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Preparation of Silicon Carbide Composite Powders and the Integrated Additive Manufacturing Technology for Its Complex Ceramic Components

Yusheng Shi, Chunzeyan, Chenhui Li, Shifeng Wen, Lichao Zhang, Yang Zou

Huazhong University of Science and Technology

Dr. Shi has been engaged in the field of additive manufacturing (AM) for 25 years and devoted his expertise to the advanced preparation and forming techniques of high-performance polymeric, metallic, and ceramic materials for AM. He is a Distinguished Professor at Huazhong University of Science and Technology. He serves as Chair of the AM Branch of Non-ferrous Metals Society of China, Chair of the AM Materials Branch of the Chinese Materials Research Society, Director of the Expert Committee of the AM Technology Center of China Aerospace Science and Technology Corporation, etc.

Abstract. Complex silicon carbide (SiC) ceramic components have significant strategic importance for national security and cutting-edge technology development. However, the inherent characteristics of SiC ceramics such as high brittleness, brittleness, and defect sensitivity, render it challenging, or even unrealistic to fabricate SiC components with high geometric complexity using traditional manufacturing methods. Therefore, the overall formation of complex SiC components has become aglobal "stuck neck" issue. To address this challenge, Professor Yusheng Shi and his research group from Huazhong University of Science and Technologypioneered the “Preparation of SiCcomposite powders and the integrated additive manufacturing (AM)technology for its complex ceramic components”. This cutting-edgetechnology primarily consists of several critical components such as specific high-performance SiC feedstocks for AM, complex 3D model data processing and process planning software, and forming equipment and processes. Related research results have formed a set of full theories and technologies of material-software-equipment-process for integrated AM of complex SiC ceramic composite components, and has been used to fabricate a variety of typical complex SiC components, including square mirrors for integrated circuit lithography machines, reflector mirrors for space remote sensing satellites, and impellers for slurry pumps, some of which have been successfully applied. The maximum size of the fabricated SiC composite components is more than 1.6 meters, and the relative density is greater than 99 %.The research ideas and progress of this cutting-edgetechnology will be introduced in detail in this report.

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