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Aerospace
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Additive Manufacturing of Ceramic Materials in Aerospace
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Additive Manufacturing of Ceramic Materials in Aerospace

A special issue of Aerospace (ISSN 2226-4310). This special issue belongs to the section "Aeronautics".

Deadline for manuscript submissions: closed (30 September 2022) | Viewed by 6563

Special Issue Editors

Prof. Dr. Khamis Essa

E-Mail Website
Guest Editor
Mechanical Engineering, University of Birmingham, Edgbaston, Birmingham B15 2TT, UK
Interests: digital manufacturing; advanced manufacturing technologies; biomedical materials; material and process interaction; process and material behaviours; finite-element modelling
Special Issues, Collections and Topics in MDPI journals
Dr. Hany Hassanin

E-Mail Website
Guest Editor
Canterbury Christ Church University, Canterbury, United Kingdom
Interests: Topics related to elastomers, additive manufacturing of polymers, composite materials, 3D printing, 4D printing, and mechanical properties and design.
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM), one of the key pillars of Industry 4.0, has become an underpinning technology for the global manufacturing sector, driven by the introduction of a vast amount of research and interest from aerospace industry. On the other hand, there is growing interest in ceramics as high-temperature materials due to their unique high hardness, high chemical resistance, and low thermal expansion. However, ceramic processing is very challenging, and now, there is a need to look beyond the current technology to the future of creating netshape smart multi-functional ceramic products. In this Special Issue, we focus on the next generation of ceramic additive manufacturing, including the state art of AM, current challenges and new processes and materials. We will cover all aspects of AM manufacturing research, including 3D and 4D printing, micro AM, hybrid AM, thrusters, aerospace applications, modelling, optimisation, sintering, post processing techniques, functional materials, surface modification, artificial intelligence, materials characterisation, process integration, and education. We invite researchers in ceramics and additive manufacturing to contribute original research, reviews, commentaries, perspectives, and future outlooks on related topics. We will also discuss technological breakthroughs and the latest developments in the formats of both short communications and full papers. The goal of this Special Issue is to invite the research community to address the current progress and next generation of ceramic 3D printing in order to make a greater impact on society and the aerospace industry.

Dr. Khamis Essa
Dr. Hany Hassanin
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Aerospace is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • aerospace
  • additive manufacturing
  • 3D printing
  • high-temperature ceramics
  • ceramic matrix composites
  • ceramic thrusters
  • sintering
  • high-density ceramics
  • functional ceramics
  • hybrid manufacturing
  • modelling
  • artificial intelligence

Published Papers (2 papers)

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Research

15 pages, 5654 KiB  
Article
Numerical Simulation of Sintering of DLP Printed Alumina Ceramics
by Michele De Lisi, Nikolina Kovacev, Usama M. Attia and Khamis Essa
Aerospace 2022, 9(7), 336; https://doi.org/10.3390/aerospace9070336 - 24 Jun 2022
Cited by 4 | Viewed by 2139
Abstract
Digital Light Processing (DLP) technology exhibits the capability of producing components with complex structures for a variety of technical applications. Postprocessing of additively printed ceramic components has been shown to be an important step in determining the final product resolution and mechanical qualities, [...] Read more.
Digital Light Processing (DLP) technology exhibits the capability of producing components with complex structures for a variety of technical applications. Postprocessing of additively printed ceramic components has been shown to be an important step in determining the final product resolution and mechanical qualities, particularly with regard to distortions and resultant density. The goal of this research is to study the sintering process parameters to create a nearly fully dense, defect-free, ceramic component. A high-solid-loading alumina slurry with suitable rheological and photopolymerisable characteristics for DLP was created. TGA/DSC analysis was used to estimate thermal debinding parameters. The sintering process of the debound parts was studied by employing a numerical model based on thermo-viscoelasticity theory to describe the sintering process. The validated Finite Element Modelling (FEM) code was capable of predicting shrinkage and relative density changes during the sintering cycle, as well as providing meaningful information on the final shape. Archimedes’ principle and scanning electron microscope (SEM) were used to characterise the sintered parts and validate the numerical model. Samples with high relative density (>98.5%) were produced and numerical data showed close matches for predicted shrinkages and relative densities, with less than 2% mismatch between experimental results and simulations. The current model may allow to effectively predict the properties of alumina ceramics produced via DLP and tailor them for specific applications. Full article
(This article belongs to the Special Issue Additive Manufacturing of Ceramic Materials in Aerospace)
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15 pages, 8151 KiB  
Article
Additive Manufacturing of Novel Hybrid Monolithic Ceramic Substrates
by Nikolina Kovacev, Sheng Li, Weining Li, Soheil Zeraati-Rezaei, Athanasios Tsolakis and Khamis Essa
Aerospace 2022, 9(5), 255; https://doi.org/10.3390/aerospace9050255 - 07 May 2022
Cited by 8 | Viewed by 2305
Abstract
Additive manufacturing (AM) can revolutionise engineering by taking advantage of unconstrained design and overcoming the limitations of traditional manufacturing capabilities. A promising application of AM is in catalyst substrate manufacturing, aimed at the enhancement of the catalytic efficiency and reduction in the volume [...] Read more.
Additive manufacturing (AM) can revolutionise engineering by taking advantage of unconstrained design and overcoming the limitations of traditional manufacturing capabilities. A promising application of AM is in catalyst substrate manufacturing, aimed at the enhancement of the catalytic efficiency and reduction in the volume and weight of the catalytic reactors in the exhaust gas aftertreatment systems. This work addresses the design and fabrication of innovative, hybrid monolithic ceramic substrates using AM technology based on Digital Light Processing (DLP). The designs are based on two individual substrates integrated into a single, dual-substrate monolith by various interlocking systems. These novel dual-substrate monoliths lay the foundation for the potential reduction in the complexity and expense of the aftertreatment system. Several examples of interlocking systems for dual substrates were designed, manufactured and thermally post-processed to illustrate the viability and versatility of the DLP manufacturing process. Based on the findings, the sintered parts displayed anisotropic sintering shrinkage of approximately 14% in the X–Y direction and 19% in the Z direction, with a sintered density of 97.88 ± 0.01%. Finally, mechanical tests revealed the mechanical integrity of the designed interlocks. U-lock and Thread configurations were found to sustain more load until complete failure. Full article
(This article belongs to the Special Issue Additive Manufacturing of Ceramic Materials in Aerospace)
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