CN103242036B - Method for preparing composite ceramic core - Google Patents

Method for preparing composite ceramic core Download PDF

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CN103242036B
CN103242036B CN201210032969.8A CN201210032969A CN103242036B CN 103242036 B CN103242036 B CN 103242036B CN 201210032969 A CN201210032969 A CN 201210032969A CN 103242036 B CN103242036 B CN 103242036B
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ceramic core
powder
composite ceramic
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CN103242036A (en
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姜卫国
张健
韩汾汾
王莉
郝红全
刘涛
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Institute of Metal Research of CAS
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Abstract

The invention provides a method for preparing a composite ceramic core. An inner layer of the composite ceramic core is made from a silica-based material, and an outer layer of the composite ceramic core is made from an alumina-based or yttria-based ceramic material. The method provided by the invention mainly comprises the steps of preparing slurry, molding, baking, soaking, drying, sintering and the like. By adopting the method for preparing the composite ceramic core, provided by the invention, the composite ceramic core which has high strength and is easy to remove is prepared, and the need that airplane engine turbine blades are prepared in an efficient cooling manner is met.

Description

A kind of composite ceramic core preparation technology
Technical field
The invention belongs to field of ceramic material preparation, particularly precision casting aircraft engine turbine blade ceramic core technology of preparing.
Background technology
Along with the development of modern technical aeronautics, also more and more higher to the requirement of holding warm ability of aircraft engine turbine blade, in general, before turbine, the every raising of inlet temperature is 100 ℃, and motor power can increase by 10% left and right; For inlet temperature before the turbine that turbine part is adapted to improve constantly, must improve from following two aspects the working temperature of turbine blade, the one, improve the warm ability of holding of blade material itself, the 2nd, by improving blade cooling structure, improve the cooling performance of blade.Up to the present, the high temperature capabilities of bearing of blade material has had large increase, but compares with blade actual demand, also far can not reach requirement, therefore, need to constantly update blade cooling structure, improves blade cooling performance, meets the requirement of advanced engine.
The typical feature of efficient air cooling blade is that blade has cavity structure, and this cavity structure is very complicated, traditional technology Leaf adopts the method preparation of precision casting, the cavity of blade need adopt ceramic core to form, ceramic core will have higher intensity under hot environment, higher creep resisting ability, after blade casting, also must be able to adopt chemical process easily to remove simultaneously, therefore, ceramic core will have suitable density, if density is too low, hot strength and creep resisting ability obviously decline, if density is too high, be unfavorable for removing of ceramic core, therefore, the preparation ceramic core that has higher high-temperature behavior and easily adopt chemical process to remove, also will keep certain porosity when needing to keep the intensity of ceramic core, and this contradiction has been brought sizable difficulty to the preparation of ceramic core.
Summary of the invention
Object of the present invention: in order addressing the above problem, to the invention provides a kind of method of preparing the ceramic core that there is high strength and easily remove, to have met the needs that high efficiency cooling is prepared aircraft engine turbine blade.
Concrete technology of the present invention:
1, prepare softening agent: by paraffin or its mixture melt, under this state, add gradually polyethylene, constantly stir, be warming up to 120 ℃-160 ℃, until polyethylene is dissolved in paraffin completely, after stirring, filter, standby;
2, prepare silica slurry: by softening agent fusing, add gradually the hot powder of silicon-dioxide, limit adds powder limit to stir, and stirs and also will add the tensio-active agent of 0.5%-1.0%, churning time 2-8 hour simultaneously;
3, internal layer ceramic core moulding: silica slurry temperature is controlled to 100-140 ℃, adopts injection molding to carry out the moulding of internal layer ceramic core;
4, roasting: internal layer ceramic core is packed in aluminum oxide powder filler and carries out roasting, and burning temperature is eventually 1150-1190 ℃, time 3-5 hour;
5, preparation aluminum oxide or yttrium oxide or Zirconia Slurry: slip be combined as aluminum oxide powder and aluminium colloidal sol or yttrium oxide powder and yttrium oxide colloidal sol or zirconium white and zirconium colloidal sol composition;
6, soak, be dried: ceramic core is immersed in to 2-6 hour in aluminum oxide or yttrium oxide or Zirconia Slurry under condition of negative pressure, then in air, is dried;
7, sintering: dried ceramic core is carried out to sintering again, and burning temperature is eventually 1350-1550 ℃, and time 20-60 minute, finally makes composite ceramic core.
In technique of the present invention, in softening agent, Quality of Paraffin Waxes per-cent is 80-95%, and polyethylene is 2-5%, and all the other are beeswax or stearic acid;
In technique of the present invention, internal layer core ceramic powder is silicon dioxide base ceramic powder;
In technique of the present invention, the tensio-active agent adding in silicon dioxide base ceramic powder is oleic acid or other aliphatic alcohols materials;
In technique of the present invention, the moulding of silicon dioxide base ceramic size adopts injection molding mode moulding, and forming pressure is 0.4-0.8MPa, and be 20-120 second inject time, and the dwell time is 20-120 second;
In technique of the present invention, the softening agent in silicon-dioxide base ceramic core adopts stuffing means to remove, and filler adopts aluminium sesquioxide powder, and granularity is the industrial oxidation aluminium powder of 100-300 order;
In technique of the present invention, the silicon-dioxide base ceramic core dewaxing stage adopts the low temperature sintering that slowly heats up, and temperature is lower than 500 ℃; The whole sintering stage adopts high temperature sintering, and silica-based sintering is at 1150 ℃-1190 ℃, soaking time 3-5 hour, and then stove is chilled to room temperature;
In technique of the present invention, aluminum oxide or yttrium oxide or the Zirconia Slurry of preparation, be combined as aluminum oxide powder and aluminium colloidal sol or yttrium oxide and the yttrium oxide colloidal sol or zirconium white and zirconium colloidal sol of slip form, powder liquid mass ratio is (1-2): 1, the particle diameter of powder is 100nm-1000nm, and in colloidal sol, size of particles is 5-20nm;
In technique of the present invention, internal layer ceramic core carries out aluminum oxide or yttrium oxide or Zirconia Slurry and soaks under condition of negative pressure, and pressure is 0.01-0.05MPa;
In technique of the present invention, internal layer ceramic core soaks after aluminum oxide or yttrium oxide or Zirconia Slurry, need under 22-24 ℃ of relative humidity 50%-70% condition, be dried 4-12 hour, then ceramic core is soaked again and is dried, repeat this process 2-5 time, outer layer thickness is controlled at 0.05-2mm; Finally by this ceramic core at 1300 ℃ of-1550 ℃ of sintering 20-120 minute, furnace cooling;
In technique of the present invention, after ceramic core sintering, ceramic core is immersed in heat-reactive phenolic resin or in urea, take out at air drying.
Beneficial effect of the present invention is: the composite ceramic core that adopts preparation method of the present invention to prepare, the higher-strength under the hot environment of 1500-1580 ℃ with 12-25MPa, higher non-deformability (amount of deflection is 0.5-1.8mm), ceramic core has the density that 34-37% is suitable simultaneously, is beneficial to removing of ceramic core.
Accompanying drawing explanation
Fig. 1 is the outside drawing of the composite ceramic core of the preferred embodiment of the present invention one preparation.
Fig. 2 is the outside drawing of the composite ceramic core of the preferred embodiment of the present invention two preparations.
Embodiment
Embodiment mono-
By melted paraffin wax and add 1% polyethylene, constantly stir, be warming up to 130 ℃, until polyethylene is dissolved in paraffin completely, add gradually hot powder, the mass ratio of powder and softening agent is 85: 15, powder is thick silica powder and fine quartz powder, and the quality proportioning of the two is 30: 70, and limit adds ceramic powder limit to stir, stir the tensio-active agent oleic acid that simultaneously also will add total mass 1.0%, churning time 6 hours; After softening agent, powder, tensio-active agent mix, temperature remains between 120 ℃.Adopt injection press ceramic core, forming pressure is 0.4MPa, and be 20 seconds inject time, and the dwell time is 60 seconds; Ceramic core is packed in filler, and filler adopts aluminium sesquioxide powder, and granularity is the industrial oxidation aluminium powder of 200 order; The ceramic core dewaxing stage adopts the low temperature sintering that slowly heats up, and heat-up rate is 5 ℃/min, while rising to 500 ℃, is incubated 1 hour; Burn 1150 ℃ of temperature, 4 hours time eventually.Preparation alumina slurry, slip consist of aluminum oxide powder and aluminium sol solution composition, powder liquid mass ratio is 1: 1, the particle diameter of aluminum oxide powder is 200nm, in colloidal sol, size of particles is 10nm; Internal layer ceramic core is soaked in alumina slurry 20 minutes under 0.01MPa condition, then take out ceramic core and be dried 4 hours under 24 ℃ of relative humidity 70% conditions, repeat this technological process 4 times, then by this ceramic core at 1450 ℃ of sintering 20 minutes, furnace cooling; Finally, ceramic core is immersed in heat-reactive phenolic resin or in urea, take out at air drying.
Fig. 1 is shown in by the ceramic core of preparation, and the composite ceramic core of the embodiment of the present invention one preparation has typical ectonexine structure as can be seen from Figure 1; Have good over-all properties, 1500 ℃ of high-temperature bending strengths can reach 15MPa after testing simultaneously, and deflection value can reach 0.8mm; And its 1500 ℃ of high-temperature bending strengths of ceramic core that adopt silica-based preparation in traditional preparation technology only reach 7MPa, deflection value has reached 1.8mm.
Embodiment bis-
By melted paraffin wax and add 1% polyethylene, constantly stir, be warming up to 130 ℃, until polyethylene is dissolved in paraffin completely, add gradually hot powder, the mass ratio of powder and softening agent is 85: 15, powder is thick silica powder and fine quartz powder, and the quality proportioning of the two is 30: 70, and limit adds ceramic powder limit to stir, stir the tensio-active agent oleic acid that simultaneously also will add total mass 1.0%, churning time 6 hours; After softening agent, powder, tensio-active agent mix, temperature remains between 120 ℃.Adopt injection press ceramic core, forming pressure is 0.4MPa, and be 20 seconds inject time, and the dwell time is 60 seconds; Ceramic core is packed in filler, and filler adopts aluminium sesquioxide powder, and granularity is the industrial oxidation aluminium powder of 200 order; The ceramic core dewaxing stage adopts the low temperature sintering that slowly heats up, and heat-up rate is 5 ℃/min, while rising to 500 ℃, is incubated 1 hour; Burn 1150 ℃ of temperature, 4 hours time eventually.Preparation Zirconia Slurry, slip consist of zirconia powder and zirconium sol solution composition, powder liquid mass ratio is 1: 1, the particle diameter of zirconia powder is 200nm, in colloidal sol, size of particles is 10nm; Internal layer ceramic core is soaked in Zirconia Slurry 20 minutes under 0.01MPa condition, then take out ceramic core and be dried 4 hours under 24 ℃ of relative humidity 70% conditions, repeat this technological process 4 times, then by this ceramic core at 1390 ℃ of sintering 40 minutes, furnace cooling; Finally, ceramic core is immersed in heat-reactive phenolic resin or in urea, take out at air drying.
Fig. 2 is the outside drawing of the composite ceramic core of the preferred embodiment of the present invention two preparations, as can be seen from the figure composite ceramic core has typical ectonexine structure, have good over-all properties, 1550 ℃ of high-temperature bending strengths can reach 12MPa, and deflection value can reach 1.2mm; And its 1550 ℃ of high-temperature bending strengths of ceramic core that adopt silica-based preparation in traditional preparation technology only reach 3MPa, deflection value has reached 3.2mm.
Embodiment tri-
By melted paraffin wax and add 1% polyethylene, constantly stir, be warming up to 130 ℃, until polyethylene is dissolved in paraffin completely, add gradually hot powder, the mass ratio of powder and softening agent is 85: 15, powder is thick silica powder and fine quartz powder, and the quality proportioning of the two is 30: 70, and limit adds ceramic powder limit to stir, stir the tensio-active agent oleic acid that simultaneously also will add total mass 1.0%, churning time 6 hours; After softening agent, powder, tensio-active agent mix, temperature remains between 120 ℃.Adopt injection press ceramic core, forming pressure is 0.4MPa, and be 20 seconds inject time, and the dwell time is 60 seconds; Ceramic core is packed in filler, and filler adopts aluminium sesquioxide powder, and granularity is the industrial oxidation aluminium powder of 200 order; The ceramic core dewaxing stage adopts the low temperature sintering that slowly heats up, and heat-up rate is 5 ℃/min, while rising to 500 ℃, is incubated 1 hour; Burn 1150 ℃ of temperature, 4 hours time eventually.Preparation yttrium oxide slip, slip consist of yttrium oxide powder and yttrium sol solution composition, powder liquid mass ratio is 1: 1, the particle diameter of yttrium oxide powder is 200nm, in colloidal sol, size of particles is 10nm; Internal layer ceramic core is soaked in yttrium oxide slip 20 minutes under 0.01MPa condition, then take out ceramic core and be dried 4 hours under 24 ℃ of relative humidity 70% conditions, repeat this technological process 5 times, then by this ceramic core at 1400 ℃ of sintering 30 minutes, furnace cooling; Finally, ceramic core is immersed in heat-reactive phenolic resin or in urea, take out at air drying.
The composite ceramic core of embodiment tri-preparations has typical ectonexine structure, has good over-all properties, and 1500 ℃ of high-temperature bending strengths can reach 18MPa, and deflection value can reach 0.9mm.And its 1500 ℃ of high-temperature bending strengths of ceramic core that adopt silica-based preparation only reach 7MPa, deflection value has reached 1.8mm.
In sum, the composite ceramic core that adopts preparation method of the present invention to prepare, the higher-strength under the hot environment of 1500-1580 ℃ with 12-25MPa, higher non-deformability (amount of deflection is 0.5-1.8mm), ceramic core has the density that 34-37% is suitable simultaneously, be beneficial to removing of ceramic core, met the needs that high efficiency cooling is prepared aircraft engine turbine blade.
The foregoing is only preferred embodiment of the present invention, not in order to limit application range of the present invention; All other do not depart from the equivalence completing under disclosed essence and change or modify, and all should be included within the scope of following claims.

Claims (4)

1. a composite ceramic core preparation method, the internal layer of described composite ceramic core is silica-based materials, skin is alumina base or yttria-base or zirconia-based material; It is characterized in that: described composite ceramic core preparation method comprises the steps:
(1) prepare softening agent: polyethylene will be added after melted paraffin wax, constantly stir, be warming up to 120 ℃-160 ℃, until polyethylene is dissolved in paraffin completely, after stirring, filter;
(2) prepare silica slurry: by described softening agent fusing, add gradually the hot powder of silicon-dioxide, stir while adding, stir the tensio-active agent that simultaneously adds 0.5%-1.0%, churning time 2-8 hour, described tensio-active agent is oleic acid or other aliphatic alcohols materials;
(3) internal layer ceramic core moulding: described silica slurry temperature is controlled to 100-140 ℃, adopts injection molding to carry out moulding;
(4) roasting (removing softening agent): internal layer ceramic core is packed in aluminum oxide powder filler and carries out roasting, and burning temperature is eventually 1150-1190 ℃, time 3-5 hour;
(5) the outer slip of preparation ceramic core: be preparation aluminum oxide or yttrium oxide or Zirconia Slurry, be combined as aluminum oxide powder and aluminium colloidal sol or yttrium oxide and the yttrium oxide colloidal sol or zirconium white and zirconium colloidal sol of slip form, powder liquid mass ratio is (1-2): 1, the particle diameter of powder is 100nm-1000nm, and in colloidal sol, size of particles is 5-20nm;
(6) soak, be dried: under 0.01-0.05MPa condition of negative pressure, internal layer ceramic core is immersed in to 2-6 hour in outer slip, then at air drying, need under 22-24 ℃ of relative humidity 50%-70% condition, be dried 4-12 hour, then ceramic core soaked again and be dried again, repeat this process 2-5 time, outer layer thickness is controlled at 0.05-2mm;
(7) sintering: dried ceramic core is carried out to sintering again, and burning temperature is eventually 1350-1550 ℃, and time 20-60 minute, finally makes composite ceramic core.
2. composite ceramic core preparation method according to claim 1, is characterized in that: the Quality of Paraffin Waxes per-cent in described step 1 softening agent is 80-95%, and polyethylene mass percent is 2-5%, and all the other are beeswax or stearic acid.
3. composite ceramic core preparation method according to claim 1 and 2, is characterized in that: described injection molding forming pressure is 0.4-0.8MPa, and be 20-120 second inject time, and the dwell time is 20-120 second.
4. composite ceramic core preparation method according to claim 1, it is characterized in that: in described roasting (removing softening agent) step, pack described internal layer ceramic core into aluminium sesquioxide powder, granularity is to carry out roasting in the industrial oxidation aluminium powder of 100-300 order, burning temperature is eventually 1150-1190 ℃, time 3-5 hour.
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