Extrusion-based additive manufacturing of alumina ceramics through controlled extrusion pressure

Abstract

The development of dense alumina ceramics through additive manufacturing necessitates the careful analysis of various parameters. The extrusion pressure during printing is a crucial but often overlooked factor in the literature. This study investigates the impact of extrusion pressure on the densification and mechanical properties of alumina ceramics. The primary objective is to analyze extrusion pressure to achieve superior physical and mechanical characteristics while maintaining minimal shrinkage. All other printing parameters were kept constant, and the extrusion pressure was varied from 1 to 2.85 bar during the extrusion-based additive manufacturing of alumina green bodies. The printed and sintered samples were analyzed for linear shrinkage, density, compressive strength, and microhardness. The results indicate that an extrusion pressure in the 2.2–2.5 bar range leads to alumina ceramics with the best combination of densification and other mechanical properties. Additionally, the interparticle bonding mechanisms contributing to the improved properties of the alumina ceramics were examined. This study provides valuable insights into the role of extrusion pressure in the additive manufacturing process, underscoring its significance in achieving high-quality alumina ceramics.