Synergistic Optimization of Porosity and Flexural Strength of Alumina Porous Ceramics Fabricated by 3D Printing Method Based on Response Surface Methodology

doi:10.3901/JME.2025.19.386

Abstract

Abstract: Alumina porous ceramics have widespread applications in the filtration field, while its porosity and flexural strength typically exhibit a negative correlation. However, efficient filtration materials require a combination of high porosity and high strength. Alumina porous ceramics is fabricated by slurry extrusion 3D printing technology, based on response surface methodology, filling rate, layer height, and printing speed are analyzed as independent variables to assess their effects on the porosity and flexural strength of the sintered alumina ceramics. The interaction effects among process parameters are analyzed, and a second-order nonlinear correlation mathematical equation are established. The results indicate that the interaction between filling rate and other process parameters have the most significant effect on porosity and flexural strength, followed by printing speed and layer height. The optimal process parameters for synergistic optimization of porosity and flexural strength are obtained, presenting a nozzle diameter of 0.41 mm, a filling rate of 50%, a layer height of 67% of the nozzle diameter, and a printing speed of 1 100 mm/min, the corresponding alumina porous ceramics achieved a porosity of 69.28%, a flexural strength of 9.04 MPa, with shrinkage rates of 3.86%, 4.21%, and 5.63% in the X, Y, and Z directions, respectively, and a side surface roughness of 18.16 μm. These findings provide a theoretical basis for optimizing the 3D printing process of porous ceramics and offer valuable insights for the design and fabrication of high-porosity, high-strength filtration ceramics.

Key words: alumina porous ceramics, slurry extrusion 3D printing, response surface methodology, flexural strength, porosity

CLC Number:

TG241
TH164

LIU Fuchu, WANG Miao, ZHANG Chi, LIN Xuexiong. Synergistic Optimization of Porosity and Flexural Strength of Alumina Porous Ceramics Fabricated by 3D Printing Method Based on Response Surface Methodology[J]. Journal of Mechanical Engineering, 2025, 61(19): 386-396.

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