Research progress on formation and suppression of crack defects in oxide eutectic ceramics by laser additive manufacturing

Oxide eutectic ceramics have excellent high specific strength, high temperature resistance, corrosion resistance, oxidation and creep resistance, and so on, which are considered to be the promising materials to be used in ultra-high temperature oxidation, corrosion and other extreme environments. It shows great application prospects in the new generation of high thrust-to-weight ratio aero-engine for high-temperature hot-end structural components. Laser additive manufacturing technology has become one of the most promising cutting-edge technologies for the preparation of high-performance complex structural components in recent years. Crack defect is easy to occur in the process of laser rapid solidification of ceramics, which seriously affects the quality and performance of the oxide eutectic ceramics components. So, it has become a key factor restricting the engineering application. Two typical laser additive manufacturing technologies for ceramics including laser engineered net shaping and laser power bed fusion were briefly summarized. The crack morphology characteristics of different shaped components formed by the above two technologies were analyzed and compared. The formation mechanism of cracks in laser additive manufacturing of oxide ceramics was explored from the perspectives of microstructure characteristics, stress state. Further, a systematic summary was presented focusing on the improvement of microstructures and the reduction of thermal stress to inhibit crack formation through optimization of process parameters, compositional design, and outfield assistance. Finally, it is pointed out that the future development trends and breakthrough directions of oxide eutectic ceramics by laser additive manufacturing in terms of powder properties, forming primary and secondary factors, and forming technology research.