Abstract
Using hydroxyapatite as an example, first results of research on a new additive method of manufacturing ceramic products are presented. The method consists of repeated sequential application of suspension layers with high content of powder material and their rapid 24 GHz microwave sintering. The stability of aqueous suspensions of hydroxyapatite powder with submicron particle size depending on the pH of the dispersion medium and dispersants was studied. Suspensions with a high value of the solid load mass and a fluidity sufficient to ensure the continuity of layers applied by the doctor blade method were obtained. By the method of layer-by-layer microwave sintering with a heating rate of up to 30°C/min and a maximum temperature of up to 1330°C, ceramic samples with a closed system of micron-sized pores and a density of up to 92% of the theoretical value were obtained.
Similar content being viewed by others
REFERENCES
Zocca, A., Colombo, P., Gomes, C.M., and Günster, J., Additive manufacturing of ceramics: issues, potentialities, and opportunities, J. Am. Ceram. Soc., 2015, vol. 98, pp. 1983–2001.
Gao, W., Zhang, Y., Ramanujan, D., et al., The status, challenges, and future of additive manufacturing in engineering, Comput. Des., 2015, vol. 69, pp. 65–89.
Travitzky, N., Bonet, A., Dermeik, B., et al., Additive manufacturing of ceramic-based materials, Adv. Eng. Mater., 2014, vol. 16, pp. 729–754.
Nguyen, A.K., Goering, P.L., Skoog, S.A., and Narayan, R.J., Physical characterization and in vitro evaluation of 3D printed hydroxyapatite, tricalcium phosphate, zirconia, alumina, and SiAlON structures made by lithographic ceramic manufacturing, MRS Adv., 2020, vol. 5, pp. 2419–2428.
Bykov, Y.V., Rybakov, K.I., and Semenov, V.E., High-temperature microwave processing of materials, J. Phys. D: Appl. Phys., 2001, vol. 34, pp. R55–R75.
Curto, H., Thuault, A., Jean, F., et al., Coupling additive manufacturing and microwave sintering: a fast processing route of alumina ceramics, J. Eur. Ceram. Soc., 2020, vol. 40, pp. 2548–2554.
Bykov, Yu.V., Eremeev, A.G., Glyavin, M.Yu., et al., Millimeter-range gyrotron research system: I. Description of the system, Izv. Vyssh. Uchebn. Zaved., Radiofiz., 2018, vol. 61, pp. 843–855.
Glyavin, M.Yu., Morozkin, M.V., Tsvetkov, A.I., et al., Automated microwave system based on a cw gyrotron with an operating frequency of 263 GHz and output power of 1 kW, Izv. Vyssh. Uchebn. Zaved., Radiofiz., 2015, vol. 58, pp. 709–719.
Bykov, Y., Egorov, S., Eremeev, A., et al., On the mechanism of microwave flash sintering of ceramics, Materials (Basel), 2016, vol. 9, pp. 684–690.
Bykov, Yu.V., Egorov, S.V., Eremeev, A.G., et al., Flash sintering of oxide ceramics under microwave heating, Tech. Phys., 2018, vol. 88, pp. 391–397.
Egorov, S.V., Eremeev, A.G., Kholoptsev, V.V., et al., Rapid microwave sintering of zinc oxide-based varistor ceramics, J. Eur. Ceram. Soc., 2021, vol. 41, pp. 6508–6515.
Bykov, Y.V., Egorov, S.V., Eremeev, A.G., et al., Ultra-rapid microwave sintering of pure and Y2O3-doped MgAl2O4, J. Am. Ceram. Soc., 2018, vol. 102, no. 2, pp. 559–568.
Egorov, S.V., Eremeev, A.G., Kholoptsev, V.V., et al., On the correlation between the thermal instability onset and the flash sintering event, Scr. Mater., 2020, vol. 174, pp. 68–71.
Bykov, Y.V., Egorov, S.V., Eremeev, A.G., et al., Flash microwave sintering of transparent Yb:(LaY)2O3 ceramics, J. Am. Ceram. Soc., 2015, vol. 98, pp. 3518–3524.
Puzyrev, I.S., Lipilin, A.S., Ivanov, V.V., and Yatluk, Y.G., Stabilization of isopropanol dispersions of nanosized powders of yttrium oxide-stabilized zirconium dioxide, Colloid J., 2011, vol. 73, pp. 97–103.
Cesarano, J., Aksay, I.A., and Bleier, A., Stability of aqueous alpha-Al2O3 suspensions with poly(methacrylic acid) polyelectrolyte, J. Am. Ceram. Soc., 1988, vol. 71, pp. 250–255.
Hackley, V.A., Colloidal processing of silicon nitride with poly(acrylic acid): I. Adsorption and electrostatic interactions, J. Am. Ceram. Soc., 2005, vol. 80, pp. 2315–2325.
Pina, A., Nakache, E., Feret, B., and Depraetere, P., Copolymer polyelectrolyte adsorption onto titanium dioxide, Colloids Surf., A, 1999, vol. 158, pp. 375–384.
Kamiya, H., Fukuda, Y., Suzuki, Y., et al., Effect of polymer dispersant structure on electrosteric interaction and dense alumina suspension behavior, J. Am. Ceram. Soc., 2004, vol. 82, pp. 3407–3412.
Ahmed, Y., Ewais, E., and El-Sheikh, S., Effect of dispersion parameters on the consolidation of starch-loaded hydroxyapatite slurry, Process. Appl. Ceram., 2014, vol. 8, pp. 127–135.
Tripathi, G. and Basu, B., A porous hydroxyapatite scaffold for bone tissue engineering: physico-mechanical and biological evaluations, Ceram. Int., 2012, vol. 38, pp. 341–349.
Knowles, J., Characterisation of the rheological properties and zeta potential of a range of hydroxyapatite powders, Biomaterials, 2000, vol. 21, pp. 1387–1392.
Gardini, D., Galassi, C., and Lapasin, R., Rheology of hydroxyapatite dispersions, J. Am. Ceram. Soc., 2005, vol. 88, pp. 271–276.
ACKNOWLEDGMENTS
This work was supported by the Russian Foundation for Basic Research (project 18-29-11045).
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
The authors declare that they have no conflicts of interest.
Rights and permissions
About this article
Cite this article
Balabanov, S.S., Egorov, S.V., Eremeev, A.G. et al. Fabrication of Hydroxyapatite Ceramics by Rapid Microwave Layer-by-Layer Sintering. Inorg Mater 58, 764–771 (2022). https://doi.org/10.1134/S0020168522060012
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1134/S0020168522060012