Additive manufacturing of porous ceramic structures by indirect powder bed fusion with laser beam using a novel polyamide/ alumina-based feedstock

Porous alumina structures were developed by indirect Powder Bed Fusion with Laser Beam (PBF-LB), employing a novel feedstock (composite granules) based on alumina (Al2O3), bio-renewable polyamide 612 (PA612), and micron-sized graphite (MG) using a commercial PBF-LB machine that operates with a low-power visible light diode laser. Regular and slightly rounded composite granules were prepared via the thermally induced phase separation (TIPS) process in dimethyl sulfoxide (DMSO) using 0.05 vol% of PA612, 40/60 vol% of Al2O3/PA612 and 6.25 wt% of MG, and then characterized via density measurements, Hausner's ratio, SEM-EDS, particle size distribution, Raman spectroscopy, DSC, and TGA. Experimental conditions to be used in the PBF-LB process were determined in order to obtain high-quality green porous structures with a controlled geometry. After the heating treatments, sintered components with good structural integrity, a high open porosity associated with interconnected pores in the struts, and a ceramic matrix with microsized-equiaxial grains were obtained. The evaluation of the mechanical properties was performed by diametral compression testing. In order to improve these properties, a vacuum infiltration process involving a low-concentration alumina-ethanol suspension was used on pre-sintered discs. As a consequence of the infiltration process, the discs showed improved mechanical properties after sintering without the porosity having been significantly affected.