Additive manufacturing of alumina parts by indirect selective laser sintering and post processing

Abstract Innovative powder preparation and post-processing techniques can be employed to obtain high density ceramic parts by means of indirect selective laser sintering. Thermally induced phase separation (TIPS) was used to produce polymer and polymer–ceramic composite particles. The effect of polymer concentration, cooling rate, stirring and alumina particles on polymer and polymer–ceramic composite particles was investigated. Homogeneous spherical alumina–polypropylene (PP) composite powder was synthesized by TIPS for selective laser sintering (SLS). Green Al2O3–PP component parts with a density of 34% could be produced by conventional SLS of the polymer under optimized laser power, scan speed, scan spacing and powder preheating temperature. Various post-processing techniques like pressure infiltration (PI), warm isostatic pressing (WIPing) or a combination of both were applied to increase the green density of the Al2O3–PP SLM parts. Infiltrating the open porosity green SLS parts with a 30 vol% alumina-powder based ethanol suspension allowed to increase the sintered density, i.e. after polymer debinding and pressureless sintering in air at 1600 °C, from 38 to 64% of the theoretical density (TD). WIPing of the SLS and SLS/infiltrated green parts at 135 °C and 64 MPa allowed raising the green density up to 93 and 83% TD and a sintered density up to 89 and 88% TD, respectively.