Sample selection for models to represent ceramic cores fabricated by stereolithography three-dimensional printing

doi:10.1016/j.jmst.2021.12.058

Abstract

Abstract:

In this study, ceramic cores were fabricated by stereolithography three-dimensional printing (SLA-3DP) with excellent synthetic mechanical properties. To this end, green body samples were first three-dimensionally printed in three models, after which the samples were sintered at different temperatures. High-temperature flexural strengths of the ceramic core samples printed in model 2 reached a maximum value of 24.2 MPa at a sintering temperature of 1250 °C during casting heat test at 1550°C. Meanwhile, the high- and room-temperature flexural strengths of ceramic core samples printed in model 2 were much stronger than those printed in models 1 and 3. Moreover, shrinkage, porosities, bulk densities and phase compositions of ceramic core samples printed in three models at different sintering temperatures did not show obvious differences. The ceramic core samples showed distinct mechanical properties as they had different fracture modes. We call this the “surface effect”. The anisotropy flexural strength was induced by weak binding between layers. The recommended choice of sample for different models to represent ceramic cores fabricated by stereolithography three-dimensional printing is model 2. Herein, based on the results of systematic characterization of high-throughput samples, we report the basic research, evaluation and prediction system of composition design, process optimization, microstructure and property defect analysis of ceramic cores made of SLA-3DP.

Key words: Ceramic cores, Stereolithography three-dimensional printing, Surface effect, High solid loading, Hollow turbine blades

X.L. An, J.J. Liang, J.G. Li, J.W. Chen, Y.Z. Zhou, X.F. Sun. Sample selection for models to represent ceramic cores fabricated by stereolithography three-dimensional printing[J]. J. Mater. Sci. Technol., 2022, 121: 117-123.

Figures/Tables 5

Fig. 1. (A) Schematic illustration of the three printing models of ceramic core samples; (B) Number of printing slice layers of the three printing models of ceramic core samples; (C) Profiles of debinding and sintering processes.

Fig. 2. Shrinkage (A--C), bulk densities (D), open porosities rates (E) and flexural strengths of ceramic core samples printed in different models and sintered at different temperatures tested at room-temperature (F, G) and 1550 °C high-temperature (H, I) to simulate casting heat teat.

Fig. 3. (A) Schematic illustration of fracture location, cracks, pores of model 1, model 2, model 3 samples after 1250 °C sintering; Crack propagation behavior and pores distribution of (B) model 1, (C) model 2, (D) model 3, from vertical view, front view and side view; (E) Schematic illustration of three-point bending test of ceramic core samples printed in three models; (F) 3D model fracture diagram of room temperature bending resistance of model 1, model 2, model 3 samples sintered at 1250 °C.

Fig. 4. SEM images of surface macrostructures of ceramic core samples printed in different models and sintered at different temperatures: 1100, 1150, 1200, 1250 °C.

Fig. 5. (A) High-temperature X-ray diffraction (XRD) patterns of 1200 °C sintered ceramic core samples printed in model 2 measured at 25, 950, 1150, 1350, 1350, 1550 °C during heating process and 1000, 500, 30 °C during cooling process in vacuum to simulate casting heat teat; (B) Room-temperature XRD patterns of 1200 °C sintered ceramic core samples printed in three models; (C) Room-temperature XRD patterns of 1200 °C sintered ceramic core samples printed in three models after flexural strength test at 1550 °C.

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