SPP 2419: 3D printing of alumina components via Fused Granulate Fabrication technology and solvent-free debinding of highly filled feedstocks comprising (LD)-polyethylene and cellulose
Type of the data | Collection | |
Total size of the dataset | 12499919 | |
Author | Brachhold, Nora | |
Author | Heuer, Claudia | |
Author | Bock-Seefeld, Benjamin | |
Author | Kaiser, Patricia | |
Author | Weigelt, Christian | |
Author | Malczyk, Piotr | |
Author | Trimis, Dimosthenis | |
Author | Aneziris, Christos G. | |
Upload date | 2026-03-30T11:52:04Z | |
Publication date | 2026-03-30T11:52:04Z | |
Publication date | 2026-03-30 | |
Abstract of the dataset | This study focuses on the development of components in gyroid structure based on alumina as integral part of the novel burner designed for the non-premixed combustion of ammonia. During application, the component has to withstand repeated thermal shocks of approx. 600 K or more. Due to the high geometric complexity of the gyroid structure and the need for lightweight design with both macroporous regions and microporous features only the 3D printing was suitable as manufacturing technology; in the present work Fused Granulate Fabrication was used. The manufacturing routine for the employed granules with special regard to the binder system is developed. A customized thermal debinding regime without wick or solvent debinding is presented. Challenges such as the formation of bubbles and the swelling of the samples during thermal debinding were met by adjusting the printing parameters to create porosity and cavities between the deposited strands during 3D printing. Sintered bars fabricated using optimized printing parameters had a shrinkage of 13 %, an open porosity of 41 % and a flexural strength of 50 MPa, respectively. These values are sufficient for the application of the components in the novel burners. As last part of this work sheet-gyroid structures were prepared using a 1.0 mm and 0.4 mm nozzles. These structures successfully survived 5 thermal shock cycles, each involving heating to 1100 ◦C followed by air quenching, which is an excellent result in terms of thermal shock performance. | |
Public reference to this page | https://opara.zih.tu-dresden.de/handle/123456789/2162 | |
Publisher | Technische Universität Bergakademie Freiberg | |
Specification of the discipline(s) | 4::43::405::405-02 | |
Title of the dataset | SPP 2419: 3D printing of alumina components via Fused Granulate Fabrication technology and solvent-free debinding of highly filled feedstocks comprising (LD)-polyethylene and cellulose | |
Project abstract | The project focuses on the thermochemical energy conversion process of the carbon-free chemical energy carrier ammonia and of ammonia/hydrogen mixtures. Ammonia is considered as one of the future energy and hydrogen carriers, especially in terms of long-distance transport since its thermal properties are similar to those of propane and it can easily be liquefied for storage and transport with an established transportation network. However, the combustion of ammonia poses considerable challenges. The three major challenges are its low burning velocity compared to hydrocarbons resulting in poor flame stability, extremely high levels of nitrogen oxide formation and high toxicity even at trace levels. Conventional approaches to address these challenges are the addition of highly reactive fuels like hydrogen or methane to address the issue of flame stability, conversion in staged fuel rich/lean processes to address the high NOx formation and post treatment for avoiding unburnt ammonia emissions. We propose to address all challenges at once by a novel concept for non-premixed combustion of ammonia in Porous Inert Media (PIM). Combustion in PIM can increase burning velocities by more than one order of magnitude compared with non-PIM combustion due to heat recirculation through the solid phase. Heat recirculation combined with the thermal inertia of the solid phase resolves the issue of flame stability. The non-premixed approach results in high temperatures of the initial fuel rich or pure fuel streams decomposing ammonia without significant NOx formation, while the good mixing and temperature homogenization effects by the flow through the PIM lead to a complete burnout of remaining ammonia in a post-combustion zone. In order to realize such concept, tailored high temperature-resistant materials are required, both in terms of geometry as well as spatial distribution of thermal properties. Additive manufacturing (ADM) of PIM structures from composite ceramic materials is needed to control the process through customized properties regarding heat conduction, radiation properties, dispersion and the flow field. The fundamental research and design of the non-premixed PIM burner for ammonia and ammonia/hydrogen-mixtures requires a strong interdisciplinary research team in the fields of high-fidelity experiments for combustion in PIM (EXP, KIT), detailed pore-resolved numerical simulations (SIM, KIT) and additive manufacturing methods for thermal shock and corrosion-resistant functional components (ADM, TU BAF). | |
Funding Acknowledgement | The dataset was generated within the framwork of the Priority Program SPP 2419 (project ID: 523876164) funded by ther German Research Foundation (DFG) | |
Public project website(s) | https://spp2419.rwth-aachen.de/ | |
Public project website(s) | https://gepris.dfg.de/gepris/projekt/523876164 | |
Project title | SPP 2419_SP10 - Non-premixed ammonia combustion in tailored ceramic porous inert media |