Properties of SiC-Si made via binder jet 3D printing of SiC powder, carbon addition, and silicon melt infiltration

Cramer, Corson; Elliott, Amy; Lara-Curzio, Edgar; Flores-Betancourt, Alexis; Lance, Michael J.; Han, Lu; Blacker, Jesse; Trofimov, Artem; Wang, Hsin; Nawaz, Kashif

doi:10.1111/jace.17933

Title: Properties of SiC-Si made via binder jet 3D printing of SiC powder, carbon addition, and silicon melt infiltration

Journal Article · Mon May 24 00:00:00 EDT 2021 · Journal of the American Ceramic Society

DOI:https://doi.org/10.1111/jace.17933· OSTI ID:1813244

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Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
ExOne Company, North Huntingdon, PA (United States)

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.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Advanced Research Projects Agency - Energy (ARPA-E)

Grant/Contract Number:: AC05-00OR22725; AR0000958

OSTI ID:: 1813244

Alternate ID(s):: OSTI ID: 1787897

Journal Information:: Journal of the American Ceramic Society, Vol. 104, Issue 11; ISSN 0002-7820

Publisher:: American Ceramic SocietyCopyright Statement

Country of Publication:: United States

Language:: English

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