Holistic high-temperature assistance for laser directed energy deposition of Al2O3/ZrO2 eutectic ceramics: cracking behavior

Dong-Jiang Wu , Cheng-Xin Li , Ming-Ze Xu , Xue-Xin Yu , Guang-Yi Ma , Huan-Yue Zhang , Cong Zhou , Bi Zhang , Fang-Yong Niu

Advances in Manufacturing ›› : 1 -25.

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Advances in Manufacturing ›› :1 -25. DOI: 10.1007/s40436-025-00572-x
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Holistic high-temperature assistance for laser directed energy deposition of Al2O3/ZrO2 eutectic ceramics: cracking behavior

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Abstract

Laser-directed energy deposition (LDED) has emerged as a primary technology for the direct additive manufacturing of melt-growth ceramics (MGCs). However, cracking during fabrication severely limits further development of this technology. This study investigated a new holistic high-temperature-assisted method for LDED to solve the cracking problem. This method mitigates the high temperature gradients caused by the low thermal conductivity of the material during fabrication, thereby suppressing crack formation. The LDED of Al2O3/ZrO2 eutectic ceramics was performed at a holistic auxiliary temperature of up to 1 273 K, and the crack-suppressing effectiveness and mechanism were verified by combining numerical simulations and experiments. The results demonstrated that holistic high-temperature assistance significantly mitigated cracking in Al2O3/ZrO2 eutectic ceramics fabricated via LDED. At an auxiliary temperature of 1 273 K, the stress level in the fabricated sample was reduced by an order of magnitude compared to that at room temperature. Consequently, the lengths and densities of the cracks in the fabricated samples decreased by 47.6% and 55.6%, respectively. This study confirmed that the holistic high-temperature-assisted LDED method could play an important role in the additive manufacturing of low-ductility materials.

Keywords

Additive manufacturing / Laser directed energy deposition (LDED) / Ceramics / Cracks / High-temperature assisted

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Dong-Jiang Wu, Cheng-Xin Li, Ming-Ze Xu, Xue-Xin Yu, Guang-Yi Ma, Huan-Yue Zhang, Cong Zhou, Bi Zhang, Fang-Yong Niu. Holistic high-temperature assistance for laser directed energy deposition of Al2O3/ZrO2 eutectic ceramics: cracking behavior. Advances in Manufacturing 1-25 DOI:10.1007/s40436-025-00572-x

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Funding

National Natural Science Foundation of China(No. 52375312)

Fundamental Research Funds for the Central Universities(No. DUT23YG230)

National Key Research and Development Program of China(2023YFB4605900)

Liaoning Province Science and Technology Plan Joint Program(2023JH2/101700299)

Shenzhen Science and Technology Innovation Commission(JCYJ20210324115413036)

RIGHTS & PERMISSIONS

Shanghai University and Periodicals Agency of Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature

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