Optimization of inorganic powder properties for manufacturing ceramic filter using binder jetting process

Abstract

Porous ceramics are employed in an extensive range of industrial applications due to superior thermal insulation and physical properties that permit their use for separation and storage. However, in conventional manufacturing environments, an additional process is required for artificial pore control. Furthermore, these methods are inferior in terms of the geometric design of the fabricated products owing to limitations in the forming process. To improve these disadvantages, many studies have recently been conducted on the porous structures using additive manufacturing techniques. In particular, binder jetting method can be utilized for fabricating porous ceramics to overcome the limitations of conventional manufacturing process. This study demonstrates an optimal process for the fabrication of porous ceramics by applying binder jetting technology. Powder flowability and compatibility were optimized using the flow agent and the secondary binder. The effects of adding glass frit and adjusting the sintering temperature on the microstructure, porosity, and mechanical properties of the final product were also investigated in detail. Additionally, various filter design of inner flow path was investigated using computational fluid dynamics to improve the filtering efficiency and fabricated using the optimized ceramic powder through binder jetting technique.