Laser Directed Energy Deposited Eutectic Ceramic

Large-size sintering-free

Directly fabricates large-size, high-density eutectic ceramics via a double-track overlapping scanning strategy, overcoming manufacturing bottlenecks for ultra-high-temperature oxide ceramics.

Shen, Zhonglin · Su, Haijun · Chen, Qian · Guo, Yinuo · Jiang, Hao · Jiatong, Yao · Yu, Minghui · Li, Xiang · Dong, Dong · Yang, Peixin · Zhang, Zhuo · Guo, Min

Journal of Materials Science and Technology 2026

Specifications

Diameter

{'zh': '8–9', 'en': '8–9'} mm

Height

{'zh': '135', 'en': '135'} mm

Relative density

{'zh': '98.5', 'en': '98.5'} %

Crack density

{'zh': '0.41', 'en': '0.41'} mm⁻¹

Fracture toughness

{'zh': '6.35', 'en': '6.35'} MPa m1/2

Advantages

Sintering-free direct fabrication

Using a double-track overlapping scanning strategy, laser directed energy deposition directly creates large-size eutectic ceramics, eliminating the sintering step and related defects.

Low crack density

Crack density decreased to a minimum of 0.41 mm⁻¹ at a scanning speed of 360 mm/min, showing that crack formation can be effectively suppressed by adjusting scanning speed.

Enhanced fracture toughness

A maximum fracture toughness of 6.35 MPa m1/2 was achieved at 450 W laser power and 270 mm/min scanning speed, fulfilling the toughness requirements for high-temperature structural applications.

Applications

• Hot-section components of aerospace engines：Used to fabricate hot-section components in aerospace engines, replacing traditional superalloys to withstand higher temperatures.
• Ultra-high-temperature structural materials：As ultra-high-temperature structural materials, they maintain strength in oxidizing and corrosive environments, extending component life.
• High-load complex components：They enable near-net-shape fabrication of complex high-load components, reducing post-processing.
• Additive manufacturing：Using laser directed energy deposition additive manufacturing, large-size ceramics can be directly formed.