In Situ Mullite Toughening of Zirconia‐Toughened Alumina Ceramics via Digital Light Processing 3D Printing

Alumina‐based ceramics demonstrate remarkable hardness and wear resistance; however, their intrinsic high brittleness and low fracture toughness pose significant challenges in the fabrication of complex components using conventional processing techniques. The emergence of additive manufacturing technology has enabled the fabrication of complex‐structured alumina ceramics. In this study, nano‐silica (SiO 2 ) was incorporated into zirconia‐toughened alumina (ZTA) ceramic powders for digital light processing (DLP) 3D printing. During subsequent debinding and sintering, the SiO 2 reacted in situ with alumina to form mullite particles, which contributed to microstructural refinement and toughening. Optimal properties‐Vickers hardness (16.2 GPa), flexural strength (463.8 MPa), and fracture toughness (4.34 MPa·m 1/2 )‐were achieved at 3 wt% SiO 2 . The mechanical performance of the printed ceramics was significantly enhanced, demonstrating a novel strategy for producing high‐strength alumina‐based ceramics via DLP 3D printing.