New laser machining technology of Al2O3 ceramic with complex shape

A new method was developed for the fabrication of complex-shaped Al2O3 ceramic parts by combining laser machining and gelcasting technique. The unwanted ceramic powders parts were selectively removed by laser machining specified by a computer program, and the gelcast Al2O3 green bodies were machined to a designed shape by a CO2 laser at a wavelength of 10.6 μm. The influences of solid loading, laser output power, scanning speed and nitrogen purge on the machining of green Al2O3 ceramic bodies were studied. The experimental parameters were optimized, the green Al2O3 bodies with solid loading of 40 vol% or below were easier to be machined, while the green bodies with solid loading of 45 vol% or above were hard to be further machined due to the surface sintering. Better machining quality and deeper machining depth could be obtained when the laser power is 30 W. The green Al2O3 bodies with complex shape were obtained by the laser machining.