Polyethylene–SiC composite filaments: Processing, printability, and formation of porous SiC preform via additive manufacturing
Journal of Materials Research and Technology, vol.42, pp.10612-10624, 2026 (SCI-Expanded, Scopus)
- Publication Type: Article / Article
- Volume: 42
- Publication Date: 2026
- Doi Number: 10.1016/j.jmrt.2026.05.060
- Journal Name: Journal of Materials Research and Technology
- Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Compendex, INSPEC, Directory of Open Access Journals
- Page Numbers: pp.10612-10624
- Keywords: Composite filament, Fused filament fabrication, Polyethylene, Porous ceramics, Pre-sintering, Silicon carbide
- Dokuz Eylül University Affiliated: Yes
Abstract
Polyethylene/silicon carbide (PE/SiC) composite filaments containing Al2O3 and Y2O3 as sintering aids were developed for fused filament fabrication (FFF). Feedstocks with 50–65 wt% SiC were prepared by melt compounding and filament extrusion. The formulation with 60 wt% SiC exhibited the most stable extrusion behavior, uniform filament diameter (1.75 ± 0.05 mm), and reliable printability. As-printed green specimens showed sufficient mechanical integrity, with an ultimate tensile strength of 0.94 ± 0.06 MPa and a Young's modulus of 48 ± 3 MPa. Thermal analysis confirmed complete binder removal above 500 °C without ceramic degradation. After debinding and pre-sintering at 1200 °C under argon, porous SiC preforms with an interconnected ceramic framework were obtained, exhibiting a bulk density of 1.73 ± 0.03 g cm−3, 35 ± 1% open porosity, and a Vickers hardness of 1350 ± 12 HV. These results demonstrate that the developed PE/SiC feedstock enables the fabrication of mechanically stable porous SiC preforms suitable for subsequent high-temperature densification or functional porous ceramic applications.