Abstract
Most techniques employed for powder bed additive manufacturing (AM) only can handle a single material. However, additional functionality of the structures built, e.g., local insulation, is desirable for more sophisticated applications. In the present work, a multi-material process allowing for realization of a ceramic coating on a steel substrate and a novel sandwich system are introduced. Both were manufactured by selective laser melting (SLM). As a first step, the microstructure of a bulk zirconia–alumina ceramic, directly manufactured by SLM, was examined and its tensile strength determined. Afterwards, the ceramic was manufactured directly on the as-built surface of a tool steel processed by SLM. For this compound, the adhesive strength was determined. Finally, an open porous structure, made of the same tool steel, was built on top of the ceramic layer. The results clearly prove that the SLM process can be used for direct manufacturing of a multi-material sandwich structure made from metal and ceramic, providing an important step towards complex structures functionalized for electric insulation.
Similar content being viewed by others
References
W. Meiners: Direktes selektives Laser-Sintern einkomponentiger metallischer Werkstoffe, Dissertation, Aachen, 1999.
I Gibson, D Rosen, and B Stucker: Additive Manufacturing Technologies, 2nd ed., Springer Science+Buisness Media, New York, 2009.
Andreas Gebhardt and Jan-Steffen Hötter: Additive Manufacturing: 3D Printing for Prototyping and Manufacturing, Carl Hanser Verlag, München, 2016.
Dirk Herzog, Vanessa Seyda, Eric Wycisk, and Claus Emmelmann: Acta Mater., 2016, vol. 117, pp. 371–92.
T. DebRoy, H. L. Wei, J. S. Zuback, T. Mukherjee, J. W. Elmer, J. O. Milewski, A. M. Beese, A. Wilson-Heid, A. De, and W. Zhang: Prog. Mater. Sci., 2018, vol. 92, pp. 112–224.
E. Malone and H. Lipson: in Proceedings of the ASME 2008 9th Biennial Conference on Engineering Systems Design and Analysis, 2008, pp. 345–53.
Dirk Lehmhus, Claus Aumund-Kopp, Frank Petzoldt, Dirk Godlinski, Arne Haberkorn, Volker Zöllmer, and Matthias Busse: Procedia Technol., 2016, vol. 26, pp. 284–301.
F. Brueckner, A. Seidel, E. Lopéz, C. Leyens, and E. Beyer: Solid Free. Fabr. Symp., 2017, pp. 2530–38.
Mohammad Vaezi, Srisit Chianrabutra, Brian Mellor, and Shoufeng Yang: Virtual Phys. Prototyp., 2013, vol. 8, pp. 19–50.
Z H Liu, D Q Zhang, S L Sing, C K Chua, and L E Loh: Mater. Charact., 2014, vol. 94, pp. 116–25.
S L Sing, L P Lam, D Q Zhang, Z H Liu, and C K Chua: Mater. Charact., 2015, vol. 107, pp. 220–27.
A.G. Demir and B. Previtali: Manuf. Lett., 2017, vol. 11, pp. 8–11.
A. Syed-Khaja and J. Franke: in Proceedings of Electronic Components and Technology Conference, 2016, pp. 837–42.
A.-M. Nagel and H. Exner: in Proceedings of SPIE—International Society for Optical Engineering, 1999.
Kai Zhang, Tingting Liu, Wenhe Liao, Changdong Zhang, Daozhong Du, and Yi Zheng: Optik (Stuttg)., 2018, vol. 156, pp. 487–97.
Zhiqi Fan, Mingyuan Lu, and Han Huang: Ceram. Int., 2018, vol. 44, pp. 9484–93.
J.I. Wilkes: Selektives Laserschmelze zur generativen Herstellung von Bauteilen aus hochfester Oxidkeramik, Dissertation, Aachen, 2009.
Qi Liu, Yoann Danlos, Bo Song, Baicheng Zhang, Shuo Yin, and Hanlin Liao: J. Mater. Process. Technol., 2015, vol. 222, pp. 61–74.
Julian Krell, Arne Röttger, Karina Geenen, and Werner Theisen: J. Mater. Process. Technol., 2018, vol. 255, pp. 679–88.
H.L. Calambás Pulgarín and M.P. Albano: Procedia Mater. Sci., 2015, vol. 8, pp. 180–89.
A. Baumann: Pulverspritzgießen von Metall-Keramik-Verbunden, Dissertation, Freiberg, 2010.
A.M. Alper: in Ceramic Microstructures: Their Analysis, Significance, and Production, R.M. Fulrath and J.A. Pask, eds., Wiley, New York, 1969, pp. 763–99.
Fangyong Niu, Dongjiang Wu, Guangyi Ma, Jiangtian Wang, Juan Zhuang, and Zhuji Jin: Procedia CIRP, 2016, vol. 42, pp. 91–95.
Ralf Bürgel: Handbuch Hochtemperatur-Werkstofftechnik, 3rd ed., Friedrich Vieweg & Sohn Verlag, Wiesbaden, 2006.
N Mesrati, H Ajhrourh, Nguyen Du, and D Treheux: J. Therm. Spray Technol., 2000, vol. 9, pp. 95–99.
K. Suganuma, Y. Miyamoto, and M. Koizumi: Weld. Int., 1987, vol. 1, pp. 875–78.
M. Leary: Surface Roughness Optimisation for Selective Laser Melting (SLM): Accommodating Relevant and Irrelevant Surfaces, Elsevier, 2016.
Jason C. Fox, Shawn P. Moylan, and Brandon M. Lane: Procedia CIRP, 2016, vol. 45, pp. 131–34.
Giovanni Strano, Liang Hao, Richard M. Everson, and Kenneth E. Evans: J. Mater. Process. Technol., 2013, vol. 213, pp. 589–97.
W. Kniffka, M. Eichmann, G. Witt, and R. Stache: in Rapid. Tech Int. Trade Show Conference for Additive Manufacturing, W. Kniffka, G. Witt, and M. Eichmann, eds., Carl Hanser Verlag GmbH & Co. KG, 2016, pp. 380–89.
Sergij M. Lakiza and Lidia M. Lopato: J. Am. Ceram. Soc., 1997, vol. 80, pp. 893–902.
Ellen Ivers-Tiffée and Waldemar von Münch: Werkstoffe Der Elektrotechnik, 9th ed., Vieweg+Teubner Verlag, Wiesbaden, 2004.
C. H. Cáceres, C. J. Davidson, J. R. Griffiths, and C. L. Newton: Mater. Sci. Eng. A, 2002, vol. 325, pp. 344–55.
Jianbing Yu, You Wang, Feifei Zhou, Liang Wang, and Zhaoyi Pan: Appl. Surf. Sci., 2018, vol. 431, pp. 112–21.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Manuscript submitted September 27, 2018.
Rights and permissions
About this article
Cite this article
Koopmann, J., Voigt, J. & Niendorf, T. Additive Manufacturing of a Steel–Ceramic Multi-Material by Selective Laser Melting. Metall Mater Trans B 50, 1042–1051 (2019). https://doi.org/10.1007/s11663-019-01523-1
Received:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11663-019-01523-1