Microstructure and properties of silica-based ceramic cores by laser powder bed fusion combined with vacuum infiltration

doi:10.1016/j.jmst.2022.12.078

Abstract

Abstract: The silica-based ceramic core has attracted much attention in the preparation of hollow blades due to its great leachability. In this paper, the silica-based ceramic cores reinforced with ZrSiO₄ were prepared by laser powder bed fusion (LPBF) combined with vacuum infiltration (VI). To enhance the infiltration effect, the pre-sintered bodies with high porosity and hydrophilicity were obtained by pre-sintering at 1100 °C. Results showed that a large number of silica particles infiltrated into the pre-sintered bodies. The infiltrated silica promoted the generation of liquid phase in sintering, thereby promoting the removal of pores and the connection of grains. Nevertheless, the dispersed ZrSiO₄ grains prevented the viscous flow of the liquid phase, thereby increasing the porosity. ZrSiO₄ grains could hinder the propagation of cracks due to their high strength. When the addition of ZrSiO₄ was 10 wt.%, room-temperature flexural strength of silica-based ceramic cores infiltrated with slurry S1 (the mass ratio of silica sol to silica powder was 10:1) reached 17.21 MPa due to the reinforcement of sintering necks. Moreover, high-temperature flexural strength reached 13.90 MPa. Therefore, the pre-sintering process could greatly improve the mechanical properties of silica-based ceramic cores prepared by LPBF-VI technology.

Key words: Silica-based ceramic cores, Laser powder bed fusion, ZrSiO₄, Pre-sintering, Vacuum infiltration

Jie Zhang, Jia-Min Wu, Heng Liu, Wen Zheng, Chun-Sheng Ye, Shi-Feng Wen, Chun-Ze Yan, Yu-Sheng Shi. Microstructure and properties of silica-based ceramic cores by laser powder bed fusion combined with vacuum infiltration[J]. J. Mater. Sci. Technol., 2023, 157: 71-79.

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