烧结温度对3D打印硅基陶瓷型芯表面形貌及粗糙度的影响

doi:10.15541/jim20210654

无机材料学报 ›› 2022, Vol. 37 ›› Issue (3): 325-332.DOI: 10.15541/jim20210654

所属专题：【虚拟专辑】增材制造及3D打印(2021-2022)

烧结温度对3D打印硅基陶瓷型芯表面形貌及粗糙度的影响

李乔磊¹^,², 顾玥³, 于雪华⁴, 张朝威¹, 邹明科¹, 梁静静¹^,³(), 李金国¹^,³()

1.中国科学院金属研究所, 师昌绪先进材料创新中心, 沈阳 110016
2.中国科学技术大学材料科学与工程学院, 沈阳 110016
3.中国科学院太空制造技术重点实验室, 北京 100094
4.中国科学院沈阳自动化研究所, 沈阳 110016

收稿日期:2021-10-23 修回日期:2021-11-28 出版日期:2022-03-20 网络出版日期:2022-01-06
通讯作者: 梁静静, 研究员. E-mail: jjliang@imr.ac.cn; 李金国, 研究员. E-mail: jgli@imr.ac.cn
作者简介:李乔磊(1993-), 男, 博士研究生. E-mail: lql_614@163.com
基金资助:
国家科技重大专项(2017-VI-0002-0072);国家科技重大专项(Y2019-VII-0011-0151);国家重点研发计划(2018YFB1106600);中央高校基本科研业务费专项资金(WK5290000002)

Effect of Sintering Temperature on Surface Morphology and Roughness of 3D-printed Silicon Ceramic Cores

LI Qiaolei¹^,², GU Yue³, YU Xuehua⁴, ZHANG Chaowei¹, ZOU Mingke¹, LIANG Jingjing¹^,³(), LI Jinguo¹^,³()

1. Shi-changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
2. School of Materials Science and Engineering, University of Science and Technology of China, Shenyang 110016, China
3. CAS Key Laboratory of Space Manufacturing Technology, Beijing 100094, China
4. Shenyang Institute of Automation, Chinese Academy of Sciences, Shenyang 110016, China

Received:2021-10-23 Revised:2021-11-28 Published:2022-03-20 Online:2022-01-06
Contact: LIANG Jingjing, professor. E-mail: jjliang@imr.ac.cn; LI Jinguo, professor. E-mail: jgli@imr.ac.cn
About author:LI Qiaolei (1993-), male, PhD candidate. E-mail: lql_614@163.com
Supported by:
National Science and Technology Major Project(2017-VI-0002-0072);National Science and Technology Major Project(Y2019-VII-0011-0151);National Key Research and Development Program of China(2018YFB1106600);Fundamental Research Funds for Central Universities(WK5290000002)

摘要/Abstract

摘要：

单晶高温合金空心叶片是航空发动机的重要部件, 其内腔结构是采用陶瓷型芯制备的。随着航空发动机推重比提高, 型芯结构越来越复杂, 传统制备工艺受限, 光固化3D打印陶瓷型芯技术为复杂结构型芯的制备提供了一种可行方案。为了改善光固化3D打印陶瓷型芯因台阶效应导致的表面粗糙度较大的问题, 本研究利用固含量体积分数63%的硅基型芯浆料进行光固化3D打印型芯, 并在1100~1300 ℃对型芯素坯进行烧结, 对烧成的硅基陶瓷型芯的微观结构、元素分布、相组成、型芯打印面和打印堆积方向的表面形貌和粗糙度进行分析。研究发现型芯打印面平整, 无明显表面缺陷, 1100、1200和1300 ℃烧结型芯的打印面粗糙度分别为1.83、1.24和1.44 μm; 片层堆积方向的表面有片层结构特征, 片层间出现微裂纹, 1200 ℃以上烧结的型芯表面粗糙度达到空心叶片使用要求(R_a≤2.0 μm)。结果表明不同烧结温度会改变型芯烧结过程中的液相含量、莫来石生成量、莫来石生成形态和颗粒间玻璃相的分布, 从而对光固化3D打印硅基陶瓷型芯的表面粗糙度产生明显影响。光固化3D打印陶瓷型芯技术结合烧结工艺能制备出满足先进空心叶片用硅基陶瓷型芯表面要求的粗糙度。

关键词: 光固化3D打印, 陶瓷型芯, 表面形貌, 粗糙度

Abstract:

Single crystal superalloy hollow blade is an important part of aero-engine, and its inner cavity structure is prepared by ceramic core. With the increase of thrust-weight ratio of aero-engine, the core structure is more and more complex. Traditional preparation technology is difficult to meet the requirements of complex core preparation. Stereolithography 3D printing of ceramic cores provides a feasible scheme for the preparation of complex cores. In order to improve the surface roughness of stereolithography 3D printed ceramic cores caused by step effect, this study used silicon-based core paste with solid content of 63% (in volume), and the cores of the green bodies were sintered at 1100 ℃ to 1300 ℃. Microstructure, element distribution, phase composition, surface morphology, and roughness of the silicon-based ceramic core were analyzed. It is found that printed surface of the core is smooth without obvious surface defects. Roughness of the printed surfaces of the sintered cores at 1100, 1200 and 1300 ℃ are 1.83, 1.24 and 1.44 μm, respectively. Their surface of lamellar stacking direction has lamellar structure characteristics, and microcracks appear between lamellar, and surface roughness of core sintered above 1200 ℃ meets the requirements (R_a≤2.0 μm) of hollow blade. Sintering temperatures affect the liquid content, mullite production, mullite formation morphology, and glass phase distribution of cores during the sintering process, and the surface roughness of stereolithography 3D-printed silicon ceramic cores is positively affected. Stereolithography 3D printing ceramic core technology combined with sintering process can produce a silicon-based ceramic core which surface roughness meets the requirements of an advanced hollow blade.

Key words: stereolithography 3D printing, ceramic core, surface morphology, roughness

中图分类号:

TQ174

李乔磊, 顾玥, 于雪华, 张朝威, 邹明科, 梁静静, 李金国. 烧结温度对3D打印硅基陶瓷型芯表面形貌及粗糙度的影响[J]. 无机材料学报, 2022, 37(3): 325-332.

LI Qiaolei, GU Yue, YU Xuehua, ZHANG Chaowei, ZOU Mingke, LIANG Jingjing, LI Jinguo. Effect of Sintering Temperature on Surface Morphology and Roughness of 3D-printed Silicon Ceramic Cores[J]. Journal of Inorganic Materials, 2022, 37(3): 325-332.

图/表 10

图1 陶瓷素坯的差热-失重曲线

Fig. 1 Thermal analysis graphs of ceramic green body

图2 不同温度烧结的陶瓷型芯SEM照片

Fig. 2 SEM images of ceramic cores sintered at different temperatures

图3 不同温度烧结陶瓷型芯元素分布的EPMA分析结果

Fig. 3 EPMA element distribution analysis results of ceramic cores sintered at different temperatures

图4 1250 ℃烧结陶瓷型芯的原始样品(a~c)和经1500 ℃模拟浇铸样品(d~f)的元素分布结果

Fig. 4 Element distributions of the ceramic cores sintered at 1250 ℃ for as-obtained sample (a-c) and simulated casting samples at 1500 ℃ (d-f)

图5 不同温度烧结陶瓷型芯的XRD图谱

Fig. 5 XRD patterns of ceramic cores sintered at different temperatures

图6 不同温度烧结陶瓷型芯的原始样品和经1500 ℃模拟浇铸样品的开气孔率

Fig. 6 Open porosities of the ceramic cores sintered at different temperatures for as-obtained samples and simulated casting (1500 ℃) samples

图7 不同温度烧结陶瓷型芯打印面的表面二维、三维形貌和粗糙度

Fig. 7 2D and 3D surface morphologies and roughnesses of the printed surfaces of ceramic cores sintered at different temperatures

图8 不同温度烧结陶瓷型芯打印面的表面二维、三维形貌 (商业形貌分析软件Vision64建立参考面)

Fig. 8 2D and 3D surface morphologies of the printed surfaces of ceramic cores sintered at different temperatures The reference surface was established by commercial morphology analysis software Vision64

图9 不同温度烧结陶瓷型芯打印堆积方向的表面二维、三维形貌和粗糙度

Fig. 9 2D and 3D surface morphologies and roughnesses of ceramic cores sintered at different temperatures in printing stacking direction

图10 不同温度烧结陶瓷型芯打印堆积方向的表面二维、三维形貌(商业形貌分析软件Vision64建立参考面)

Fig. 10 2D and 3D surface morphologies of ceramic cores sintered at different temperatures in printing stacking direction The reference surface was established by commercial morphology analysis software Vision64

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烧结温度对3D打印硅基陶瓷型芯表面形貌及粗糙度的影响

Effect of Sintering Temperature on Surface Morphology and Roughness of 3D-printed Silicon Ceramic Cores

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