Publications

@article{BHANDARI2024104238,

title = {Material-extrusion based additive manufacturing of BaTiO3 ceramics: from filament production to sintered properties},

author = {S. Bhandari and P. Veteška and G. Vajpayee and M. Hinterstein and Ľ. Bača and Z. Hajdúchová and Z. Špitalský and G. Franchin and M. Janek},

url = {https://www.sciencedirect.com/science/article/pii/S2214860424002847},

doi = {https://doi.org/10.1016/j.addma.2024.104238},

issn = {2214-8604},

year  = {2024},

date = {2024-01-01},

urldate = {2024-01-01},

journal = {Additive Manufacturing},

pages = {104238},

abstract = {Material extrusion (MEX) of thermoplastic filaments represents one of the most widely adopted additive manufacturing (AM) technologies. Unlike vat photopolymerization and powder-bed fusion methods that require high energy sources such as UV light and lasers, this fabrication method can be adapted for the fabrication of ceramics by using ceramic loaded filaments as feedstock, yet still employing relatively cheap equipment meant for polymeric materials with little adaptation of the process parameters; this potentially enables a broader diffusion of AM ceramic components. In this work, composite filaments with various weight fractions (60 – 80wt.%) of BaTiO3 were fabricated and characterized by electron microscopy, compressive mechanical testing, rheometry and thermogravimetric analysis to ensure a smooth and reliable printing process. After optimizing the printing parameters, the dense and porous printed samples were carefully debinded and sintered to obtain dense (~ 92%) and defect-free ceramic bodies. The sintered samples were characterized for phase development, microstructure, and pore size distribution. Careful observations reveal a particular range of pore size (0.1 – 5µm), which originates from the binder burn out process. The dielectric and ferroelectric properties of the fabricated samples were in good agreement with those reported in previous literature. This work provides a foundation for rapid prototyping of functional electro ceramics into reliable products with desired functional properties.},

keywords = {Additive Manufacturing},

pubstate = {published},

tppubtype = {article}

}

@article{OURGESSA2024100678,

title = {Sustainable construction materials from alkali-activated waste fiberglass and waste refractory},

author = {A. W. Ourgessa and J. Kraxner and H. Elsayed and D. Galusek and E. Bernardo},

url = {https://www.sciencedirect.com/science/article/pii/S2666539524001421},

doi = {https://doi.org/10.1016/j.oceram.2024.100678},

issn = {2666-5395},

year  = {2024},

date = {2024-01-01},

urldate = {2024-01-01},

journal = {Open Ceramics},

volume = {20},

pages = {100678},

abstract = {In this work, waste fiberglass was up-cycled, alone, or mixed with used alumina-zirconia-silica (AZS) refractory from dismantled glass melting furnaces. Alkali activation was performed by suspending fiberglass and fiberglass/AZS powders in NaOH aqueous solution of various concentrations (8M, 6M, and 3M). The activation of waste fiberglass with 8M NaOH yields a gel with calcium and sodium-containing aluminosilicate hydrates. The addition of AZS refractory enabled the release of aluminates into the solution, which had beneficial effects on the mechanical properties. Low molarity activation yielded weaker materials which could be used as precursors for firing at moderate temperatures (800 °C and 1000 °C) to create cellular glass-ceramics, with a total porosity of up to 92 %. The firing of 8M activated samples resulted in glass ceramics with a 66–75 % porosity range and compressive strength of 10–23Mpa. The compressive strength-to-density ratio before and after firing was comparable to that of established commercial construction materials.},

keywords = {Materials for the environment},

pubstate = {published},

tppubtype = {article}

}

@article{BIASETTO20246820,

title = {Co-extrusion of highly loaded feedstocks for fabrication of stainless steel-bioceramic core-shell structures},

author = {L. Biasetto and V. Gastaldi and H. Elsayed},

url = {https://www.sciencedirect.com/science/article/pii/S2238785424025250},

doi = {https://doi.org/10.1016/j.jmrt.2024.10.255},

issn = {2238-7854},

year  = {2024},

date = {2024-01-01},

urldate = {2024-01-01},

journal = {Journal of Materials Research and Technology},

volume = {33},

pages = {6820-6830},

abstract = {Co-extrusion of multi-materials structures shows technological challenges and opportunities. Filaments made of a metallic core and a ceramic shell are one example of how structural and functional features can be combined in a single component to provide a synergic effect. In this work, we focused on the fabrication of shell and core-shell scaffolds for potential applications as bone substitutes. Stainless steel 316L was selected for the core material, whilst in situ synthesized sphene (CaTiSiO5) bioactive ceramic was selected as a shell. The combination of a ductile core and a bioactive ceramic, so as scaffolds made of empty struts may represent a new generation of bone substitutes with mechanical properties closer to the ones of natural bone so as with improved bioactivity. Therefore, formulated inks were co-extruded in one step using a customized printing set-up. Microstructural and mechanical properties were investigated on shell and core-shell filaments and 3D structures. Shell bioceramics scaffolds possessed high porosity and target compression strength values. The sintering environment at the core-shell interface caused severe 316L oxidation thus compromising the ductility of the metallic part, however compression strength increased of 53% compared to shell structures.},

keywords = {Additive Manufacturing},

pubstate = {published},

tppubtype = {article}

}

@article{DIAMANTI202453646,

title = {Hybrid direct ink writing of bioglass-calcite-carbon composite scaffolds supported by novel silicone-based emulsions},

author = {V. Diamanti and H. Elsayed and E. Bernardo},

url = {https://www.sciencedirect.com/science/article/pii/S0272884224047369},

doi = {https://doi.org/10.1016/j.ceramint.2024.10.215},

issn = {0272-8842},

year  = {2024},

date = {2024-01-01},

urldate = {2024-01-01},

journal = {Ceramics International},

volume = {50},

number = {24, Part B},

pages = {53646-53654},

abstract = {70S30C (70 mol% SiO2, 30 % CaO) bioglass is one of the most promising bioceramics for bone tissue engineering. We discuss the feasibility of 70S30C bioglass/calcite/carbon composites derived from novel silicone-based emulsions, leading to highly porous lattice scaffolds. These are produced by direct ink writing (DIW) 3D printing, followed by ceramic conversion at 700 °C in flowing nitrogen. The emulsions consisted of droplets of concentrated calcium nitrate aqueous solution incorporated into blends of H44 commercial polysiloxane and photocurable acrylate resin. This formulation offered unprecedented opportunities in both synthesis and shaping. Specifically, the homogeneous dispersion of the CaO precursor in silicone enabled a uniform SiO2/CaO distribution, favoring the formation of a glass matrix. Additionally, the acrylate component and water content allowed for tuning of the microstructure both immediately after printing and upon firing. Photopolymerization of acrylates consolidated the printed bodies (configuring a ‘hybrid DIW’) after extrusion, while water evaporation enhanced gas evolution during ceramic conversion, promoting pore interconnectivity.},

keywords = {Additive Manufacturing},

pubstate = {published},

tppubtype = {article}

}

@article{Lago2024,

title = {Novel cesium immobilization by alkali activation and cold consolidation of waste pharmaceutical glass},

author = {D. Lago and G. Tameni and F. Zorzi and J. Kraxner and D. Galusek and E. Bernardo},

url = {https://www.scopus.com/inward/record.uri?eid=2-s2.0-85194095471&doi=10.1016%2fj.jclepro.2024.142673&partnerID=40&md5=954ab91e99c2519d54b0063aedd6394b},

doi = {10.1016/j.jclepro.2024.142673},

year  = {2024},

date = {2024-01-01},

urldate = {2024-01-01},

journal = {Journal of Cleaner Production},

volume = {461},

note = {Cited by: 1; All Open Access, Hybrid Gold Open Access},

keywords = {Materials for the environment},

pubstate = {published},

tppubtype = {article}

}

@article{Lago2024b,

title = {Cesium stabilization by engineered alkaline attack of glass for pharmaceutical containers},

author = {D. Lago and G. Tameni and J. Kraxner and D. Galusek and E. Bernardo},

url = {https://www.scopus.com/inward/record.uri?eid=2-s2.0-85199962040&doi=10.1016%2fj.matlet.2024.137097&partnerID=40&md5=0cf00a128d65142220b095702ecb01d4},

doi = {10.1016/j.matlet.2024.137097},

year  = {2024},

date = {2024-01-01},

urldate = {2024-01-01},

journal = {Materials Letters},

volume = {372},

note = {Cited by: 0},

keywords = {Materials for the environment},

pubstate = {published},

tppubtype = {article}

}

@article{Cammelli2024,

title = {Sustainable stabilization of waste foundry sands in alkali activated glass-based matrices},

author = {F. Cammelli and G. Tameni and E. Bernardo},

url = {https://www.scopus.com/inward/record.uri?eid=2-s2.0-85199569634&doi=10.1016%2fj.cscm.2024.e03538&partnerID=40&md5=b9f2019609974f651aa1945049786175},

doi = {10.1016/j.cscm.2024.e03538},

year  = {2024},

date = {2024-01-01},

urldate = {2024-01-01},

journal = {Case Studies in Construction Materials},

volume = {21},

note = {Cited by: 0; All Open Access, Hybrid Gold Open Access},

keywords = {Materials for the environment},

pubstate = {published},

tppubtype = {article}

}

@article{Biasetto2023,

title = {Ink Tuning for Direct Ink Writing of Planar Metallic Lattices},

author = {L. Biasetto and A. Gleadall and V. Gastaldi},

doi = {10.1002/adem.202201858},

issn = {1527-2648},

year  = {2023},

date = {2023-10-00},

urldate = {2023-10-00},

journal = {Adv Eng Mater},

volume = {25},

number = {20},

publisher = {Wiley},

abstract = {316L and Cu‐based inks are developed to 3D‐printed tetrachiral auxetic structures. The main objectives of the work are to study the effects of powders composition and powder:binder volume ratio on rheological properties and printability of the inks. Following these results, customized Gcode is developed using FullControl Gcode Designer open‐source software to 3D print intricate tetrachiral auxetic structures. The results reported in this work show how powder composition (316L versus Cu) has less effect on the inks’ rheological behavior than powder size distribution and powders:binder volume ratio. In terms of rheological parameters, the zero‐shear rate viscosity mainly affects the capability of the printed ink to retain its shape after printing, while the yield stress affects the printability. The printed and sintered auxetic structures achieve the intended lattice‐geometry design.},

keywords = {Additive Manufacturing},

pubstate = {published},

tppubtype = {article}

}

@article{BHANDARI2023,

title = {Ultra-rapid debinding and sintering of additively manufactured ceramics by ultrafast high-temperature sintering},

author = {S. Bhandari and C. Maniere and F. Sedona and E. De Bona and V. M. Sglavo and P. Colombo and L. Fambri and M. Biesuz and G. Franchin},

url = {https://www.sciencedirect.com/science/article/pii/S0955221923006660},

doi = {https://doi.org/10.1016/j.jeurceramsoc.2023.08.040},

issn = {0955-2219},

year  = {2023},

date = {2023-08-25},

urldate = {2023-01-01},

journal = {Journal of the European Ceramic Society},

abstract = {In recent years, additive manufacturing (AM) of ceramics has significantly advanced in terms of the range of equipment available, printing resolution and productivity. Most techniques involve the use of ceramic powders embedded in an organic binder which is typically removed through a slow thermal debinding process. Herein, we prove for the first time that ultra-rapid debinding and sintering are possible for complex 3YSZ components produced using material extrusion technology. The printed components were first chemically debinded in acetone thus removing about one-half of the binder, and then thermally debinded and sintered by ultrafast high-temperature sintering (UHS) in a single-step process (30 to 120s). Fully dense components were obtained with tailored microstructure and nanometric grain size. The sintered artefacts were crack-free even at the microscopic level. This approach paves the way for rapid processing (debinding and sintering) of additively manufactured ceramics with reduced energy consumption and carbon footprint.},

keywords = {Additive Manufacturing},

pubstate = {published},

tppubtype = {article}

}

@article{SHEZAD2023e19376,

title = {3D-printed zeolite 13X-Strontium chloride units as ammonia carriers},

author = {N. Shezad and M. D'Agostini and A. Ezzine and G. Franchin and P. Colombo and F. Akhtar},

url = {https://www.sciencedirect.com/science/article/pii/S2405844023065842},

doi = {https://doi.org/10.1016/j.heliyon.2023.e19376},

issn = {2405-8440},

year  = {2023},

date = {2023-08-22},

urldate = {2023-08-22},

journal = {Heliyon},

pages = {e19376},

abstract = {The selective catalytic reduction (SCR) system in automobile using urea solution as a source of NH3 suffer from solid deposit problem in pipe lines and poor efficiency during engine startup. Although direct use of high pressure NH3 is restricted due to safety concern, which can be overcome by using solid sorbents as NH3 carrier. Strontium chloride (SrCl2) is considered the best sorbent due to its high sorption capacity; however, challenges are associated with the processing of stable engineering structures due to extraordinary volume expansion during the NH3 sorption. This study reports the fabrication of a novel structure consisting of a zeolite cage enclosing the SrCl2 pellet (SPZC) through extrusion-based 3D printing (Direct Ink Writing). The printed SPZC structure demonstrated steady sorption of NH3 for 10 consecutive cycles without significant uptake capacity and structural integrity loss. Furthermore, the structure exhibited improved sorption and desorption kinetics than pure SrCl2. The synergistic effect of zeolite as physisorbent and SrCl2 as chemisorbent in the novel composite structure enabled the low-pressure (<0.4 bar) and high-pressure (>0.4 bar) NH3 sorption, compared to pure SrCl2, which absorbed NH3 at pressures above 0.4 bar. Regeneration of SPZC composite sorbent under evacuation showed that 87.5% percent of NH3 was desorbed at 20 °C. Thus, the results demonstrate that the rationally designed novel SPZC structure offers safe and efficient storage of NH3 in the SCR system and other applications.},

keywords = {Additive Manufacturing, Materials for the environment},

pubstate = {published},

tppubtype = {article}

}

@article{pmid37262160,

title = {Improving glass nanostructure fabrication},

author = {P. Colombo and G. Franchin},

url = {https://www.science.org/stoken/author-tokens/ST-1233/full},

doi = {10.1126/science.adi2747},

issn = {1095-9203},

year  = {2023},

date = {2023-06-01},

urldate = {2023-06-01},

journal = {Science},

volume = {380},

number = {6648},

pages = {895--896},

abstract = {A new method offers high-resolution three-dimensional printing and low-temperature firing.},

keywords = {Additive Manufacturing, Polymer-derived ceramics},

pubstate = {published},

tppubtype = {article}

}

@article{Altimari2023,

title = {Green materials for construction industry from Italian volcanic quarry scraps},

author = {F. Altimari and I. Lancellotti and C. Leonelli and F. Andreola and H. Elsayed and E. Bernardo and L. Barbieri},

doi = {10.1016/j.matlet.2022.133615},

year  = {2023},

date = {2023-01-01},

urldate = {2023-01-01},

journal = {Materials Letters},

volume = {333},

keywords = {Materials for the environment},

pubstate = {published},

tppubtype = {article}

}

@article{FENG2023,

title = {Enhanced electromagnetic microwave absorption properties of SiCN(Fe) ceramics produced by additive manufacturing via in-situ reaction of ferrocene},

author = {Y. Feng and X. Guo and H. Elsayed and K. Huang and G. Franchin and G. Motz and Y. Tong and H. Gong and P. Colombo},

url = {https://www.sciencedirect.com/science/article/pii/S0272884223012828},

doi = {https://doi.org/10.1016/j.ceramint.2023.05.035},

issn = {0272-8842},

year  = {2023},

date = {2023-01-01},

urldate = {2023-01-01},

journal = {Ceramics International},

abstract = {SiCN(Fe) ceramics with excellent electromagnetic wave (EMW) absorption performance were successfully prepared from a preceramic polymer doped with ferrocene. Additive manufacturing (Digital Light Processing), providing enhanced structural design ability, was employed to fabricate samples with complex architectures. During pyrolysis, ferrocene catalyzed the in-situ formation of a large amount of turbostratic carbon, graphite and SiC nanosized phases, which formed carrier channels in the electromagnetic field and increased the conductivity loss. Meanwhile, it also increased the dipole polarization, interface polarization and the dielectric properties of the material, which finally enhanced the EMW absorption capacity of SiCN(Fe) ceramics. When containing 0.5 wt% ferrocene, the material showed good performance with EAB 4.57 GHz at 1.30 mm, and RLmin −61.34 dB at 2.22 mm. The RLmin of 3D-SiCN-0.5 ceramics was −6 dB, and the RL of the X-band was lower than −4 dB at 2 mm.},

keywords = {Additive Manufacturing, Polymer-derived ceramics},

pubstate = {published},

tppubtype = {article}

}

@article{Contrafatto202347,

title = {Recycling Volcanic Ash and Glass Powder in the Production of Alkali Activated Materials},

author = {L. Contrafatto and D. Calderoni and S. Gazzo and E. Bernardo},

url = {https://www.scopus.com/inward/record.uri?eid=2-s2.0-85148683771&doi=10.1007%2f978-981-19-8769-4_5&partnerID=40&md5=ddbba62e90cbfbbeb918bf88730daf3e},

doi = {10.1007/978-981-19-8769-4_5},

year  = {2023},

date = {2023-01-01},

journal = {Smart Innovation, Systems and Technologies},

volume = {336 SIST},

pages = {47--55},

keywords = {Materials for the environment},

pubstate = {published},

tppubtype = {article}

}

@article{Sponchiado2023,

title = {Modeling Materials Coextrusion in Polymers Additive Manufacturing},

author = {R. Sponchiado and S. Rosso and P. Dal Fabbro and L. Grigolato and H. Elsayed and E. Bernardo and M. Maltauro and F. Uccheddu and R. Meneghello and G. Concheri and G. Savio},

url = {https://www.scopus.com/inward/record.uri?eid=2-s2.0-85146542047&doi=10.3390%2fma16020820&partnerID=40&md5=8f6d4fd9281c8e12d6011070909a93c1},

doi = {10.3390/ma16020820},

year  = {2023},

date = {2023-01-01},

journal = {Materials},

volume = {16},

number = {2},

keywords = {Additive Manufacturing},

pubstate = {published},

tppubtype = {article}

}

@article{MURACCHIOLI2023107020,

title = {Modeling the compressive strength of metakaolin-based geopolymers based on the statistical analysis of experimental data},

author = {M. Muracchioli and G. Menardi and M. D'Agostini and G. Franchin and P. Colombo},

url = {https://authors.elsevier.com/c/1hHC3cTCCHH3T},

doi = {https://doi.org/10.1016/j.clay.2023.107020},

issn = {0169-1317},

year  = {2023},

date = {2023-01-01},

urldate = {2023-01-01},

journal = {Applied Clay Science},

volume = {242},

pages = {107020},

abstract = {The relationship between the compressive strength of metakaolin-based geopolymer samples and different processing conditions has been investigated for both potassium and sodium based geopolymer systems. Cubic geopolymer samples were prepared by mixing the slurry for 1 h in a thermostatic bath at 0 °C. >1200 samples have been tested to gather enough data to carry out a meaningful statistical analysis. All the data evaluation and model development have been carried out extensively using R. The variation of curing and aging time, curing temperature, SiO2/Al2O3 and H2O/Al2O3 molar ratios has been accounted for via the application of statistical models whose reliability has been suitably checked. Curing has been performed in a sealed container at 100% relative humidity. Aging has been conducted in a climate chamber kept at 75% of relative humidity using an oversaturated solution of NaCl. Curing time has proved a positive relationship with compressive strength while aging time does not show evidence of any significant effect. Curing temperature negatively affects compressive strength. Increasing the SiO2/Al2O3 molar ratio results in an increase of the compressive strength within a certain range of values for the ratio; however, above a threshold (3.8 for the potassium-based and 3.4 for the sodium-based geopolymer system) the mechanical properties decrease. The H2O/Al2O3 molar ratio displayed an inverse proportionality with the compressive strength except for the sodium-based geopolymer, where the mechanical properties initially increased. A further comprehensive and statistically sound model has been proposed that allows us to predict the strength of geopolymer samples as a function of process variables and their composition, ranging in a rather wide set of values.},

keywords = {Materials for the environment},

pubstate = {published},

tppubtype = {article}

}

@article{BREDA2023,

title = {Production and mechanical characterization of Titanium Carbide ISOL target disks fabricated by direct ink writing},

author = {A. Breda and A. Zanini and A. Campagnolo and S. Corradetti and M. Manzolaro and G. Meneghetti and P. Colombo and M. Ballan and G. Franchin},

url = {https://www.sciencedirect.com/science/article/pii/S0272884223020485},

doi = {https://doi.org/10.1016/j.ceramint.2023.07.121},

issn = {0272-8842},

year  = {2023},

date = {2023-01-01},

urldate = {2023-01-01},

journal = {Ceramics International},

abstract = {Titanium carbide boasts a large variety of high-temperature applications from aerospace to electronics and is also employed as Isotope Separation On-Line target for the production of Radioactive Ion Beams, which are employed in numerous research and technological fields, ranging from nuclear physics to medical applications. High working temperature, open and tailored porosity and resistance to thermal stresses are fundamental characteristics for this kind of targets. In this work, an extrusion-based additive manufacturing technique (Direct Ink Writing) was used for the fabrication of complex three-dimensional macro-porous structures in the shape of disks with dimensions compatible for their use as targets. An ink containing a suspension of TiC powders with solid loading of 47.5 vol% was prepared and its rheological properties were investigated. Afterwards, single filaments with an average diameter of 0.36 mm were produced and characterized with four-point bending tests to determine the bulk material tensile strength and Young's modulus. TiC targets were then manufactured and their mechanical properties were characterized with the Ball on Three Balls approach, a biaxial flexural test suitable for disk-shaped samples. For both flexural tests, a Finite Element model was developed representatively reproducing the experimental results. The calculated tensile strength values for both filaments and disks were analyzed with Weibull's statistical approach to provide reference stress limit, corresponding to a survival probability of 99.9%.},

keywords = {Additive Manufacturing},

pubstate = {published},

tppubtype = {article}

}

@article{Elsayed2023131,

title = {Direct ink writing of silicone/filler mixtures for sphene scaffolds with advanced topologies},

author = {H. Elsayed and L. Grigolato and G. Savio and P. Colombo and E. Bernardo},

url = {https://www.scopus.com/inward/record.uri?eid=2-s2.0-85136591063&doi=10.1111%2fijac.14168&partnerID=40&md5=0f6d944d98d2c53ca6f38bcf1cc75927},

doi = {10.1111/ijac.14168},

year  = {2023},

date = {2023-01-01},

journal = {International Journal of Applied Ceramic Technology},

volume = {20},

number = {1},

pages = {131--140},

keywords = {Additive Manufacturing},

pubstate = {published},

tppubtype = {article}

}

@article{Yang20234425,

title = {Mechanistic understanding of geopolymerization at the initial stage: Ab initio molecular dynamics simulations},

author = {H. Yang and S. Ma and S. Zhao and Q. Wang and X. Liu and P. He and D. Jia and P. Colombo and Y. Zhou},

url = {https://www.scopus.com/inward/record.uri?eid=2-s2.0-85150784127&doi=10.1111%2fjace.19057&partnerID=40&md5=e9191601ae9daf5b72ef3f84bc2a8432},

doi = {10.1111/jace.19057},

year  = {2023},

date = {2023-01-01},

journal = {Journal of the American Ceramic Society},

volume = {106},

number = {7},

pages = {4425--4442},

keywords = {Materials for the environment},

pubstate = {published},

tppubtype = {article}

}