Thesis
Forming miniature ceramic components using micro-forming and a field activated sintering technique (Micro-FAST)
- Creator
- Rights statement
- Awarding institution
- University of Strathclyde
- Date of award
- 2022
- Thesis identifier
- T16148
- Person Identifier (Local)
- 201456180
- Qualification Level
- Qualification Name
- Department, School or Faculty
- Abstract
- The demand for miniature products has recently significantly increased as has the need forthese products to be produced rapidly, flexibly and in a cost efficient manner. The applicationof electrical sintering shows significant potential to produce these components by using powdermaterials. However, previous research has shown that there are still challenges that need to beconsidered in order to achieve increased densification of products and simplification of theprocesses. The process concept utilised in this study is called Micro-FAST, which comprisesthe combination of an electrical-field activated sintering technique (FAST) and micro-formingprocesses.The aim of the work was to develop the process concept for the manufacture of miniaturecomponents, and to develop the necessary die sets along with other tooling for experimentalwork to enable the forming of ceramic micro components from powder materials and to alsodevelop a new tool design for mass production.A comprehensive literature review is given on micro-manufacturing processes, challenges,key issues, micro forming, micro scale size effects, sintering processes and the electrical fieldactivated sintering processes and their application. The concept of the Micro-FAST processwas explained, and development of the die sets and materials selection justification for theprocess is described.The finite element (FE) analysis of the effect of the coupled thermal-electricalcharacteristics of the die sets during the heating and cooling process was carried out. This wasdone in order to study the heating flows of the die sets using the material properties chosen forthis research, the materials were zirconia, alumina and piezoceramic. The simulation analysiswas focused on the heating distribution process resulting from the die set design. Anexperimental study has also been conducted in this work to validate the results from finiteelement (FE) analysis.The experiment was conducted using a Gleeble® 3800 testing system, a Scanning ElectronMicroscope from HITACHI S-3700N, Energy Dispersive Spectroscopy and Nano TestVantage system (Nano-indentation). The material powders that have been used for thisexperiment were three different types of zirconia, alumina (Al2O3), and piezoceramics (PZT).The first zirconia powder was yttria partially stabilized zirconia (3Y-ZrO2), the second powderis magnesia partially stabilized zirconia (MSZ) and the third powder was magnesia partiallystabilized zirconia with 5 wt% organic additives or organic binders (MSZ(#) ) to improve theforming process.Based on the results, the development of a new tool die-design concept has been introducedwhich can potentially be used for mass production to produce miniature ceramic components.The new alternative design is going to be validated and examined using the finite element (FE)analysis of the new tool design sets effect on the coupled thermal-electrical characteristicsduring the heating and cooling process using ABAQUS/CAE software. In conclusion,improvements and promising results have been presented regarding a reduced process time forthe manufacture of miniature components with a variety of ceramic powder materials.Recommendations for future work have been suggested and explained at the end of this workin order to make further improvements to the process.
- Advisor / supervisor
- Qin, Y. (Yi)
- Resource Type
- DOI
- Funder
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PDF of thesis T16148 | 2022-02-04 | Public | Télécharger |