 1998 .

[28]  John Evans,et al.  Solid freeforming of ceramics using a drop-on-demand jet printer , 1997 .

[29]  T. Ring,et al.  Dispersion of Silicon Carbide Powders in Nonaqueous Solvents , 1989 .

[30]  Michael J. Cima,et al.  Three Dimensional Printing: Rapid Tooling and Prototypes Directly from a CAD Model , 1992 .

[31]  H. Marcus,et al.  Silicon Carbide from Laser Pyrolysis of Polycarbosilane , 1995 .

[32]  Scott McMillin,et al.  Desktop manifacturing : LOM vs pressing , 1994 .

[33]  F. Lange,et al.  Powder Processing Science and Technology for Increased Reliability , 1989 .

[34]  R. Paine,et al.  SOME RECENT DEVELOPMENTS IN PRECURSOR ROUTES TO CERAMIC NANOCOMPOSITES , 1994 .

[35]  M. Mucalo,et al.  Preparation of ceramic coatings from pre-ceramic precursors , 1994, Journal of Materials Science.

[36]  John Evans,et al.  Microengineering of Ceramics by Direct Ink‐Jet Printing , 1999 .

[37]  J. Woodthorpe,et al.  Injection moulding of silicon carbide using an organic vehicle based on a preceramic polymer , 1995 .

[38]  M. Edirisinghe,et al.  Effect of pre-pyrolysis heat treatment on the preparation of silicon carbide from a polycarbosilane precursor , 1999 .

[39]  Spencer E. Taylor,et al.  Dispersion of silicon carbide whiskers and powders in aqueous and non-aqueous media , 1991 .