The Effect of AlN Content on the Properties of Al2O3-AlN Composite Ceramics Fabricated by Digital Light Processing

In this work, Al2O3-AlN composite ceramics with high bending strength and thermal conductivity were fabricated by Digital Light Processing (DLP). The influence of AlN content on the rheological and cure behavior of Al2O3-AlN suspensions, as well as the microstructure, thermal conductivity, and bending strength of Al2O3-AlN ceramics, were systematically investigated. The result shows that the viscosity and cure ability of the suspensions were decreased with the increase of AlN content, which are beneficial to the spreading and printing accuracy of the suspensions. Besides, the bending strength of ceramics can be improved due to the residual stress by the introduction of AlN. Approaches were employed to minimize the formation of AlON in Al2O3-AlN ceramics by optimizing the amount of AlN and the sintering temperature. The thermal conductivity and bending strength of Al2O3-AlN ceramics were 31.72 ± 0.45 W/(m·K) and 572.73 ± 59.40 MPa, respectively, which are much higher than those of Al2O3 ceramics fabricated under the same condition. Finally, complex-shaped Al2O3-AlN ceramics components have been successfully fabricated by DLP, which may provide an opportunity to broaden the application of Al2O3-AlN composite ceramics in heat dissipation components.