Fabrication of Al2O3-based composites by indirect 3D-printing

A powder mixture of alumina and dextrin was used as a precursor material for fabrication of porous alumina preforms by indirect three-dimensional printing. Post-pressureless infiltration of the fabricated preforms with copper alloys resulted in dense composites with interpenetrating microstructure. The fabrication procedure involves four steps: a) freeze-drying of Al2O3/dextrin blends, b) three-dimensional printing of the green bodies, c) drying, dextrin decomposition and sintering of the printed bodies and d) post-pressureless infiltration of Cu-alloy into as-fabricated Al2O3 porous preforms. As result of the dextrin decomposition and Al2O3 sintering an average linear shrinkage of 17.7% was measured. After sintering the Al2O3 preforms with ∼36 vol.% porosity were obtained. A post-infiltration with copper alloy at 1300 °C for 1.5 h led to formation of dense Al2O3/Cu parts. X-ray analysis showed the presence of α-Al2O3, Cu and Cu2O only. Al2O3/Cu composite exhibits a fracture toughness of ∼5.5 MPa m1 / 2 and bending strength of ∼236 MPa. Fractographic analysis showed that crack bridging by plastically deformed metal phase may control the fracture toughness of this composite.