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In the preparation of porous ceramic structure by binder jetting process, the stability and strength of porous ceramic structure caused by different powder composition have attracted much attention. Therefore, a pore filling method was proposed in this paper, in which nano-hydroxyapatite (nano-HA) particles with different contents were filled into yttrium-stabilized zirconia (YSZ) ceramic powders to solve the poor porosity and weak mechanical properties of porous ceramic structure. The effects of nano-HA content on the pore formation, surface quality, phase stability, compressive strength and microstructure of porous YSZ/nano-HA structure were studied. The results showed that as the mass percentage of nano-HA increased to 25 wt.%, the surface roughness of the top, side, and bottom decreased, whereas the relative density increased from 39.3% to 48.8%. After sintering at 1450°C the porous YSZ/nano-HA structures revealed a decrease in shrinkage (18.1% −11.5%) and water absorption (4.4% −2.3%), but an increase in compressive strength (30.9 MPa − 41.2 MPa). The sintered phase of YSZ/nano-HA structure presented a new microstructure evolution process, in which  t -ZrO 2  and Ca 3 (PO 4 ) 2  acted as the main crystal phase, with trace amounts of Ca 0.15 Zr 0.85 O 1.85  cubic solid solution.

Fabrication and properties of a stable and porous YSZ/nano-HA structure by binder jetting processes