SFA-AM - Strategic Focus Area Advanced Manufacturing
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FUORCLAM

Fundamental Understanding of Oxide Refractory Ceramics and
Laser Additive Manufacturing
Selective laser sintering (SLS) and selective laser melting (SLM) is already getting a mature technology in metals and polymer processing. In contrary, in high tech ceramics based materials there is no existing SLS process available to consolidate, either by solid state or by liquid state sintering processes, ceramic powders to dense structures with convenient materials properties. The consortium will study the laser interaction of oxide based starting materials and the effect of composite granule composition and morphology on the absorption behaviour of pulsed lasers. The new SLM process will offer the opportunity to create ceramic gradient structures with defined porosities and possible applications as implant materials or as machine parts, where the formation of intimate contacts between metal and ceramic parts is still an issue.
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Scope of Research Activities
  • Flame spray synthesis of doped nano-alumina (n-Al2O3)
  • Manufacturing of alumina granules (Al2O3) by spray drying
  • Design of Al2O3-n-Al2O3 granule structures
  • Laser processing (SLM) of alumina powders
  • Creation of gradient and dense structures
  • Characterization of alumina powders and produced samples
  • In situ solidification experiments

Key Technical Problems to Solve
  • Laser light / ceramic absorption behaviour
  • Powder flowability and bed packing density
  • Process design for one step sintering approach
  • Thermal stresses leading to cracks during processing

Demonstrators
  • 5 mm cube with high density
  • Parts with locally graded densities
  • Dental implants

Linked Scientific Publications

2022
  • Pfeiffer, S., K. Florio, M. Makowska, F. Marone, S. Yüzbasi, C. G. Aneziris, H. Van Swygenhoven, K. Wegener and T. Graule (2022). "Crack-reduced alumina/aluminum titanate composites additive manufactured by laser powder bed fusion of black TiO2−x doped alumina granules." Journal of the European Ceramic Society 42(8): 3515-3529.

2021
  • Florio, K., D. Puccio, G. Viganò, S. Pfeiffer, F. Verga, M. Grasso, B. M. Colosimo, T. Graule and K. Wegener (2021). "Process characterization and analysis of ceramic powder bed fusion." The International Journal of Advanced Manufacturing Technology 117(7): 2105-2116.
  • Pfeiffer, S., K. Florio, D. Puccio, M. Grasso, B. M. Colosimo, C. G. Aneziris, K. Wegener and T. Graule (2021). "Direct laser additive manufacturing of high performance oxide ceramics: A state-of-the-art review." Journal of the European Ceramic Society 41(13): 6087-6114.
  • Verga, F., M. Makowska, G. Cellerai, K. Florio, M. Schmid and K. Wegener (2021). "Crack-healing, a novel approach for a laser-based powder bed fusion of high-performance ceramic oxides." Additive Manufacturing Letters 1: 100021.

2020
  • Pfeiffer, S., M. Makowska, K. Florio, D. F. Sanchez, F. Marone, X. Zhang, C. G. Aneziris, H. Van Swygenhoven, K. Wegener and T. Graule (2020). "Selective laser melting of thermal pre-treated metal oxide doped aluminum oxide granules." Open Ceramics 2: 100007.
  • Verga, F., M. Borlaf, L. Conti, K. Florio, M. Vetterli, T. Graule, M. Schmid and K. Wegener (2020). "Laser-based powder bed fusion of alumina toughened zirconia." Additive Manufacturing 31: 100959.
  • Zhang, X., S. Pfeiffer, P. Rutkowski, M. Makowska, D. Kata, J. Yang and T. Graule (2020). "Laser cladding of manganese oxide doped aluminum oxide granules on titanium alloy for biomedical applications." Applied Surface Science 520: 146304.

2019
  • Florio, K., S. Pfeiffer, M. Makowska, N. Casati, F. Verga, T. Graule, H. Van Swygenhoven and K. Wegener (2019). "An Innovative Selective Laser Melting Process for Hematite-Doped Aluminum Oxide." Advanced Engineering Materials 21(6): 1801352.
  • Makowska, M., S. Pfeiffer, N. Casati, K. Florio, M. Vetterli, K. Wegener, T. Graule and H. van Swygenhoven (2019). "Pre-processing of hematite-doped alumina granules for Selective Laser Melting." Ceramics International 45(14): 17014-17022.
  • Pfeiffer, S., K. Florio, M. Makowska, D. Ferreira Sanchez, H. Van Swygenhoven, C. G. Aneziris, K. Wegener and T. Graule (2019). "Iron Oxide Doped Spray Dried Aluminum Oxide Granules for Selective Laser Sintering and Melting of Ceramic Parts." Advanced Engineering Materials 21(6): 1801351.
Leading Principal Investigator
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Prof. Dr. Konrad Wegener
Institute of Machine Tools and Manufacturing, ETH Zürich

Project Consortium
  • Prof. Dr. Thomas Graule, Laboratory for High Performance Ceramics, Empa
  • Prof. Dr. Helena Van Swygenhoven, Photons for Engineering and Manufacturing Group, PSI
An initiative of the ETH Board
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Participating Institutions of the ETH Domain
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Disclaimer
Imprint
© COPYRIGHT 2021. ALL RIGHTS RESERVED.
  • Home
  • Focus Areas
    • Focus Areas 2017-2020 >
      • Precision Free-Form Manufacturing
      • Printed Electronics
      • Sustainable Digital Manufacturing and Design
      • Sensing Technologies
      • Intelligent Systems and Advanced Automation
    • Focus Areas 2021-2024 >
      • Manufacturing Technologies
      • Functionality Integration
      • Sensing Technologies
      • Intelligent Systems and Advanced Automation
  • Projects
    • Projects Initial Program 2017-2020 >
      • Ceramic X.0
      • FUORCLAM
      • Powder Focusing
      • PREAMPA
      • FOXIP
      • CFRP-AM
      • SD4D
    • Projects Expansion Program 2017-2020 >
      • D-SENSE
      • MOCONT
      • Nano Assembly
      • SOL4BAT
    • Projects Program 2021-2024 >
      • AMYS
      • ClosedLoop-LM
      • DiPrintProtect
      • MANUFHAPTICS
      • Microfluidics
      • Multi-Mat
      • SCALAR
      • SMARTAM
  • Events
    • Annual Meetings >
      • Annual Review Meeting 2022
      • Annual Review Meeting 2021
      • Annual Review Meeting 2020
      • Annual Review Meeting 2019
      • Annual Review Meeting 2018
    • Industry Workshops >
      • Sensors
    • Other Events >
      • CERAMIC X.0 Workshop
      • Workshop 13 July 2020
      • Launch Event 13 Nov 2017
      • Workshop 6 July 2017
      • Workshop 17 Oct 2016
    • SAMCE
  • About
    • Steering Committee
    • Participating ETH Institutions
    • Calls & Selection >
      • Initial Program 2017-2020
      • Expansion Program 2017-2020
      • Continuation Program 2021-2024
  • Contact