Phase separation during the direct powder bed fusion of SiC

Benjamin W. Lamm, Omer Karakoc, Keyou Mao, Takaaki Koyanagi, Jian Liu, Yutai Katoh

Research output: Contribution to journalArticlepeer-review

Abstract

Powder bed fusion (PBF) is an attractive additive manufacturing option for fabrication of SiC object with complex geometries. However, the density and microstructure controls remain a challenge. This study is aimed at understanding laser–SiC interactions, with emphasis on microstructure-processing relationships, to identify potential solutions for the process improvement. SiC tubes were fabricated by PBF of pure SiC powders without sintering additives. Comprehensive analysis by X-ray diffraction, Raman spectroscopy, and electron microscopy indicated that binding of SiC particles was achieved by incongruent melting of SiC to a Si/C mixture containing SiC micro- and nanocrystallites. The phase evolution under laser irradiation of SiC was explained by phase diagrams. This study uncovered the PBF SiC microstructure at different length scales and the relationship between the microstructure and the processing parameters.

Original languageEnglish
Pages (from-to)1722-1734
Number of pages13
JournalInternational Journal of Applied Ceramic Technology
Volume21
Issue number3
DOIs
StatePublished - May 1 2024

Funding

This research was sponsored by US DOE, Advanced Research Projects Agency‐Energy (ARPA‐E) under contract DE‐AC05‐00OR22725 with UT‐Battelle, LLC. The microstructural analysis and thermodynamic calculation were also supported by US DOE, Office of Fusion Energy Sciences, Fusion Materials Program. The authors would like to thank Ercan Cakmak (MSTD, ORNL) for performing the Rietveld analysis. This manuscript has been authored by UT‐Battelle, LLC, under contract DE‐AC05‐00OR22725 with the US Department of Energy (DOE). The US government retains the manuscript and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid‐up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe‐public‐access‐plan ).

Keywords

  • additive manufacturing
  • phase transition
  • silicon carbide

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