Complex shaped boron carbides from negative additive manufacturing

Lu, Ryan; Chandrasekaran, Swetha; Du Frane, Wyatt L.; Landingham, Richard L.; Worsley, Marcus A.; Kuntz, Joshua D.

doi:10.1016/j.matdes.2018.03.026

Complex shaped boron carbides from negative additive manufacturing

Journal Article · Tue Mar 13 04:00:00 EDT 2018 · Materials & Design

DOI:https://doi.org/10.1016/j.matdes.2018.03.026· OSTI ID:1438673

^[1]; Chandrasekaran, Swetha ^[1]; ^[1]; Landingham, Richard L. ^[1]; Worsley, Marcus A. ^[1]; Kuntz, Joshua D. ^[1]

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

In this paper, complex shaped boron carbide with carbon (B₄C/C) at near-full densities were achieved for the first time using negative additive manufacturing techniques via gelcasting. Negative additive manufacturing involves 3D printing of sacrificial molds used for casting negative copies. B₄C powder distributions and rheology of suspensions were optimized to successfully cast complex shapes. In addition to demonstrating scalability of these complex geometries, hierarchically meso-porous structures were also shown to be possible from this technique. Resorcinol-Formaldehyde (RF) polymer was selected as the gelling agent and can also pyrolyze into a carbon aerogel network to act as the sintering aid for B₄C. Finally, due to the highly effective distribution of in situ carbon for the B₄C matrix, near-full sintered density of 97–98% of theoretical maximum density was achieved.

View Accepted Manuscript (DOE)

Research Organization:: Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC52-07NA27344

OSTI ID:: 1438673

Alternate ID(s):: OSTI ID: 23089351

Report Number(s):: LLNL-JRNL--748179

Journal Information:: Materials & Design, Journal Name: Materials & Design Vol. 148; ISSN 0264-1275

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (36)

Additive Manufacturing of Ceramic-Based Materials: Additive Manufacturing of Ceramic-Based Materials Travitzky, Nahum; Bonet, Alexander; Dermeik, Benjamin Advanced Engineering Materials, Vol. 16, Issue 6 https://doi.org/10.1002/adem.201400097	journal	April 2014
Preparation and Properties of Resorcinol-Formaldehyde Organic and Carbon Gels Al-Muhtaseb, S. A.; Ritter, J. A. Advanced Materials, Vol. 15, Issue 2, p. 101-114 https://doi.org/10.1002/adma.200390020	journal	January 2003
Prediction of sintered density for bimodal powder mixtures German, R. M. Metallurgical Transactions A, Vol. 23, Issue 5 https://doi.org/10.1007/BF02647329	journal	May 1992
The influence of carbon on the microstructure and mechanical properties of sintered boron carbide Schwetz, K. A.; Grellner, W. Journal of the Less Common Metals, Vol. 82 https://doi.org/10.1016/0022-5088(81)90195-8	journal	November 1981
Stoichiometric limits of carbon-rich boron carbide phases Beauvy, M. Journal of the Less Common Metals, Vol. 90, Issue 2 https://doi.org/10.1016/0022-5088(83)90067-X	journal	April 1983
Boron carbide—A comprehensive review Thévenot, Francois Journal of the European Ceramic Society, Vol. 6, Issue 4 https://doi.org/10.1016/0955-2219(90)90048-K	journal	January 1990
Microstructure and mechanical properties of boron carbide thin films Han, Zenghu; Li, Geyang; Tian, Jiawan Materials Letters, Vol. 57, Issue 4 https://doi.org/10.1016/S0167-577X(02)00892-3	journal	December 2002
Gelcasting, a near net shape technique Gilissen, R.; Erauw, J. P.; Smolders, A. Materials & Design, Vol. 21, Issue 4 https://doi.org/10.1016/S0261-3069(99)00075-8	journal	August 2000
Gelcasting: From laboratory development toward industrial production Omatete, Ogbemi O.; Janney, Mark A.; Nunn, Stephen D. Journal of the European Ceramic Society, Vol. 17, Issue 2-3 https://doi.org/10.1016/S0955-2219(96)00147-1	journal	January 1997
Pressureless sintering of boron carbide Roy, T. K.; Subramanian, C.; Suri, A. K. Ceramics International, Vol. 32, Issue 3 https://doi.org/10.1016/j.ceramint.2005.02.008	journal	January 2006
Gel-cast hierarchical porous B 4 C/C preform and its role in fabricating reaction bonded boron carbide composites Xu, Yufeng; Ru, Hongqiang; Long, Haibo Ceramics International, Vol. 43, Issue 5 https://doi.org/10.1016/j.ceramint.2016.11.193	journal	April 2017
Stabilization of highly-loaded boron carbide aqueous suspensions Diaz-Cano, Andres; Trice, Rodney W.; Youngblood, Jeffrey P. Ceramics International, Vol. 43, Issue 12 https://doi.org/10.1016/j.ceramint.2017.03.111	journal	August 2017
Fabrication of complicated silicon carbide ceramic components using combined 3D printing with gelcasting Chen, Fangjie; Liu, Kai; Sun, Huajun Ceramics International, Vol. 44, Issue 1 https://doi.org/10.1016/j.ceramint.2017.09.166	journal	January 2018
Comparisons of the densification, microstructure and mechanical properties of boron carbide sintered by hot pressing and spark plasma sintering Zhang, Xiaorong; Zhang, Zhixiao; Wen, Ruolin Ceramics International, Vol. 44, Issue 2 https://doi.org/10.1016/j.ceramint.2017.10.230	journal	February 2018
Consolidation of cubic and hexagonal boron nitride composites Du Frane, W. L.; Cervantes, O.; Ellsworth, G. F. Diamond and Related Materials, Vol. 62 https://doi.org/10.1016/j.diamond.2015.12.003	journal	February 2016
Carbonisation of resorcinol–formaldehyde organic xerogels: Effect of temperature, particle size and heating rate on the porosity of carbon xerogels Moreno, A. H.; Arenillas, A.; Calvo, E. G. Journal of Analytical and Applied Pyrolysis, Vol. 100 https://doi.org/10.1016/j.jaap.2012.12.004	journal	March 2013
Tailoring microstructure and properties of bilayer-graded Al/B4C/MgAl2O4 composites by single-stage pressureless infiltration Bahrami, A.; Pech-Canul, M. I.; Soltani, N. Journal of Alloys and Compounds, Vol. 694 https://doi.org/10.1016/j.jallcom.2016.09.284	journal	February 2017
Recent developments in gelcasting of ceramics Yang, Jinlong; Yu, Juanli; Huang, Yong Journal of the European Ceramic Society, Vol. 31, Issue 14 https://doi.org/10.1016/j.jeurceramsoc.2010.12.035	journal	November 2011
Additive manufacturing of boron carbide via continuous filament direct ink writing of aqueous ceramic suspensions Costakis, William J.; Rueschhoff, Lisa M.; Diaz-Cano, Andres I. Journal of the European Ceramic Society, Vol. 36, Issue 14 https://doi.org/10.1016/j.jeurceramsoc.2016.06.002	journal	November 2016
Rapid fabrication of alumina-based ceramic cores for gas turbine blades by stereolithography and gelcasting Wu, Haihua; Li, Dichen; Tang, Yiping Journal of Materials Processing Technology, Vol. 209, Issue 18-19 https://doi.org/10.1016/j.jmatprotec.2009.07.002	journal	September 2009
Additive manufacturing of complex-shaped graded TiC/steel composites Levy, Asaf; Miriyev, Aslan; Elliott, Amy Materials & Design, Vol. 118 https://doi.org/10.1016/j.matdes.2017.01.024	journal	March 2017
Damage-tolerant metallic composites via melt infiltration of additively manufactured preforms Pawlowski, Alexander E.; Cordero, Zachary C.; French, Matthew R. Materials & Design, Vol. 127 https://doi.org/10.1016/j.matdes.2017.04.072	journal	August 2017
Cellular ceramics produced by rapid prototyping and replication Ortona, Alberto; D'Angelo, Claudio; Gianella, Sandro Materials Letters, Vol. 80 https://doi.org/10.1016/j.matlet.2012.04.050	journal	August 2012
Erosion wear of boron carbide ceramic nozzles by abrasive air-jets Jianxin, Deng Materials Science and Engineering: A, Vol. 408, Issue 1-2 https://doi.org/10.1016/j.msea.2005.07.029	journal	November 2005
On the synthesis and structure of resorcinol-formaldehyde polymeric networks – Precursors to 3D-carbon macroassemblies Lewicki, James P.; Fox, Christina A.; Worsley, Marcus A. Polymer, Vol. 69 https://doi.org/10.1016/j.polymer.2015.05.016	journal	July 2015
Design and optimization of a light-emitting diode projection micro-stereolithography three-dimensional manufacturing system Zheng, Xiaoyu; Deotte, Joshua; Alonso, Matthew P. Review of Scientific Instruments, Vol. 83, Issue 12 https://doi.org/10.1063/1.4769050	journal	December 2012
New possibilities using additive manufacturing with materials that are difficult to process and with complex structures Olsson, Anders; Hellsing, Maja S.; Rennie, Adrian R. Physica Scripta, Vol. 92, Issue 5 https://doi.org/10.1088/1402-4896/aa694e	journal	April 2017
Pressureless Sintering of Boron Carbide Lee, Hyukjae; Speyer, Robert F. Journal of the American Ceramic Society, Vol. 86, Issue 9 https://doi.org/10.1111/j.1151-2916.2003.tb03498.x	journal	September 2003
Rapid Prototyping of Piezoelectric Ceramics via Selective Laser Sintering and Gelcasting Guo, Dong; Li, Long-tu; Cai, Kai Journal of the American Ceramic Society, Vol. 87, Issue 1 https://doi.org/10.1111/j.1151-2916.2004.tb19938.x	journal	January 2004
Boron Carbide: Structure, Properties, and Stability under Stress Domnich, Vladislav; Reynaud, Sara; Haber, Richard A. Journal of the American Ceramic Society, Vol. 94, Issue 11 https://doi.org/10.1111/j.1551-2916.2011.04865.x	journal	October 2011
Additive Manufacturing of Ceramics: Issues, Potentialities, and Opportunities Zocca, Andrea; Colombo, Paolo; Gomes, Cynthia M. Journal of the American Ceramic Society, Vol. 98, Issue 7 https://doi.org/10.1111/jace.13700	journal	July 2015
Improved crystallographic data for graphite Howe, J. Y.; Rawn, C. J.; Jones, L. E. Powder Diffraction, Vol. 18, Issue 2 https://doi.org/10.1154/1.1536926	journal	June 2003
Reaction bonded boron carbide: recent developments Dariel, M. P.; Frage, N. Advances in Applied Ceramics, Vol. 111, Issue 5-6 https://doi.org/10.1179/1743676111Y.0000000078	journal	August 2012
Crystal Structure Refinements of Rhombohedral Symmetry Materials Containing Boron-Rich Icosahedra Morosin, B.; Aselage, T. L.; Feigelson, R. S. MRS Proceedings, Vol. 97 https://doi.org/10.1557/PROC-97-145	journal	January 1987
炭化ほう素の焼結に及ぼす炭素の影響 Suzuki, Hiroshige; Hase, Teizo; Maruyama, Tadashi Journal of the Ceramic Association, Japan, Vol. 87, Issue 1008 https://doi.org/10.2109/jcersj1950.87.1008_430	journal	January 1979
Aqueous processing of boron carbide powders Zhang, Jingxian; Jiang, Dongliang; Lin, Qingling Journal of the Ceramic Society of Japan, Vol. 116, Issue 1354 https://doi.org/10.2109/jcersj2.116.681	journal	January 2008

Cited By (1)

Study on formability and strain hardening index: influence of particle size of boron carbide (B ₄ C) in magnesium matrix composites fabricated by powder metallurgy technique Rajkumar, P. R.; Kailasanathan, C.; Senthilkumar, A. Materials Research Express, Vol. 7, Issue 1 https://doi.org/10.1088/2053-1591/ab6c0b	journal	January 2020

Similar Records

Negative Additive Manufacturing of Complex Shaped Boron Carbides

Journal Article · Tue Sep 18 00:00:00 EDT 2018 · Journal of Visualized Experiments · OSTI ID:1491640

A comparison study on the densification behavior and mechanical properties of gelcast vs conventionally formed B{sub 4}C sintered conventionally and by microwaves

Technical Report · Sat Jun 01 00:00:00 EDT 1996 · OSTI ID:244628

Advanced powder processing

Technical Report · Mon Mar 31 23:00:00 EST 1997 · OSTI ID:494128

Related Subjects

36 MATERIALS SCIENCE
boron carbide
gelcasting
negative additive manufacturing
resorcinol formaldehyde
sintering

Complex shaped boron carbides from negative additive manufacturing

Citation Formats

References (36)

Cited By (1)

Similar Records

Related Subjects