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.

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

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

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