Additive manufacturing of high-performance SiO2-Al2O3-K2O (Na2O) ceramic components via binder jetting technology

To resolve issues such as high sintering temperatures and relatively low relative densities and bending strengths of sintered bodies during the preparation of ceramic parts using binder jetting (BJ) additive manufacturing (AM) technology. In this study, high-performance SiO2-Al2O3-K2O (Na2O) ceramics were fabricated using quartz, kaolin, potassium feldspar, and sodium feldspar as raw materials through BJ technology. Initially, the sintering process of the BJ ceramics was studied by adjusting the ratio of potassium feldspar to sodium feldspar and the sintering temperature, which enhanced the relative density and bending strength of the silicate ceramics. Subsequently, using response surface methodology (RSM), the effects of print layer thickness (A), scraper speed (B), and ink volume per unit area (C) on the performance of the ceramics after sintering were investigated. Results indicated that the optimal parameters of the BJ printing process were determined using RSM: A was 250 mu m, B was 3.44 mg cm- 3 , and C was 35 mm s- 1 . Under these conditions, the sintered ceramics achieved optimal relative densities, closed porosities, and flexural strengths of 89.05 %, 10.85 %, and 69.19 MPa for relative density, closed porosity, and flexural strength, respectively.