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<p>Additive manufacturing for dense ceramic applications has faced challenges due to the use of high-organic-content slurries or powder-based feedstocks. To overcome these limitations, a novel approach termed Selective Reaction Hardening (SRH) was developed, employing an alumina slurry comprising 24.8 wt% water, 74.6 wt% alumina, and only 0.58 wt% organic binder for a dense green body. In this process, alumina powder and sodium alginate were used to form a ceramic slurry, while aluminum nitrate-based hardener was applied <i>via</i> inkjet spraying to induce ionic crosslinking at room temperature without thermal curing. This approach enabled the layer-by-layer fabrication of green bodies with enhanced packing density and mechanical integrity. As-printed green bodies achieved a high relative density of approximately 84.0% and exhibited reduced shrinkage rates of 17.9% in the XY direction and 13.5% in the Z direction after sintering. Final sintered parts reached a high theoretical density of 99.0% and demonstrated a high Rockwell hardness of 94.9 HRA. These results demonstrate that the SRH process can significantly simplify post-processing by reducing the time and cost associated with traditional debinding and sintering steps while also improving the final ceramic quality. This research establishes a promising strategy for high-performance ceramic components using additive manufacturing.</p>

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A Novel Approach to High-Density Ceramic 3D Printing Using Selective Reaction Hardening of Alumina Slurry

  • 期刊论文

  • 发表日期：

    2025年11月7日

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  • Yoon Seong Joo,
  • Suk-Hee Park,
  • Jong Wan Ko

摘要

Additive manufacturing for dense ceramic applications has faced challenges due to the use of high-organic-content slurries or powder-based feedstocks. To overcome these limitations, a novel approach termed Selective Reaction Hardening (SRH) was developed, employing an alumina slurry comprising 24.8 wt% water, 74.6 wt% alumina, and only 0.58 wt% organic binder for a dense green body. In this process, alumina powder and sodium alginate were used to form a ceramic slurry, while aluminum nitrate-based hardener was applied via inkjet spraying to induce ionic crosslinking at room temperature without thermal curing. This approach enabled the layer-by-layer fabrication of green bodies with enhanced packing density and mechanical integrity. As-printed green bodies achieved a high relative density of approximately 84.0% and exhibited reduced shrinkage rates of 17.9% in the XY direction and 13.5% in the Z direction after sintering. Final sintered parts reached a high theoretical density of 99.0% and demonstrated a high Rockwell hardness of 94.9 HRA. These results demonstrate that the SRH process can significantly simplify post-processing by reducing the time and cost associated with traditional debinding and sintering steps while also improving the final ceramic quality. This research establishes a promising strategy for high-performance ceramic components using additive manufacturing.