Additive manufacturing apparatus with powder-integrated preceramic mixture and related methods
An additive manufacturing apparatus includes powder supplies, a preceramic binder supply, and a mixer device downstream from the powder supplies and the preceramic binder supply and configured to generate a powder-integrated preceramic mixture. The additive manufacturing apparatus also includes a nozzle device downstream from the mixer device and configured to output the powder-integrated preceramic mixture, and a heat source configured to heat the powder-integrated preceramic mixture to initiate a self-sustainable ceramization reaction to generate a ceramic matrix composite.
1 . An additive manufacturing apparatus comprising:
a plurality of powder supplies;
a preceramic binder supply;
a mixer device downstream from the plurality of powder supplies and the preceramic binder supply and configured to generate a powder-integrated preceramic mixture;
a fiber supply configured to output a continuous fiber;
a nozzle device downstream from the mixer device and the fiber supply, the nozzle device configured to receive the continuous fiber and output the powder-integrated preceramic mixture surrounding the continuous fiber; and
an infrared laser source configured to apply a transient thermal initiation energy to the powder-integrated preceramic mixture to initiate a self-sustainable ceramization reaction to generate a ceramic matrix composite, the transient thermal initiation energy having a duration less than 5 seconds.
2 . The additive manufacturing apparatus of claim 1 wherein the powder-integrated preceramic mixture comprises a reactive powder-integrated preceramic oligomer.
3 . The additive manufacturing apparatus of claim 1 wherein the nozzle device includes an input funnel coupled to an output of the mixer device, and a mixing chamber coupled downstream from the input funnel.
4 . The additive manufacturing apparatus of claim 3 wherein the mixing chamber comprises a motor, and an auger powered by the motor.
5 . The additive manufacturing apparatus of claim 1 wherein the plurality of powder supplies comprises a plurality of inorganic reactive powder supplies.
6 . The additive manufacturing apparatus of claim 1 wherein the preceramic binder supply comprises a preceramic oligomer binder supply.
7 . The additive manufacturing apparatus of claim 1 further comprising an ultraviolet radiation source configured to cure the powder-integrated preceramic mixture before initiating a self-sustainable ceramization reaction.
8 . The additive manufacturing apparatus of claim 1 wherein the infrared laser source is configured to heat the powder-integrated preceramic mixture for set time period and deliver less than 2000 Joules of energy to initiate the self-sustainable ceramization reaction.
9 . An additive manufacturing apparatus comprising:
a plurality of powder supplies;
a preceramic binder supply;
a mixer device downstream from the plurality of powder supplies and the preceramic binder supply and configured to generate a reactive powder-integrated preceramic oligomer;
a fiber supply configured to output a continuous fiber;
a nozzle device downstream from the mixer device and the fiber supply, the nozzle device configured to receive the continuous fiber and comprising
an input funnel coupled to an output of the mixer device, and
a mixing chamber coupled downstream from the input funnel and configured to output the reactive powder-integrated preceramic oligomer surrounding the continuous fiber; and
an infrared laser source configured to apply a transient thermal initiation energy to the reactive powder-integrated preceramic oligomer to initiate a self-sustainable ceramization reaction to generate a ceramic matrix composite, the transient thermal initiation energy having a duration less than 5 seconds.
10 . The additive manufacturing apparatus of claim 9 wherein the mixing chamber comprises a motor, and an auger powered by the motor.
11 . The additive manufacturing apparatus of claim 9 wherein the plurality of powder supplies comprises a plurality of inorganic reactive powder supplies.
12 . The additive manufacturing apparatus of claim 9 wherein the preceramic binder supply comprises a preceramic oligomer binder supply.
13 . The additive manufacturing apparatus of claim 9 further comprising an ultraviolet radiation source configured to cure the reactive powder-integrated preceramic oligomer before initiating a self-sustainable ceramization reaction.
14 . The additive manufacturing apparatus of claim 9 wherein the infrared laser source is configured to heat the reactive powder-integrated preceramic oligomer for set time period and deliver less than 2000 Joules of energy to initiate the self-sustainable ceramization reaction.
15 . A three-dimensional (3D) printing device comprising:
a plurality of powder supplies;
a preceramic binder supply;
a mixer device downstream from the plurality of powder supplies and the preceramic binder supply and configured to generate a powder-integrated preceramic mixture;
a fiber supply configured to output a continuous fiber;
a nozzle device downstream from the mixer device and the fiber supply, the nozzle device configured to receive the continuous fiber and comprising
an input funnel coupled to an output of the mixer device, and
a mixing chamber coupled downstream from the input funnel and configured to output the powder-integrated preceramic mixture surrounding the continuous fiber;
an ultraviolet radiation source configured to cure the powder-integrated preceramic mixture before initiating a self-sustainable ceramization reaction; and
an infrared laser source configured to apply transient thermal initiation energy to the powder-integrated preceramic mixture to initiate the self-sustainable ceramization reaction to generate a ceramic matrix composite, the transient thermal initiation energy having a duration less than 5 seconds.
16 . The 3D printing device of claim 15 wherein the plurality of powder supplies comprises a plurality of inorganic reactive powder supplies.
17 . The 3D printing device of claim 15 wherein the infrared laser source is configured to heat the powder-integrated preceramic mixture for set time period and deliver less than 2000 Joules of energy to initiate the self-sustainable ceramization reaction.
18 . The additive manufacturing apparatus of claim 1 wherein the infrared laser source configured to apply the transient thermal initiation energy to initiate the self-sustainable ceramization reaction at a triggering point, the self-sustainable ceramization reaction spreading through an entire structure of the ceramic matrix composite.
19 . The additive manufacturing apparatus of claim 9 wherein the infrared laser source configured to apply the transient thermal initiation energy to initiate the self-sustainable ceramization reaction at a triggering point, the self-sustainable ceramization reaction spreading through an entire structure of the ceramic matrix composite.
20 . The 3D printing device of claim 15 wherein the infrared laser source configured to apply the transient thermal initiation energy to initiate the self-sustainable ceramization reaction at a triggering point, the self-sustainable ceramization reaction spreading through an entire structure of the ceramic matrix composite.