成果報告書詳細
管理番号20150000000431
タイトル*平成26年度中間年報 SIP(戦略的イノベーション創造プログラム) 革新的設計生産技術 高付加価値セラミックス造形技術の開発
公開日2015/7/18
報告書年度2014 - 2014
委託先名TOTO株式会社 日本ガイシ株式会社 日本特殊陶業株式会社 株式会社ノリタケカンパニーリミテド 国立大学法人大阪大学接合科学研究所 一般財団法人ファインセラミックスセンター 独立行政法人産業技術総合研究所
プロジェクト番号P14030
部署名ロボット・機械システム部
和文要約
英文要約Title: CSTI, SIP, Innovative Design/ Manufacturing Technologies, High-Value Added Ceramic Products Manufacturing Technologies (FY2014-FY2015) FY2014 Annual Report

For innovative ceramic manufacturing technologies, this project focuses on the three primary development items including (1) Additive Manufacturing (powder/slurry layer manufacturing (PLM/SLM) for complex- shaped products, and ceramic laser sintering free of post-sintering), (2) Hybrid Coating (hybrid aerosol deposition (HAD) and ultrafine-particle thermal spraying (UPTS) for highly adhesive coating onto 3D product surfaces) and (3) Product Manufacturing based on these two developments for various target applications (semiconductor manufacturing parts, plasma-resistant parts, ceramic filters, knee joint prosthesis, bone prosthesis, and ceramic cores). As for the Additive Manufacturing, suitable ceramic raw powders and organic binders were investigated for PLM, resulting in laminated and post-sintered ceramic samples. Precise shape control of SLM was realized in relatively large products composed of micro parts. For the ceramic laser sintering, highly concentrated ceramic slurries were developed, which were dewaxed and dried without cracking and deformation. Investigated were also fundamental sintering behaviors of ceramics under laser irradiation. Regarding the Hybrid Coating, it was found that the deposition rate substantially increased in plasma-assisted HAD without thermal damage on substrate, indicating substantial surface activation effects of plasma. Fracture behaviors of various raw particles were evaluated under compression as well, for clarifying fundamental mechanisms of aerosol deposition. High-potentiality of rapid and dense deposition was identified in UPTS. In the Product Manufacturing for the semiconductor manufacturing parts, the raw materials suitable for PLM and SLM were examined, and laminated samples were produced thereby. For the plasma-resistant parts, the intermediate-target hardness was obtained in HAD and the target solid concentration was attained in UPTS. For sealing the ceramic filters, alumina coating was made by HAD and raw slurry with suitable solid concentration was developed for UPTS. As for substrates of the ceramic filters, laminated bodies were obtained by SLM. For the knee joint prosthesis, sintered samples with ~90% density were produced by SLM, and preliminary evaluation was made for alumna onto polythene coated by HAD. Slurry with suitable thixotropy was obtained for SLM of the bone prosthesis. As for the ceramic cores, raw materials were prepared for SLM and PLM by mixing powder with thermosetting and photo-curable resins, and laminated samples were produced by both the methods. In addition, various activities have been initiated including cooperation with other projects under “Innovative Design/ Manufacturing Technologies” for demonstration and practice of innovation style.
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