Balancing flexural strength and porosity in DLP-3D printing Al2O3 cores for hollow turbine blades

doi:10.1016/j.jmst.2021.05.077

Abstract

Abstract:

High porosity and high strength are usually mutually exclusive in the preparation of ceramic materials. However, high porosity and flexural strength are required for the preparation of complex ceramic cores for hollow turbine blades. In this study, Al₂O₃ cores with high porosity and high flexural strength were successfully prepared using digital light processing (DLP) 3D printing technology. The influence of sintering temperature on the microstructure, pore evolution, and flexural strength of the cores were investigated. With an increase in the sintering temperature, the porosity of the ceramic cores first increased and then decreased, reaching a maximum value of 35% at 1400 ℃. The flexural strength increased with the increase in sintering temperature, but at 1400℃ the incremental enhancement of flexural strength was greatest. Combined with the core service requirements and core performance, this study selected 1400 ℃ (open porosity of 35.1% and flexural strength of 20.3 MPa) as the optimal sintering temperature for the DLP-3D printed Al₂O₃ core.

Key words: 3D printing, Ceramic cores, Flexural strength, Porosity, Sintering temperature

Qiaolei Li, Xiaolong An, Jingjing Liang, Yongsheng Liu, Kehui Hu, Zhigang Lu, Xinyan Yue, Jinguo Li, Yizhou Zhou, Xiaofeng Sun. Balancing flexural strength and porosity in DLP-3D printing Al₂O₃ cores for hollow turbine blades[J]. J. Mater. Sci. Technol., 2022, 104: 19-32.

Figures/Tables 15

Fig. 1. Al2O3 core of a hollow blade of a turbine engine prepared by DLP-3D printing technology: (a) core model, (b) sintered core.

Fig. 2. Schematic of DLP-3D printing equipment.

Fig. 3. SEM image of the cross-section of the DLP-3D printed Al2O3 cores. (For interpretation of the references to color in this figure, the reader is referred to the web version of this article.).

Fig. 4. EPMA analysis results for the DLP-3D printed Al2O3 cores.

Fig. 5. XPS analysis results of Al2O3 cores at sintering temperatures of 1300 ℃, 1350 ℃, 1400 ℃, 1450 ℃, 1500 ℃, and 1550 ℃: (a) full spectrum, (b) O 1s, (c) C 1s, (d) Al 2p.

Fig. 6. XRD analysis results of Al2O3 cores at sintering temperatures of 1300 ℃, 1350 ℃, 1400 ℃, 1450 ℃, 1500 ℃ and 1550 ℃.

Fig. 7. EBSD analysis results of Al2O3 cores sintered at 1300 ℃, 1400 ℃ and 1500 ℃ showing Kikuchi band contrast, phase maps, and Euler angle maps.

Fig. 8. Open porosity and bulk density of the Al2O3 core by the Archimedes density method as a function of sintering temperature.

Fig. 9. Flexural strength (a) and incremental change (b) of Al2O3 core at 1300 ℃.

Fig. 10. Analysis results of core recrystallization grains by EBSD. (a) 1300 ℃ sintered core, (b) 1400 ℃ sintered core, (c) 1500 ℃ sintered core.

Fig. 11. Grain boundary diagram, grain orientation difference and grain size analysis results obtained from EBSD detection data: (a-c) 1300 ℃ sintered core, (d-f) 1400 ℃ sintered core, (g-i) 1500 ℃ sintered core. (a, d, g) Grain boundary diagram, (b, e, h) grain orientation difference, (c, f, i) grain size.

Fig. 12. TEM images of the sintered morphology of particles inside the core at (a) 1300 ℃, (b) 1350 ℃, (c) 1400 ℃, (d) 1450 ℃, (e) 1500 ℃, and (f) 1550 ℃.

Fig. 13. Mechanism diagram of the effect of different sintering stages on core properties. (a, b) Core degreasing and sintering process, (c, d, e) initial stage of sintering, (f, g, h) middle stage of sintering, (i, j, k) later stage of sintering.

Fig. 14. Fracture morphologies of cores with different sintering temperatures after flexural strength testing at (a) 1300 ℃, (b) 1350 ℃, (c) 1400℃, (d) 1450 ℃, (e) 1500 ℃, and (f) 1550 ℃.

Fig. 15. Crack growth diagram of the sintered core at (a) 1300 ℃, (b) 1400 ℃, and (c) 1500 ℃ during the flexural strength test.

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Balancing flexural strength and porosity in DLP-3D printing Al₂O₃ cores for hollow turbine blades

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