Eric Schwarzer

Additive Manufacturing of Ceramic Heat Exchanger: Opportunities and Limits of the Lithography-Based Ceramic Manufacturing (LCM)

Additive manufacturing (AM) techniques allow the preparation of tailor-made structures for specific applications with a high flexibility in regard to shape and design. The lithography-based ceramic manufacturing (LCM) technology allows the AM of high-performance alumina and zirconia components. There are still some restrictions in regard to possible geometries. The opportunities and limits of the LCM technology are discussed in the following paper using the example of ceramic heat exchangers. Structures are presented which combine a large surface for heat exchange with a small component volume and low pressure drop. This paper concludes summarizing the essential remarks.

Ceramic-Based 4D-Components: Additive Manufacturing (AM) of Ceramic-Based Functionally Graded Materials (FGM) by Thermoplastic 3D-Printing (T3DP)

In our study, we investigated the additive manufacturing (AM) of ceramic-based functionally graded materials (FGM) by the direct AM technology thermoplastic 3D printing (T3DP). Zirconia components with varying microstructures were additively manufactured by using thermoplastic suspensions with different contents of pore-forming agents (PFA), which were co-sintered defect-free. Different materials were investigated concerning their suitability as PFA for the T3DP process. Diverse zirconia-based suspensions were prepared and used for the AM of single- and multi-material test components. All of the samples were sintered defect-free, and in the end, we could realize a brick wall-like component consisting of dense (<1% porosity) and porous (approx. 5% porosity) zirconia areas to combine different properties in one component. T3DP opens the door to the AM of further ceramic-based 4D components, such as multi-color, multi-material, or especially, multi-functional components.

New Lightweight Kiln Furniture Made by Combination of Ceramic Green Tapes and Extrudates

Manufacturing technology for new kiln furniture with a significantly lower density and thermal capacity are presented. Extrusion and tape casting are used as two highly productive technologies to produce different green ceramic pre-products, which are combined and co-sintered to realize kiln furniture. Planar green tapes are laminated with an extruded supporting structure including macroscopic cavities to allow passage of the kiln atmosphere and additionally reduce the density and heat capacity of the structure. With such kiln furniture high heating and cooling rates up to 10 K/min can be realized without any defects resulting from thermal stresses. The improved temperature distribution achieved allows a reduction of necessary dwell times. Both make it possible to save energy and time.