Additive Manufacturing via the Direct Ink Writing Technique of Kaolinite-Based Clay with Electric Arc Furnace Steel Dust (EAF Dust)

Electric arc furnace steel dust (EAF dust) is used in this research as a complemented material in the additive manufacturing (AM) of kaolinite-based clays. The AM technique used was the direct ink writing method. The addition of steel dust waste to the clay is beneficial for the environment because the residues can be immobilized and therefore reduce the contamination of water. EAF dust is a hazardous waste available in millions of tons generated by the metallurgical industry worldwide. The current investigation shows the possibility of using EAF dust not only as admixture with clays ceramics after sintering, but also in 3D printed parts. Different samples were built with several water to clay ratios (W/C), and with waste contents between 0 and 20 wt%. Cylinders for compression tests were printed, and after a sintering process at 1100 degrees C for 2 h in air atmosphere, these were evaluated. Other materials characterization included scanning electron microscopy and density tests.