TY - JOUR
T1 - Enhanced comprehensive properties of stereolithography 3D printed alumina ceramic cores with high porosities by a powder gradation design
AU - Li, Xiang
AU - Su, Haijun
AU - Dong, Dong
AU - Zhao, Di
AU - Liu, Yuan
AU - Shen, Zhonglin
AU - Jiang, Hao
AU - Guo, Yinuo
AU - Liu, Haifang
AU - Fan, Guangrao
AU - Yang, Wenchao
AU - Huang, Taiwen
AU - Zhang, Jun
AU - Liu, Lin
AU - Fu, Hengzhi
N1 - Publisher Copyright:
© 2022
PY - 2022/12/20
Y1 - 2022/12/20
N2 - Ceramic cores with complex structures and optimized properties are critical for hollow turbine blades applied in aeroengines. Compared to traditional methods, additive manufacturing (AM) presents great advantages in forming complex ceramic cores, but how to balance the porosity and strength is an enormous challenge. In this work, alumina ceramic cores with high porosity, moderate strength, and low high-temperature deflection were prepared using stereolithography (SLA) 3D printing by a novel powder gradation design strategy. The contradiction between porosity and flexural strength is well adjusted when the mass ratio of the coarse, medium, and fine particles is 2:1:1 and the sintering temperature is 1600 °C. The fracture mode of coarse particles in sintered SLA 3D printing ceramic transforms from intergranular fracture to transgranular fracture with the increase of sintering temperature and the proportion of fine powders in powder system. The sintered porosity has a greater influence on the high-temperature deflection of SLA 3D printed ceramic cores than grain size. On this basis, a "non-skeleton" microstructure model of SLA 3D printed alumina ceramic cores is created to explain the relationship between the sintering process and properties. As a result, high porosity (36.4%), appropriate strength (50.1 MPa), and low high-temperature deflection (2.27 mm) were achieved by optimizing particle size gradation and sintering process, which provides an insight into the important enhancement of the comprehensive properties of SLA 3D printed ceramic cores.
AB - Ceramic cores with complex structures and optimized properties are critical for hollow turbine blades applied in aeroengines. Compared to traditional methods, additive manufacturing (AM) presents great advantages in forming complex ceramic cores, but how to balance the porosity and strength is an enormous challenge. In this work, alumina ceramic cores with high porosity, moderate strength, and low high-temperature deflection were prepared using stereolithography (SLA) 3D printing by a novel powder gradation design strategy. The contradiction between porosity and flexural strength is well adjusted when the mass ratio of the coarse, medium, and fine particles is 2:1:1 and the sintering temperature is 1600 °C. The fracture mode of coarse particles in sintered SLA 3D printing ceramic transforms from intergranular fracture to transgranular fracture with the increase of sintering temperature and the proportion of fine powders in powder system. The sintered porosity has a greater influence on the high-temperature deflection of SLA 3D printed ceramic cores than grain size. On this basis, a "non-skeleton" microstructure model of SLA 3D printed alumina ceramic cores is created to explain the relationship between the sintering process and properties. As a result, high porosity (36.4%), appropriate strength (50.1 MPa), and low high-temperature deflection (2.27 mm) were achieved by optimizing particle size gradation and sintering process, which provides an insight into the important enhancement of the comprehensive properties of SLA 3D printed ceramic cores.
KW - Ceramic cores
KW - Comprehensive properties
KW - Powder gradation design
KW - Sintering temperature
KW - Stereolithography (SLA)
UR - http://www.scopus.com/inward/record.url?scp=85132915076&partnerID=8YFLogxK
U2 - 10.1016/j.jmst.2022.04.040
DO - 10.1016/j.jmst.2022.04.040
M3 - 文章
AN - SCOPUS:85132915076
SN - 1005-0302
VL - 131
SP - 264
EP - 275
JO - Journal of Materials Science and Technology
JF - Journal of Materials Science and Technology
ER -