Properties of SiC-Si made via binder jet 3D printing of SiC powder, carbon addition, and silicon melt infiltration
Abstract
Abstract We report the physical and mechanical properties of ceramic composite materials fabricated by binder jet 3D printing (BJ3DP) with silicon carbide (SiC) powders, followed by phenolic resin infiltration and pyrolysis (IP) to generate carbon, and a final reactive silicon melt infiltration step. After two phenolic resin infiltration and pyrolysis cycles; porosity was less than 2%, Young's modulus was close to 300 GPa, and the flexural strength was 517.6 ± 24.8 MPa. However, diminishing returns were obtained after more than two phenolic resin infiltration and pyrolysis cycles as surface pores in carbon were closed upon the formation of SiC, resulting in reaction choking and residual‐free carbon and porosity. The instantaneous coefficient of thermal expansion of the composite was found to be independent of the number of phenolic IP cycles and had values of between 4.2 and 5.0 ppm/°C between 300 and 1000℃, whereas the thermal conductivity was found to have a weak dependence on the number of phenolic IP cycles. While the manufacturing procedures described here yielded highly dense, gas impermeable, siliconized SiC composites with properties comparable to those of bulk siliconized silicon carbide processed according to conventional techniques, BJ3DP enables the manufacture of objects with complex shape, unlike conventional techniques.
- Authors:
-
[1];
[1];
[1];
[1];
[1];
[1];
[1];
[1]
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- ExOne Company, North Huntingdon, PA (United States)
- Publication Date:
- Research Org.:
- Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
- Sponsoring Org.:
- USDOE Advanced Research Projects Agency - Energy (ARPA-E)
- OSTI Identifier:
- 1813244
- Alternate Identifier(s):
- OSTI ID: 1787897
- Grant/Contract Number:
- AC05-00OR22725; AR0000958
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Journal of the American Ceramic Society
- Additional Journal Information:
- Journal Volume: 104; Journal Issue: 11; Journal ID: ISSN 0002-7820
- Publisher:
- American Ceramic Society
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; Binder Jet 3D Printing; SiC; Phenolic Impregnation and Pyrolysis; Reactive Melt Infiltration
Citation Formats
Cramer, Corson, Elliott, Amy, Lara-Curzio, Edgar, Flores-Betancourt, Alexis, Lance, Michael J., Han, Lu, Blacker, Jesse, Trofimov, Artem, Wang, Hsin, and Nawaz, Kashif. Properties of SiC-Si made via binder jet 3D printing of SiC powder, carbon addition, and silicon melt infiltration. United States: N. p., 2021.
Web. doi:10.1111/jace.17933.
Cramer, Corson, Elliott, Amy, Lara-Curzio, Edgar, Flores-Betancourt, Alexis, Lance, Michael J., Han, Lu, Blacker, Jesse, Trofimov, Artem, Wang, Hsin, & Nawaz, Kashif. Properties of SiC-Si made via binder jet 3D printing of SiC powder, carbon addition, and silicon melt infiltration. United States. https://doi.org/10.1111/jace.17933
Cramer, Corson, Elliott, Amy, Lara-Curzio, Edgar, Flores-Betancourt, Alexis, Lance, Michael J., Han, Lu, Blacker, Jesse, Trofimov, Artem, Wang, Hsin, and Nawaz, Kashif. Mon .
"Properties of SiC-Si made via binder jet 3D printing of SiC powder, carbon addition, and silicon melt infiltration". United States. https://doi.org/10.1111/jace.17933. https://www.osti.gov/servlets/purl/1813244.
@article{osti_1813244,
title = {Properties of SiC-Si made via binder jet 3D printing of SiC powder, carbon addition, and silicon melt infiltration},
author = {Cramer, Corson and Elliott, Amy and Lara-Curzio, Edgar and Flores-Betancourt, Alexis and Lance, Michael J. and Han, Lu and Blacker, Jesse and Trofimov, Artem and Wang, Hsin and Nawaz, Kashif},
abstractNote = {Abstract We report the physical and mechanical properties of ceramic composite materials fabricated by binder jet 3D printing (BJ3DP) with silicon carbide (SiC) powders, followed by phenolic resin infiltration and pyrolysis (IP) to generate carbon, and a final reactive silicon melt infiltration step. After two phenolic resin infiltration and pyrolysis cycles; porosity was less than 2%, Young's modulus was close to 300 GPa, and the flexural strength was 517.6 ± 24.8 MPa. However, diminishing returns were obtained after more than two phenolic resin infiltration and pyrolysis cycles as surface pores in carbon were closed upon the formation of SiC, resulting in reaction choking and residual‐free carbon and porosity. The instantaneous coefficient of thermal expansion of the composite was found to be independent of the number of phenolic IP cycles and had values of between 4.2 and 5.0 ppm/°C between 300 and 1000℃, whereas the thermal conductivity was found to have a weak dependence on the number of phenolic IP cycles. While the manufacturing procedures described here yielded highly dense, gas impermeable, siliconized SiC composites with properties comparable to those of bulk siliconized silicon carbide processed according to conventional techniques, BJ3DP enables the manufacture of objects with complex shape, unlike conventional techniques.},
doi = {10.1111/jace.17933},
journal = {Journal of the American Ceramic Society},
number = 11,
volume = 104,
place = {United States},
year = {Mon May 24 00:00:00 EDT 2021},
month = {Mon May 24 00:00:00 EDT 2021}
}
Free Publicly Available Full Text
Publisher's Version of Record
Other availability
Search WorldCat to find libraries that may hold this journal
Save to My Library
You must Sign In or Create an Account in order to save documents to your library.
Works referenced in this record:
High Thermal Conductivity Materials
journal, June 2001
- Watari, Koji; Shinde, Subhash L.
- MRS Bulletin, Vol. 26, Issue 6
Handbook of SiC properties for fuel performance modeling
journal, September 2007
- Snead, Lance L.; Nozawa, Takashi; Katoh, Yutai
- Journal of Nuclear Materials, Vol. 371, Issue 1-3
Young's Modulus of Various Refractory Materials as a Function of Temperature
journal, May 1959
- Wachtman, J. B.; Lam, D. G.
- Journal of the American Ceramic Society, Vol. 42, Issue 5
Comparison of different experimental techniques for determination of elastic properties of solids
journal, March 2004
- Radovic, M.; Lara-Curzio, E.; Riester, L.
- Materials Science and Engineering: A, Vol. 368, Issue 1-2
Thermal Expansion and Thermal Expansion Anisotropy of SiC Polytypes
journal, July 1987
- Li, Z.; Bradt, R. C.
- Journal of the American Ceramic Society, Vol. 70, Issue 7
Density Change in Silicon upon Melting
journal, March 1959
- Logan, R. A.; Bond, W. L.
- Journal of Applied Physics, Vol. 30, Issue 3
Capillary Infiltration Rates into Porous Media with Applications to Silcomp Processing
journal, February 1996
- Einset, Erik O.
- Journal of the American Ceramic Society, Vol. 79, Issue 2
High‐temperature flexural strength of SiC ceramics prepared by additive manufacturing
journal, October 2019
- Xu, Teng‐Teng; Cheng, Su; Jin, Lai‐Zhen
- International Journal of Applied Ceramic Technology, Vol. 17, Issue 2
Reaction bonding of silicon carbides by Binder Jet 3D-Printing, phenolic resin binder impregnation and capillary liquid silicon infiltration
journal, October 2019
- Fleisher, A.; Zolotaryov, D.; Kovalevsky, A.
- Ceramics International, Vol. 45, Issue 14
Raman microprobe studies on carbon materials
journal, January 1994
- Cuesta, A.; Dhamelincourt, P.; Laureyns, J.
- Carbon, Vol. 32, Issue 8
Formation of dense silicon carbide by liquid silicon infiltration of carbon with engineered structure
journal, May 2008
- Margiotta, Jesse C.; Zhang, Dajie; Nagle, Dennis C.
- Journal of Materials Research, Vol. 23, Issue 5
Fabrication of Silicon Carbide Fiber-Reinforced Silicon Carbide Matrix Composites Using Binder Jetting Additive Manufacturing from Irregularly-Shaped and Spherical Powders
journal, April 2020
- Polozov, Igor; Razumov, Nikolay; Masaylo, Dmitriy
- Materials, Vol. 13, Issue 7
Influence of grain size, free silicon content and temperature on the strength and toughness of reaction-bonded silicon carbide
journal, January 1994
- Chakrabarti, O. P.; Ghosh, S.; Mukerji, J.
- Ceramics International, Vol. 20, Issue 5
Additive Manufacturing of Ceramics: Issues, Potentialities, and Opportunities
journal, July 2015
- Zocca, Andrea; Colombo, Paolo; Gomes, Cynthia M.
- Journal of the American Ceramic Society, Vol. 98, Issue 7
Crack propagation and fracture in silicon carbide
journal, October 1975
- Evans, A. G.; Lange, F. F.
- Journal of Materials Science, Vol. 10, Issue 10
Thermal conductivity studies on Si/SiC ceramic composites
journal, January 2011
- Amirthan, G.; Udaya kumar, A.; Balasubramanian, M.
- Ceramics International, Vol. 37, Issue 1
A Comparison of the Oxidation Kinetics of SiC and Si[sub 3]N[sub 4]
journal, January 1995
- Ogbuji, Linus U. J. T.
- Journal of The Electrochemical Society, Vol. 142, Issue 3
Fabrication of functionally graded reaction infiltrated SiC–Si composite by three-dimensional printing (3DP™) process
journal, January 2001
- Moon, Jooho; Caballero, Amador C.; Hozer, Leszek
- Materials Science and Engineering: A, Vol. 298, Issue 1-2
High-temperature strength and toughness behaviors for reaction-bonded SiC ceramics below 1400 °C
journal, June 2005
- Huang, Qing-Wei; Zhu, Li-Hui
- Materials Letters, Vol. 59, Issue 14-15
Kinetics Model for the Growth of Silicon Carbide by the Reaction of Liquid Silicon with Carbon
journal, September 1995
- Zhou, Hong; Singh, Raj N.
- Journal of the American Ceramic Society, Vol. 78, Issue 9
Time-Dependent Strength Degradation of a Siliconized Silicon Carbide Determined by Dynamic Fatigue
journal, October 1995
- Breder, Kristin
- Journal of the American Ceramic Society, Vol. 78, Issue 10
3D printing of ceramics: A review
journal, April 2019
- Chen, Zhangwei; Li, Ziyong; Li, Junjie
- Journal of the European Ceramic Society, Vol. 39, Issue 4
Binder jet 3D printing—Process parameters, materials, properties, modeling, and challenges
journal, June 2020
- Mostafaei, Amir; Elliott, Amy M.; Barnes, John E.
- Progress in Materials Science
Melt Infiltration Approach to Ceramic Matrix Composites
journal, February 1988
- Hillig, William B.
- Journal of the American Ceramic Society, Vol. 71, Issue 2
Radiation loss in the flash method for thermal diffusivity
journal, February 1975
- Clark III, L. M.; Taylor, R. E.
- Journal of Applied Physics, Vol. 46, Issue 2
Silicon Carbide Oxidation in Steam up to 2 MPa
journal, July 2014
- Terrani, Kurt A.; Pint, Bruce A.; Parish, Chad M.
- Journal of the American Ceramic Society, Vol. 97, Issue 8
Processing and properties of SiC composites made via binder jet 3D printing and infiltration and pyrolysis of preceramic polymer
journal, September 2020
- Cramer, Corson L.; Armstrong, Herb; Flores‐Betancourt, Alexis
- International Journal of Ceramic Engineering & Science, Vol. 2, Issue 6
High temperature properties of SiC and diamond CVD-monofilaments
journal, July 2005
- Chollon, Georges; Naslain, Roger; Prentice, Calvin
- Journal of the European Ceramic Society, Vol. 25, Issue 11
3D printing of high‐purity silicon carbide
journal, October 2019
- Terrani, Kurt; Jolly, Brian; Trammell, Michael
- Journal of the American Ceramic Society, Vol. 103, Issue 3
SiC Recession Caused by SiO 2 Scale Volatility under Combustion Conditions: II, Thermodynamics and Gaseous-Diffusion Model
journal, July 1999
- Opila, Elizabeth J.; Smialek, James L.; Robinson, Raymond C.
- Journal of the American Ceramic Society, Vol. 82, Issue 7
High-Temperature Time-Dependent Strength of an Si/SiC Composite
journal, March 1977
- Trantina, G. G.; Mehan, R. L.
- Journal of the American Ceramic Society, Vol. 60, Issue 3-4
Reaction mechanism in carbon-liquid silicon systems at elevated temperatures
journal, January 1986
- Pampuch, R.; Walasek, E.; Bialoskórski, J.
- Ceramics International, Vol. 12, Issue 2
Pulse Method of Measuring Thermal Diffusivity at High Temperatures
journal, April 1963
- Cowan, Robert D.
- Journal of Applied Physics, Vol. 34, Issue 4