Fabrication of self-supporting structures made of washcoat materials (γ-Al2O3-CeO2) by ceramic stereolithography: Towards digital manufacturing of enhanced catalytic converters

Setareh Zakeri, Teemu Vastamäki, Mari Honkanen, Matti Järveläinen, Minnamari Vippola, Erkki Levänen

Tutkimustuotos: ArtikkeliTieteellinenvertaisarvioitu

9 Sitaatiot (Scopus)
33 Lataukset (Pure)

Abstrakti

Despite increasing interest in the use of alternative fuel, conventional diesel or gasoline powered vehicles still dominate road transportation; removal of their emitted pollutants is a challenge to sustainable transportation. The automotive industry has employed catalytic converters (CCs) to effectively modify or eliminate toxic pollutants emitted by combustion engines. The efficiency of a CC greatly depends on its geometry and is hindered by limitations in fabrication techniques. To go beyond these limits and further enhance the performance of CCs, one can use state-of-the-art ceramic stereolithography (CSL) technology, which enables fabrication of complex-shaped structures. In this work, a novel photocurable ceramic resin made of γ-Al2O3 and CeO2 (the commonly used washcoat materials in CCs) is shaped into the honeycomb and twisted honeycomb structures using CSL. Measurements reveal that upon the addition of CeO2 to the plain γ-Al2O3 resin, the penetration depth of light is significantly decreased from 408.06 μm to 75.19 μm. This research also focuses on the balance between having a high surface area and achieving good physical stability in the printed structures. Accordingly, the appropriately debinded structures are sintered at two different temperatures: 900 °C and 1100 °C. It is found that the structure sintered at 900 °C has a higher surface area, and thus, it is a better candidate for catalytic applications. Furthermore, investigation of the stabilizing effect of CeO2 on printed γ-Al2O3 finds that CeO2 is effective in stabilizing the printed γ-Al2O3 at1100 °C but not 900 °C. Targeting the realization of green and sustainable transportation, the applied CSL technique in this study enables flexible control in the design and fabrication of self-supporting structures that are expected to open promising ways for the optimization of CCs.

AlkuperäiskieliEnglanti
Artikkeli110115
Sivumäärä12
JulkaisuMaterials and Design
Vuosikerta210
DOI - pysyväislinkit
TilaJulkaistu - 15 marrask. 2021
OKM-julkaisutyyppiA1 Alkuperäisartikkeli tieteellisessä aikakauslehdessä

Rahoitus

The authors gratefully acknowledge the Finnish Cultural Foundation and the Graduate School of Tampere University (TAU) for supporting and funding this research. Moreover, the authors acknowledge Dinex Finland Oy for their cooperation in this research. In addition, the authors are grateful to Research Manager Jorma Vihinen from the Automation Technology and Mechanical Engineering unit of TAU for providing us the Lithoz 3D printer. Many thanks also to Sasol for providing us the Puralox SBa 150 powder. The electron microscopy work in this research made use of the facilities of the Tampere Microscopy Center at TAU.

Julkaisufoorumi-taso

  • Jufo-taso 2

!!ASJC Scopus subject areas

  • Yleinen materiaalitiede
  • Mechanics of Materials
  • Mechanical Engineering

Sormenjälki

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