本文へジャンプ

成果報告書詳細
管理番号20170000000389
タイトル*平成28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2017/6/7
報告書年度2016 - 2016
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) FY2016 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, processing conditions were optimized for PLM with attaining the intermediate targets, and producing several 3D product models. Rapid shaping was realized for SLM in 7~8 hours for a large product of 200 x 200 x 100 mm. For CLS, multi-layer direct sintering of oxide ceramics was tried based on the mono-layer sintering technologies developed so far. Investigated were also direct sintering behaviors of non-oxide ceramics under laser irradiation. Regarding the Hybrid Coating, the deposition rate was increased about 40 times in HAD, compared to conventional AD. Also successful coating was made possible even in substrates of 3D shape or large-sale area. Furthermore, “Coating Base” was established for widely spreading developed technologies. For UPTS, that rapid deposition of 50 μm/s was attained by using high-concentration slurry. In the Product Manufacturing for the semiconductor manufacturing parts, the processes were adjusted for PLM, leading to a truss-structured stage model component of 200 x 200 x 80 mm, etc. The hardness and plasma-resistance exceeding the intermediate targets were obtained by HAD for the plasma-resistant parts. HAD was also successfully applied to resin substrates for the portable toilets. For sealing the ceramic filters, alumina coating of 100~200 micron thickness was made on porous substrates by HAD, resulting in the intermediate target sealing property. As for substrates of the filters, formed bodies were prepared at rates 3 times higher than conventional by adjusting process conditions in a new SLM facility. For the knee joint prosthesis, sintered samples with the target density, strength and wear-resistance 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, the target bending strength and porosity were obtained in PLM and SLM through optimizing process conditions, and produced components were subjected to evaluation of a customer company. In addition, various activities were conducted towards dissemination of research achievements, etc.
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