Leaching improvement of ceramic cores for hollow turbine blades based on additive manufacturing

doi:10.1007/s40436-019-00273-2

Advances in Manufacturing ›› 2019, Vol. 7 ›› Issue (4): 353-363.doi: 10.1007/s40436-019-00273-2

• ARTICLES • 下一篇

Leaching improvement of ceramic cores for hollow turbine blades based on additive manufacturing

Wei-Jun Zhu^1,2, Guo-Qiang Tian^2,3, Yang Lu², Kai Miao², Di-Chen Li²

1 School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, People's Republic of China;
2 State Key Laboratory for Manufacturing Systems Engineering, Xi'an Jiaotong University, Xi'an 710049, People's Republic of China;
3 School of Aeronautical Engineering, Zhengzhou University of Aeronautics, Zhengzhou 450046, People's Republic of China

收稿日期:2019-02-26 修回日期:2019-04-03 出版日期:2019-12-25 发布日期:2019-12-26
通讯作者: Wei-Jun Zhu E-mail:wjzhu@xjtu.edu.cn
基金资助:
This work was supported by the National Natural Science Foundation of China (Grant No. 51505457), the National Science and Technology Major Project (Grant No. 2017-VII-0008-0101), the Key Research and Development Program of Shaanxi Province (Grant No. 2018ZDXM-GY-059), the Open Fund of State Key Laboratory of Manufacturing Systems Engineering (Grant No. SKLMS2016013), the Fundamental Research Funds for the Central Universities, and the Youth Innovation Team of Shaanxi Universities.

Leaching improvement of ceramic cores for hollow turbine blades based on additive manufacturing

Wei-Jun Zhu^1,2, Guo-Qiang Tian^2,3, Yang Lu², Kai Miao², Di-Chen Li²

1 School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, People's Republic of China;
2 State Key Laboratory for Manufacturing Systems Engineering, Xi'an Jiaotong University, Xi'an 710049, People's Republic of China;
3 School of Aeronautical Engineering, Zhengzhou University of Aeronautics, Zhengzhou 450046, People's Republic of China

Received:2019-02-26 Revised:2019-04-03 Online:2019-12-25 Published:2019-12-26
Contact: Wei-Jun Zhu E-mail:wjzhu@xjtu.edu.cn
Supported by:
This work was supported by the National Natural Science Foundation of China (Grant No. 51505457), the National Science and Technology Major Project (Grant No. 2017-VII-0008-0101), the Key Research and Development Program of Shaanxi Province (Grant No. 2018ZDXM-GY-059), the Open Fund of State Key Laboratory of Manufacturing Systems Engineering (Grant No. SKLMS2016013), the Fundamental Research Funds for the Central Universities, and the Youth Innovation Team of Shaanxi Universities.

摘要/Abstract

摘要： The precision casting method based on aluminabased ceramic cores is one of the main techniques used to manufacture hollow turbine blades. Additive manufacturing (AM) technology provides an alternate solution to fabricating ceramic cores quickly and precisely. As the complexity of the structure increases and the strength of the material improves, the leaching process of the cores becomes more complicated. This study proposes a compound pore-forming method to increase the porosity of ceramic cores by adding a preformed-pore agent and materials that convert to easy-to-corrode phases. The preformed-pore agents (e.g., carbon fibers) can be burned off during sintering to form pores before the leaching, and the easy-to-corrode phases (e.g., CaCO₃, SiO₂, β-Al₂O₃) can be leached firstly to form pores during the leaching process. The pores formed in the aforementioned two stages increase the contact area of the cores and leaching solution, thus improving the leaching rate. In the current study, the additive amount of the preformed-pore agent was optimized, and the effect of the easy-to-corrode phases on the comprehensive properties of the cores was then compared. Based on this, the corresponding model was established.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-019-00273-2

关键词: Alumina-based ceramic core, Leaching, Alkali solution, Additive manufacturing (AM), Stereolithography

Abstract: The precision casting method based on aluminabased ceramic cores is one of the main techniques used to manufacture hollow turbine blades. Additive manufacturing (AM) technology provides an alternate solution to fabricating ceramic cores quickly and precisely. As the complexity of the structure increases and the strength of the material improves, the leaching process of the cores becomes more complicated. This study proposes a compound pore-forming method to increase the porosity of ceramic cores by adding a preformed-pore agent and materials that convert to easy-to-corrode phases. The preformed-pore agents (e.g., carbon fibers) can be burned off during sintering to form pores before the leaching, and the easy-to-corrode phases (e.g., CaCO₃, SiO₂, β-Al₂O₃) can be leached firstly to form pores during the leaching process. The pores formed in the aforementioned two stages increase the contact area of the cores and leaching solution, thus improving the leaching rate. In the current study, the additive amount of the preformed-pore agent was optimized, and the effect of the easy-to-corrode phases on the comprehensive properties of the cores was then compared. Based on this, the corresponding model was established.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-019-00273-2

Key words: Alumina-based ceramic core, Leaching, Alkali solution, Additive manufacturing (AM), Stereolithography

Wei-Jun Zhu, Guo-Qiang Tian, Yang Lu, Kai Miao, Di-Chen Li. Leaching improvement of ceramic cores for hollow turbine blades based on additive manufacturing[J]. Advances in Manufacturing, 2019, 7(4): 353-363.

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Leaching improvement of ceramic cores for hollow turbine blades based on additive manufacturing

Leaching improvement of ceramic cores for hollow turbine blades based on additive manufacturing

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