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| Performance of silicon oxide-based ceramic cores made by rapid prototyping for single crystal turbine blades |
Quanwei WANG, Chengdong WANG, Zhongliang LU( ), Kai MIAO(), Zichao AI, Dichen LI |
| State Key Laboratory of Mechanical Manufacturing System Engineering, Xi'an Jiaotong University, Xi'an 710049, China |
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Abstract The shortcomings of long period, high cost and slow response in making ceramic core by using investment casting method were overcome by using stereolithography and gel casting, which is of great significance for the rapid manufacturing of the single crystal blades with complex structure. The evolution rule of high temperature strength and shrinkage of silica based ceramic core was studied. The addition amount of nano zirconia power and aluminum powder and sintering time were explored. The micro morphology of the sample was characterized by field emission scanning electron microscope, and the high temperature strength of the sample was measured by three-point bending method. The results show that: when the mass fraction of nano zirconia power is 2.16%, the mass fraction of aluminum powder is 9.8% and the sintering time is 3.9 h, the maximum high temperature strength value of silicon oxide-based ceramic core reaches 14.3 MPa. The value of high temperature strength meets the needs of directional solidification casting of single crystal blade. There are no obvious cracks on the surface of the prepared ceramic core, the structure is complete and the molding quality is good.
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Received: 01 September 2021
Published: 18 July 2022
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Corresponding Authors:
Zhongliang LU,Kai MIAO
E-mail: zllu@mail.xjtu.edu.cn;kaimiao@xjtu.edu.cn
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Micromorphology of quartz powder with different grain size
(a)100 μm; (b)40 μm; (c)5 μm; (d)2 μm
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Micromorphology of Al powder
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Influence of zirconia content on high temperature strength and shrinkage
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Micromorphology of ceramic with different nano-zirconia content
(a)0%;(b)2%;(c)4%;(d)6%;(e)8%
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Influence of Al powder content on high temperature strength and shrinkage
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Sintering morphology of ceramic with different Al powder content
(a)0%;(b)5%;(c)10%;(d)15%
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Influence of sintering time on high temperature strength and shrinkage
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Micromorphology of ceramic cross-section at different sintering time
(a)2 h; (b)5 h; (c)8 h
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| Level | Factor | | A/h | B/% | C/% | | -1.682 | 2.5 | 5 | 0.5 | | -1 | 3.5 | 7 | 1.5 | | 0 | 5 | 10 | 3 | | 1 | 6.5 | 13 | 4.5 | | 1.682 | 7.5 | 15 | 5.5 |
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Experimental factors and levels design of CCD
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| No | A/h | B/% | C/% | RV/MPa | | 1 | 3.5 | 4.5 | 13 | 11.05 | | 2 | 5 | 3 | 15 | 9.50 | | 3 | 5 | 3 | 5 | 11.51 | | 4 | 6.5 | 4.5 | 7 | 10.56 | | 5 | 6.5 | 1.5 | 7 | 10.52 | | 6 | 5 | 0.5 | 10 | 12.24 | | 7 | 5 | 3 | 10 | 12.17 | | 8 | 5 | 3 | 10 | 13.44 | | 9 | 7.5 | 3 | 10 | 9.45 | | 10 | 2.5 | 3 | 10 | 12.54 | | 11 | 5 | 3 | 10 | 12.87 | | 12 | 3.5 | 1.5 | 13 | 12.36 | | 13 | 6.5 | 1.5 | 13 | 7.17 | | 14 | 3.5 | 4.5 | 7 | 10.12 | | 15 | 5 | 3 | 10 | 13.91 | | 16 | 5 | 3 | 10 | 13.37 | | 17 | 5 | 3 | 10 | 13.66 | | 18 | 3.5 | 1.5 | 7 | 12.47 | | 19 | 5 | 5.5 | 10 | 10.25 | | 20 | 6.5 | 4.5 | 13 | 8.31 |
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Experimental parameters design of RSM and response values
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| Source | p value | | Model | < 0.0001 | | A | < 0.0001 | | B | 0.0027 | | C | 0.0180 | | AB | 0.0023 | | AC | 0.0119 | | BC | 0.2049 | | A2 | 0.0001 | | B2 | < 0.0001 | | C2 | 0.0003 | | Lack of fit | 0.7149 |
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ANOVA for quadratic model
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Interactive item graphs
(a)effects of sintering time and aluminum powder content on high temperature strength; (b)effect of aluminum powder content and zirconia content on high temperature strength; (c)effects of sintering time and zirconia content on high temperature strength
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| Al powder content/% | ZrO2 content/% | Sintering time/h | Predicted strength/MPa | Experimental value/MPa | Error/% | | 9.8 | 2.16 | 3.9 | 13.8 | 14.3 | 3.4 |
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Formula of optimum process parameters and response values
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Three dimensional model(a) and figure(b) of ceramic core
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2022, Vol. 50 
