Fabrication and characterization of SiC whiskers toughened Al2O3 paste for stereolithography 3D printing applications.

To prevent the agglomeration of silicon carbide whiskers (SiC w) in photosensitive ceramic paste, a butanone-ethanol azeotropic solvent is employed to facilitate the dispersion of alumina particles, SiC whiskers and UV resins. Moreover, SiC w /Al 2 O 3 ceramic pastes, with 5–15 vol % SiC w , are prepared by using ball milling, stirring and distillation processes. The mixture of butanone-ethanol solvent and resins can be effectively separated at 70 °C without weakening the polymerization of UV resin. Moreover, an empirical equation is established to evaluate the relationship between SiC w content, aspect ratio and viscosity of resulting ceramic paste. The 15 vol % SiC w /Al 2 O 3 composite ceramic, with SiC w aspect ratio of 50, renders higher resistance to liquid flow and results in a high viscosity of 30,000 mPa s at the shear rate of 30 s−1. Furthermore, a modified equation is established to predicate the curing depth of ceramic pastes with different amounts of SiC w , where 15 vol % SiC w /Al 2 O 3 composite results in higher light scattering properties, leading to lowest C d of ∼0.061 mm. Finally, the complex-shaped SiC w /Al 2 O 3 ceramic component, prepared by SL 3D printing technology, debinding and sintering processes, exhibited a superior fracture toughness of 7.1 ± 1.20 MPa m1/2 and a higher hardness of 17.6 ± 0.78 GPa. • A novel technology was proposed for preparing a 50 vol% SiC w /Al 2 O 3 photosensitive paste. • The dispersing process can effectively prevent the agglomeration of SiC whiskers. • 5-15 vol% SiC w contents influence on the pastes corresponding properties were evaluated. • Complex SiC w /Al 2 O 3 part with 7.1 ± 1.20 MPa m1/2 was 3D printed and sintered. [ABSTRACT FROM AUTHOR]