LAUSR

Abstract Directed laser deposition (DLD) has demonstrated the potential for rapid preparing high-performance melt-grown ceramics applied for the aero-engine hot section components. Mullite has excellent potential for applications in harsh environments and extreme conditions. However, there are defects (pores and cracks) in melt-grown mullite ceramics (MGMC), limiting its application, related to unclear processes, microstructure, and properties. In this work, we investigated the impact of z-increment on shaping quality, microstructure, and mechanical properties. The results reveal that oxygen vacancy concentration is responsible for the variety of sample colors. Low z-increment is beneficial to decreasing porosity, while high z-increment is beneficial to crack suppression. The formation and propagation mechanism of internal cracks at low z-increment are discussed in detail. Mullite crystals in the sample center are "tabular cellular", which are 2:1 high-alumina mullite. While mullite crystals at the sample edge are 3:2 mullite, undergo four stages as z-increment increase; "tabular cellular", "facet dendrite", "rod cellular", and mixed crystal. This evolution of crystal morphology is attributed to the decrease in temperature gradient and the increase of supersaturation. Besides, the flexural strength and microhardness increase first and then decrease with the rise of z-increment, which is the function of defects, compactness, and microstructure.