DOI QR코드

DOI QR Code

The Effect of Fused Silica Crystallization on Flexural Strength and Shrinkage of Ceramic Cores for Investment Casting

  • Kim, Young-Hwan (Advanced Materials and Devices Laboratory, Korea Institute of Energy Research) ;
  • Yeo, Jeong-Gu (Advanced Materials and Devices Laboratory, Korea Institute of Energy Research) ;
  • Choi, Sung-Churl (Division of Materials Science and Engineering, Hanyang University)
  • Received : 2016.01.05
  • Accepted : 2016.03.02
  • Published : 2016.03.31

Abstract

Complex designed silica-based ceramic cores were fabricated by ceramic injection molding. Slow heating rate (0.2K/min) for debinding restrained bloating on the surface of ceramic cores. To investigate effect of sintering conditions on mechanical properties of ceramic cores, green bodies were sintered at temperatures in a range from $1150^{\circ}C$ to $1400^{\circ}C$ for various dwelling times (6 h to 48 h). Sintering above $1300^{\circ}C$ for 12 h and dwelling time over 24 h at $1200^{\circ}C$ reduce the flexural strength and increase the linear shrinkage of ceramic cores. Cristobalite, formed by high sintering temperature or long dwelling time, induces reduction of mechanical properties due to its phase transformation, which is accompanied by volume contraction and microcracking. Ceramic core sintered at $1200^{\circ}C$ for 12 h endured wax patterning and shell molding, and was manufactured successfully.

Keywords

References

  1. J. W. Kim, D. H. Kim, I. S. Kim, Y. S. Yoo, J. C. Kim, and C. Y. Jo, "Study on the Fabrication of Ceramic Core Using a Gel-Casting Process in Aqueous Medium(I) : Gelation Behavior of Polydispered Ceramic Slip (in Korean)," Korean J. Mater. Res., 11 [2] 137-45 (2001).
  2. I. Huseby, M. Borom, and C. Greskovich, "High Temperature Characterization of Silica-Base Cores for Superalloys," Am. Ceram. Soc. Bull., 58 448-52 (1979).
  3. P. Wilson, S. Blackburn, R. Greenwood, B. Prajapti, and K. Smalley, "The Role of Zircon Particle Size Distribution, Surface Area and Contamination on The Properties of Silica-Zircon Ceramic Materials," J. Eur. Ceram. Soc., 31 [9] 1849-55 (2011). https://doi.org/10.1016/j.jeurceramsoc.2011.03.005
  4. A. Wereszczak, K. Breder, M. Ferber, T. Kirkland, E. Payzant, C. Rawn, E. Krug, C. Larocco, R. Pietras, and M. Karakus, "Dimensional Changes and Creep of Silica Core Ceramics used in Investment Casting of Superalloys," J. Mater. Sci., 37 [19] 4235-45 (2002). https://doi.org/10.1023/A:1020060508311
  5. C. H. Chao and H. Y. Lu, "Optimal Composition of Zircon-Fused Silica Ceramic Cores for Casting Superalloys," J. Am. Ceram. Soc., 85 [4] 773-79 (2002). https://doi.org/10.1111/j.1151-2916.2002.tb00171.x
  6. C. J. Bae and J. W. Halloran, "Integrally Cored Ceramic Mold Fabricated by Ceramic Stereolithography," Int. J. Appl. Ceram. Tec., 8 [6] 1255-62 (2011). https://doi.org/10.1111/j.1744-7402.2010.02568.x
  7. L. Y. Wang and M. H. Hon, "The Effects of Zircon Addition on The Crystallization of Fused Silica. A Kinetic Study," J. Ceram. Soc. Jpn., 102 [6] 517-21 (1994). https://doi.org/10.2109/jcersj.102.517
  8. J. W. Kim, D. H. Kim, I. S. Kim, Y. S. Yoo, B. K. Choi, E. H. Kim, and C. Y. Jo, "Study on The Fabrication of Ceramic Core using a Gel-casting Process in Aqueous Medium(II) : Physical Properties of Sintered Ceramic Core Body (in Korean)," Korean J. Mater. Res., 11 [6] 465-71 (2001).
  9. M. Gromada, A. Swieca, M. Kostechki, A. Olszyna, and R. Cygan "Ceramic Cores for Turbine Blades via Injection Moulding," J. Mater. Process. Tech, 220 107-12 (2015). https://doi.org/10.1016/j.jmatprotec.2015.01.010
  10. B. C. Mutsuddy and R. G. Ford, Ceramic Injection Molding; pp. 245-90, Chapman & Hall, London, 1994.
  11. ASTM C1161-13, "Standard Test Method for Flexural Strength of Advanced Ceramics at Ambient Temperature," ASTM International, West Conshohocken, PA, 2013.
  12. C. J. Bae, "Integrally Cored Ceramic Investment Casting Mold Fabricated by Ceramic Stereolithography," pp. 174-210, in Ph. D. Thesis, University of Michigan, Ann Arbor, 2008.
  13. A. Kazemi, M. A. Faghihi-Sani, M. Nayyeri, M. Mohammadi, and M. Hajfathalian, "Effect of Zircon Content on Chemical and Mechanical Behavior of Silica-based Ceramic Cores," Ceram. Int., 40 [1] 1093-98 (2014). https://doi.org/10.1016/j.ceramint.2013.06.108
  14. A. Kazemi, M. A. Faghihi-Sani, and H.R. Alizadeh, "Investigation on Cristobalite Crystallization in Silica-based Ceramic Cores for Investment Casting," J. Eur. Ceram. Soc., 33 [15] 3397-402 (2013). https://doi.org/10.1016/j.jeurceramsoc.2013.06.025
  15. A. Leadbetter and A. Wright, "The ${\alpha}$-${\beta}$ Transition in The Cristobalite Phases of $SiO_2$ and $AIPO_4$ I. X-ray Studies," Philos. Mag., 33 [1] 105-12 (1976). https://doi.org/10.1080/14786437608221095
  16. C. H. Chao and H. Y. Lu, "Stress-Induced ${\beta}{\rightarrow}{\alpha}$-Cristobalite Phase Transformation in ($Na_2O$ + $Al_2O_3$)-Codoped Silica," Mat. Sci. Eng. A, 328 [1] 267-76 (2002) https://doi.org/10.1016/S0921-5093(01)01703-8
  17. R. C. Breneman and J. W. Halloran, "Effect of Cristobalite on the Strength of Sintered Fused Silica Above and Below the Cristobalite Transformation," J. Am. Ceram. Soc., 98 [5] 1611-17 (2015). https://doi.org/10.1111/jace.13505
  18. N. Lequeux, N. Richard, and P. Boch, "Shrinkage Reduction in Silica-Based Refractory Cores Infiltrated with Boehmite," J. Am. Ceram. Soc., 78 [11] 2961-66 (1995). https://doi.org/10.1111/j.1151-2916.1995.tb09070.x

Cited by

  1. Effect of silica fiber on the mechanical and chemical behavior of alumina-based ceramic core material vol.5, pp.4, 2017, https://doi.org/10.1016/j.jascer.2017.09.002
  2. Leaching improvement of ceramic cores for hollow turbine blades based on additive manufacturing vol.7, pp.4, 2019, https://doi.org/10.1007/s40436-019-00273-2