Improved mechanical properties of SiC fiber reinforced silica-based ceramic cores fabricated by stereolithography

doi:10.1016/j.jmst.2021.12.012

Abstract

Abstract:

Silica-based ceramic cores have been widely used to fabricate aero-engine hollow blades due to their moderate high temperature mechanical properties and excellent leachability. In this study, silica-based ceramics with SiC fiber addition were prepared via stereolithography, and the influence of SiC fiber content on mechanical properties of the obtained silica-based ceramics was investigated. With the increase of SiC fiber content, linear shrinkage gradually decreased, while room temperature flexural strength and high temperature flexural strength first increased and then decreased. As SiC fiber content increased to 4.0 wt%, linear shrinkage was reduced to 0.62% resulting from the oxidation of SiC. Furthermore, room temperature flexural strength was improved from 11.79 MPa to 23.83 MPa and high temperature flexural strength was enhanced from 15.64 MPa to 34.62 MPa with 4.0 wt% SiC fiber addition due to the reinforcement of fibers and the enhanced β-cristobalite content, which meets the need of ceramic cores. Therefore, it demonstrates the capability of fabricating high-performance and high-precision silica-based ceramic cores reinforced by SiC fibers via stereolithography for rapid manufacturing of hollow blades.

Key words: Silica-based ceramic cores, Stereolithography, SiC fiber, Mechanical properties, Hollow blades

W. Zheng, J.M. Wu, S. Chen, K.B. Yu, J. Zhang, Y.S. Shi. Improved mechanical properties of SiC fiber reinforced silica-based ceramic cores fabricated by stereolithography[J]. J. Mater. Sci. Technol., 2022, 116: 161-168.

Figures/Tables 11

Table 1. Compositions of silica slurries prepared with powders with different contents of SiC fiber powder.

Slurry code	Weight of powder (g)		Photocurable resin	Dispersant	Photoinitiator
Empty Cell	SiO₂ powder	SiC fiber	Empty Cell	Empty Cell	Empty Cell
C0	71.5	0	HDDA:PEGDA=6:4 (weight ration)	3.0 wt% 41,000 (based on powder weight)	1.0 wt% 184 (based on photocurable resin)
C1	71.5	0.72
C2	71.5	1.46
C3	71.5	2.21
C4	71.5	2.98
C5	71.5	3.76

Fig. 1. Particle size distributions and SEM images of (a, c) fused SiO2 powder and (b, d) SiC fiber powder.

Fig. 2. Schematic diagram of the procedure for preparing silica-based ceramics with different contents of SiC fiber powder via stereolithography.

Fig. 3. Debinding and sintering procedures of SiCf/SiO2 green bodies: (a) TGA-DSC curve, (b) debinding and sintering curve.

Fig. 4. Phase compositions of silica-based ceramics with different contents of SiC fiber.

Fig. 5. Microstructures of silica-based ceramics with 2 wt% SiC fiber addition sintered at different temperatures: (a) 1150 °C, (b) 1200 °C, (c) 1250 °C and (d) 1300 °C.

Fig. 6. (a) Bulk density, apparent porosity and (b) flexural strength, linear shrinkage of silica-based ceramics with 2 wt% SiC fiber addition sintered at different temperatures.

Fig. 7. Microstructures of silica-based ceramics with various contents of SiC fiber: (a) 0, (b) 1.0, (c) 2.0, (d) 3.0, (e) 4.0, (f) 5.0 wt%.

Fig. 8. XRD patterns and SEM images of silica-based ceramics measured at 1550 °C with (a, b) 2.0 wt% and (c, d) 4.0 wt% SiC fiber.

Fig. 9. (a) Linear shrinkage, (b) bulk density and apparent porosity of silica-based ceramics with different contents of SiC fiber.

Fig. 10. Flexural strength of silica-based ceramics with different contents of SiC fiber.

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