Effect of sintering temperature on the microstructures and mechanical properties of ZrO2 ceramics fabricated by additive manufacturing

The optimization of the sintering process for ceramic stereolithography-based additive manufacturing is attracting high interest important due to its correlation with the final properties of the fabricated parts. In this work, a photosensitive zirconia suspension with low viscosity and high solid loading (48 vol%) was prepared using surface-modified zirconia ceramic powders, resulting in an improvement in long-term stability. The correlations between the sintering temperature (1400–1520 °C) and mechanical properties were investigated. The results showed that and the as-sintered zirconia parts exhibited a relatively high density of 99.5 ± 0.1 % and three-point flexural strength of 821 ± 65 MPa as well as excellent fracture toughness (4.37 ± 0.22 MPa m1/2) sintering at 1480 °C, which was attributed to the highly homogeneous microstructure without obvious pores or crack. The obtained insights regarding the correlation between sintering temperature, relative density, and flexural strength can provide practical guidance for the future applications of zirconia ceramics.