Solid freeform fabrication of alumina using laser-assisted ESAVD

Electrostatic spray assisted vapour deposition (ESAVD) has been used successfully to produce films and coatings. A combination of laser-assisted (LA) deposition and ESAVD has been developed for the direct fabrication of alumina ceramics. This novel laser-assisted ESAVD technique involves spraying a liquid precursor onto a substrate whilst a laser beam is simultaneously used to heat the precursor and cause the decomposition and chemical reactions of the precursor in order to produce a solid deposit. A desired three-dimensional (3-D) object can be formed through layer-by-layer deposition using a computer-controlled platform. Dense or porous alumina ceramics can be deposited on the substrate by optimizing the processing parameters. This paper reports the fabrication of alumina parts by the laser-assisted ESAVD method. The effect of processing parameters including laser scanning speed, laser beam size and laser power on the microstructure will be presented. Scanning electron microscope (SEM) and X-ray diffraction (XRD) have been used to characterise the phase and structure of the deposited alumina parts.