成果報告書詳細
管理番号20160000000645
タイトル*平成27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2016/8/5
報告書年度2015 - 2015
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 国立研究開発法人産業技術総合研究所 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
プロジェクト番号P14030
部署名IoT推進部
和文要約
英文要約Title: CSTI, SIP, Innovative Design/ Manufacturing Technologies, High-Value Added Ceramic Products Manufacturing Technologies (FY2014-FY2018) FY2015 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 (CLS) 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, portable toilets, ceramic filters, knee joint prosthesis, bone prosthesis, and ceramic cores).
As for the Additive Manufacturing, suitable raw materials and lamination conditions were investigated for PLM, resulting in 3D components with various shapes and structures. Rapid shaping was realized for SLM in relatively large products composed of micro parts. For CLS, dense sintered layer of several hundred micron thickness was obtained for the first time in the world using the highly concentrated ceramic slurry. Investigated were also fundamental sintering behaviors of ceramics under laser irradiation. Regarding the Hybrid Coating, the deposition rate increased 10-50 times in plasma-assisted HAD of alumina-based powder, compared to conventional AD. Also raw composite particles were developed for HAD, resulting in successful alumina-based coating on polyethylene resin substrates. For UPTS, it was shown that rapid and dense deposition was possible even on cylindrical or spherical substrates. In the Product Manufacturing for the semiconductor manufacturing parts, the processes were adjusted for PLM and SLM, leading to a stage model component of 200 x 200 x 30 mm, etc. The hardness and plasma-resistance exceeding the targets were obtained by HAD for the plasma-resistant parts. HAD was also applied to the portable toilets. For sealing the ceramic filters, alumina coating of ~200 micron thickness was made on porous substrates by HAD, resulting in the target sealing property. As for substrates of the filters, raw powders, etc. were adjusted for making formed disk plates by SLM, whose joined and sintered body exhibited the properties satisfying the targets. For the knee joint prosthesis, sintered samples with the target density and bending strength, were produced using SLM, and alumina-based coating was applied on polyethylene resin substrates using HAD. Sintered porous substrates with the target pore size and pore connectivity, were prepared using SLM for the bone prosthesis. As for the ceramic cores, bending strength exceeding the target, 7 MPa, was attained for the samples prepared, and core model components with 80 x 60 x 10 mm in size were produced using PLM and SLM, via. optimizing processes. In addition, various activities were conducted towards innovation, including discussion on “delight” products.
ダウンロード成果報告書データベース(ユーザ登録必須)から、ダウンロードしてください。

▲トップに戻る