Ceramic On-Demand Extrusion (CODE)

Sponsors: Kansas City National Security Campus, Department of Energy ARPA-E Program

 

Description

This research develops a patented freeform extrusion fabrication process called Ceramic On-Demand Extrusion (CODE) and investigates using this process to fabricate 3D parts made of ceramics and ceramic composites, with applications to aerospace, energy, and other industries. Example parts that we have fabricated using the CODE process include aerospace structural components with high temperature and ultra-high temperature materials (e.g., alumina, zirconium diboride, partially stabilized zirconia, silicon nitride). Also included in our research is fabrication of composite structures consisting of two or more materials that can be distinct materials or graded materials. Our current research focuses on fabricating composite structures with non-oxide ceramics and refractory metals having near theoretical density and superior mechanical/thermal properties for extreme temperature applications. 

  1. “Advanced Ceramic Components with Embedded Sapphire Optical Fiber Sensors for High Temperature Applications,” A. Ghazanfari, W. Li, M. C. Leu, Y. Zhuang, and J. Huang, Materials & Design, Volume 112, 2016, Pages 197-206.
  2. “Extrusion-On-Demand Methods for High Solids Loading Ceramic Paste in Freeform Extrusion Fabrication,” W. Li, A. Ghazanfari, M. C. Leu, and R. G. Landers, Virtual and Physical Prototyping, 12:3, 193-205.
  3. "A Novel Freeform Extrusion Fabrication Process for Producing Solid Ceramic Components with Uniform Layered Radiation Drying." Amir Ghazanfari, Wenbin Li, Ming C.Leu, Jeremy L.Watts, Gregory E.Hilmas. Additive Manufacturing,Volume 15,2017,Pages 102-112.
  4. "Mechanical Characterization of Parts Produced by Ceramic on‐demand Extrusion Process." Amir Ghazanfari, WenbinLi, Ming C.Leu, Jeremy L.Watts, Gregory E.Hilmas, , International Journal of Applied Ceramic Technology. 2017; 14: 486‐ 494.
  5. "Additive Manufacturing and Mechanical Characterization of High Density Fully Stabilized Zirconia." Amir Ghazanfari, Wenbin Li, Ming C.Leu, Jeremy L.Watts, Ceramics International, Volume 43, Issue 8, 2017,Pages 6082-6088
  6. “Additive Manufacturing of Zirconia Parts with Organic Sacrificial Supports,” W. Li, A. Armani, D. McMillin, M. C. Leu, G. E. Hilmas, and J. L. Watts, International Journal of Applied Ceramic Technology. 2020; 17: 1544– 1553.
  7. "Characterization of zirconia specimens fabricated by ceramic on-demand extrusion," Wenbin Li, Amir Ghazanfari, Devin McMillen, Ming C.Leu, Gregory E.Hilmas, JeremyWatts, Ceramics International,Volume 44, Issue 11, 2018, Pages 12245-12252.
  8. "Mitigating Coffee-Ring Defect Formation in Ceramic On-Demand Extrusion Parts," Austin J. Martin, Wenbin Li, Jeremy Lee Watts, Ming-Chuan Leu, Gregory R. Hilmas, T.Huang, Solid Freeform Fabrication 2018, Aug 2018.
  9. "Extrusion-on-Demand Methods for High Solids Loading Ceramic Paste in Freeform Extrusion Fabrication." Wenbin Li, Amir Ghazanfari, Ming C. Leu & Robert G. Landers, Virtual and Physical Prototyping, vol. 12, no. 3, 2017, pp. 193-205.
  10. "Fabricating Ceramic Components with Water Dissolvable Support Structures by the Ceramic on-Demand Extrusion Process.", Wenbin Li, Amir Ghazanfari, Ming C.Leu, Gregory E.Hilmas, CIRP Annals,Volume 66, Issue 1,2017,Pages 225-228.