CN111231050A - Preparation method of single crystal double-wall hollow turbine blade based on photocuring technology - Google Patents
Preparation method of single crystal double-wall hollow turbine blade based on photocuring technology Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
- B28B17/02—Conditioning the material prior to shaping
- B28B17/026—Conditioning ceramic materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/14—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silica
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/14—Form or construction
- F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/284—Selection of ceramic materials
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/22—Manufacture essentially without removing material by sintering
Abstract
The invention relates to the field of precision casting, in particular to a preparation method of a single crystal double-wall hollow turbine blade based on a photocuring technology. Firstly, preparing silicon-based ceramic core slurry with high solid content, high printing performance and more stable and excellent flow settling performance; secondly, obtaining a three-dimensional model of the complex double-wall silicon-based ceramic core according to the single-crystal hollow double-wall engine blade required to be obtained, slicing the three-dimensional model of the core, and performing photocuring 3D printing path programming; step three, introducing the STL file of the core into a photocuring 3D printer, and printing layer by combining the silicon-based ceramic core slurry prepared in the step one to obtain a photocuring double-wall core biscuit; fourthly, drying and sintering the core biscuit to obtain the photocuring 3D printed complex double-wall silicon-based ceramic core; fifthly, sticking a wax mold by using the ceramic core and manufacturing a casting mold; sixthly, performing single crystal casting in a single crystal furnace to obtain the double-wall hollow turbine blade.
Description
Technical Field
The invention relates to the field of precision casting, in particular to a preparation method of a single crystal double-wall hollow turbine blade based on a photocuring technology, which is suitable for precisely casting a hollow engine blade.
Background
The photocuring 3D printing technology is used as a digital manufacturing technology without tools, so that the traditional production mode of products can be changed, and huge economic and social benefits are brought to enterprises and consumers. The 3D printing technology can manufacture products with highly complex shapes by using a layer-by-layer stacking precision machining mode. This enables the fabrication of complex structures of high precision, which in the past has been constrained by conventional machining approaches and which could not be achieved. The method greatly simplifies the product design link, improves the integration level of parts and shortens the product research and development period. Compared with the material reduction manufacturing method for processing the blank by using a cutting machine tool, the 3D printing manufacturing method reduces the consumption of raw materials and reduces the pressure on the natural environment. The 3D printing technology has wide application prospect in the fields of aviation, aerospace and the like due to the characteristics of large forming size, wide available material range, excellent material performance of a formed part and the like.
The ceramic core is a necessary link for preparing the hollow blade of the aero-engine, and the performance of the hollow blade is directly influenced by the quality of the ceramic core. With the improvement of the thrust-weight ratio requirement of an aero-engine, based on the basic principles of flow mechanics and heat transfer mechanics, the inner cavity design of an engine blade is more and more complex, so that more strict requirements are provided for the performance of a core, multiple sets of molds are needed for preparing a high-complexity double-wall silicon-based core and a precise silicon-based cavity by the traditional process, the process is complex, the cost is high, and how to simplify the process of manufacturing the complex double-wall hollow turbine blade becomes one of the problems which need to be solved by the technology.
Disclosure of Invention
The invention aims to provide a method for preparing a single crystal double-wall hollow turbine blade based on a photocuring technology, wherein a novel photocuring 3D printing technology is adopted in the process of preparing a ceramic core in an intermediate process, so that the whole set of process flow for preparing the single crystal double-wall complicated inner cavity blade is integrated, short in period, low in cost and high in efficiency.
In order to achieve the purpose, the technical scheme of the invention is as follows:
a method for preparing a single crystal double-wall hollow turbine blade based on a photocuring technology mainly comprises the steps of preparing silicon-based ceramic core slurry; manufacturing a complex double-wall silicon-based ceramic core three-dimensional model; slicing the three-dimensional model of the mold core, programming a 3D printing path, importing an STL format file, and adding silicon-based ceramic mold core slurry to perform photocuring 3D printing of the mold core; drying and sintering the core biscuit; carrying out wax mold sticking treatment by using a ceramic core and manufacturing a casting mold; and (3) performing single crystal casting in a single crystal furnace to obtain the double-wall hollow turbine blade.
According to the preparation method of the single crystal double-wall hollow turbine blade based on the photocuring technology, silicon-based ceramic core slurry with high solid content, high printing performance and more stable and excellent flowing and settling performance is prepared in the first step; secondly, obtaining a three-dimensional model of the complex double-wall silicon-based ceramic core according to the single-crystal hollow double-wall engine blade required to be obtained, slicing the three-dimensional model of the core, and performing photocuring 3D printing path programming; step three, importing the STL format file of the mold core into a photocuring 3D printer, and printing layer by combining the silicon-based ceramic mold core slurry prepared in the step one to obtain a photocuring double-wall mold core biscuit; fourthly, drying and sintering the core biscuit to finally obtain the photocuring 3D printed complex double-wall silicon-based ceramic core; fifthly, sticking a wax mold by using the ceramic core and manufacturing a casting mold; sixthly, performing single crystal casting in a single crystal furnace to obtain the double-wall hollow turbine blade.
The preparation method of the single crystal double-wall hollow turbine blade based on the light curing technology comprises the following specific steps:
(1) taking micron-level and nano-level mixed spherical silicon-based ceramic powder: fused silica with the granularity of 20-40 nm and the purity of 99.9 wt%, silica with the granularity of 100-300 mu m and the purity of 99 wt%, and gas-phase synthetic hydrophobic silica, wherein: the nanometer powder accounts for 60-75% of the total mass of the silicon-based ceramic powder, the micron powder accounts for 10-25% of the total mass of the silicon-based ceramic powder, and the gas-phase artificially synthesized hydrophobic silicon dioxide accounts for 5-20% of the total mass of the silicon-based ceramic powder;
(2) taking micron-scale and nano-scale mixed silicon-based ceramic powder, a monomer, a cross-linking agent, a dispersing agent, a photoinitiator, a light absorbing agent and a mineralizing agent;
(3) mixing silicon-based ceramic powder and a mineralizer, and carrying out ball milling on the mixture;
(4) sieving the ball-milled mixture, and drying to obtain dried and uniformly mixed powder;
(5) placing a photoinitiator, a light absorbent and a dispersant into a prepared monomer, and mixing to form a mixture;
(6) mixing the mixture obtained in the step (5) with the mixed powder obtained in the step (4), stirring the mixture into a viscous mixture by using stirrers with different powers, and gradually adjusting the rotating speed of the stirrer in the stirring process until the silicon-based ceramic core slurry for photocuring is obtained;
(7) establishing a complex double-wall silicon-based ceramic core three-dimensional model by using an Autodesk inventor, slicing the core three-dimensional model by using Simplify3D, programming a 3D printing path G code into an STL format by using C + +, then placing the photocuring silicon-based ceramic core slurry prepared in the step (6) and having high solid content, high printing performance, high reaction efficiency and more stable and excellent flow settlement performance into a receiving port of photocuring equipment, and leading an operation program into an STL format file to print a silicon-based ceramic core blank by using the photocuring 3D equipment;
(8) cleaning, drying and sintering the silicon-based ceramic core biscuit printed in the step (7) to obtain a final complex double-wall silicon-based ceramic core;
(9) carrying out wax mold sticking treatment on the silicon-based ceramic core sintered in the step (8), and then manufacturing a hollow blade casting mold shell;
(10) and (4) placing the shell prepared in the step (9) into a single crystal furnace to cast the turbine blade with the complex double-wall inner cavity of the single crystal.
According to the preparation method of the single crystal double-wall hollow turbine blade based on the photocuring technology, the volume of the silicon-based ceramic powder accounts for 50-60% of the sum of the volumes of the silicon-based ceramic powder and the monomer;
the monomer is mainly 1, 6-hexanediol diacrylate and is mixed with a part of Hexahydrophthalic Acid Diglycidyl Ester (HADE), and the volume ratio of the 1, 6-hexanediol diacrylate to the hexahydrophthalic acid diglycidyl ester and the dispersing agent in the monomer is (6-6.5): (2.5-3.0): (0.5 to 1.5);
the cross-linking agent is selected from ethoxylated pentaerythritol tetraacrylate (PPTTA), and m (HDDA) and m (PPTTA) are 5-10: 1 in mass ratio;
the dispersing agent is 1-2% of the total mass of the silicon-based ceramic core slurry for photocuring, the dispersing agent is mainly dipentaerythritol hexaacrylate, and is mixed with sodium polyacrylate, ammonium polyacrylate, stearic acid or oleic acid, the mass ratio of the dipentaerythritol hexaacrylate, the sodium polyacrylate, the ammonium polyacrylate, the stearic acid or the oleic acid is (10-20): 2-4): 1: 1;
the photoinitiator is 3 to 6 percent of the total mass of the silicon-based ceramic core slurry for photocuring, and the photoinitiator is a mixture of benzoin dimethyl ether, 2,4, 6-trimethylbenzoyl diphenyl phosphine oxide, diaryl iodonium salt and triaryl sulfonium salt;
the light absorber is 3-7% of the total mass of the silicon-based ceramic core slurry for photocuring, and mainly comprises phenyl o-hydroxybenzoate and one or two of 2, 4-dihydroxy benzophenone and 2- (2 '-hydroxy-5' -methylphenyl) benzotriazole;
the mineralizer is a mixture of alumina and zirconia with the total mass of 5-12% of the silicon-based ceramic powder, and the viscosity and the performance of the slurry are regulated and controlled; the granularity of the alumina is 20nm to 40nm or 100 to 300 mu m, and the granularity of the zirconia is 20 to 40 nm.
In the preparation method of the single crystal double-wall hollow turbine blade based on the photocuring technology, in the step (6), the rotating speed of a stirrer is gradually adjusted in the stirring process until silicon-based ceramic core slurry for photocuring is obtained; wherein the solid content range is 50-60 vol%, the reaction efficiency is 5-15 s for single-layer curing time, the silicon-based ceramic core slurry can not be layered in the printing process, good fluidity is presented at the discharge port, and the shear rate is 100s-1Viscosity of the slurry in the state<5.5Pa·s。
In the step (8), the cleaned silicon-based ceramic biscuit is placed in drying agent polyethylene glycol for 7-10 hours for full chemical drying treatment, and the silicon-based ceramic core biscuit is taken out, washed in water and then placed in a drying box for complete drying.
The preparation method of the single crystal double-wall hollow turbine blade based on the light curing technology comprises the following specific steps of: firstly, putting a dried silicon-based ceramic core into a high-temperature sintering furnace, heating the silicon-based ceramic core to 600 ℃ from room temperature for 8-12 hours, and preserving heat for 1-2 hours; then, heating from 600 ℃ to 1200 ℃ for 6-10 hours, and preserving heat for 3-5 hours; finally, the furnace is cooled to room temperature.
The design idea of the invention is as follows:
according to the invention, based on the actual use environment of the single-crystal hollow blade with the double-layer wall and the complex inner cavity, a preparation and processing process flow of the single-crystal hollow blade with the double-layer wall based on the photocuring 3D printing technology is constructed, so that the possibility of integrally and industrially producing the core of the hollow blade with the double-layer wall and the high complex structure is provided, and a corresponding evaluation system is established to meet the use requirement of precision casting.
The invention has the advantages and beneficial effects that:
1. the invention reduces the process steps of preparing the traditional turbine blade with the double-layer wall and the complex inner cavity, greatly simplifies the process flow and reduces the cost.
2. The integrally formed double-wall silicon-based ceramic core lays a technical support for industrial popularization.
3. The invention aims at the single crystal double-wall hollow turbine blade for investment casting based on the photocuring technology, and is also suitable for the hollow turbine blade with the aluminum-based ceramic material core after part of process parameters are adjusted.
4. The single crystal double-wall hollow turbine blade prepared by the invention has excellent performance of the blade in the traditional processing technology and provides technical support for providing other high-complexity double-wall and three-wall hollow turbine blades.
Drawings
FIG. 1 is a drawing of a sample of a complex double-walled silicon-based ceramic core for photocuring 3D printing of the present invention. The upper drawing is a top view of an inner cavity of the ceramic core, the lower left drawing is a main front view of the ceramic core, and the lower right drawing is a rear view of the ceramic core.
FIG. 2 is a diagram of a wax pattern process performed on a silicon-based ceramic core sample. The left drawing is a main front view of the ceramic core after the wax pattern is pasted, the middle drawing is a back view of the ceramic core after the wax pattern is pasted, and the right drawing is the core after the wax pattern is pasted and assembled on the wax pattern support.
FIG. 3 is a diagram of preparing a casting shell for a core after wax pattern attachment. Wherein, the left drawing is the casting rear shell of the front view angle, and the right drawing is the casting rear shell of the side view angle.
FIG. 4 is a drawing of a single crystal double wall hollow turbine blade after casting. The left drawing is a back view of the single crystal double-wall hollow turbine blade, the middle drawing is a front view of the single crystal double-wall hollow turbine blade, and the right drawing is a top view of an inner cavity of the single crystal double-wall hollow turbine blade.
Detailed Description
As shown in fig. 1 to 4, the method for preparing a single crystal double-walled hollow turbine blade based on the photo-curing technology mainly comprises preparing silicon-based ceramic core slurry with excellent performance such as solid content and the like; manufacturing a complex double-wall silicon-based ceramic core three-dimensional model; slicing the three-dimensional model of the core, programming a 3D printing path into an STL format, importing an STL format file and adding silicon-based ceramic core slurry to carry out photocuring 3D printing on the core; drying and sintering the core biscuit; carrying out wax mold sticking treatment by using a ceramic core and manufacturing a casting mold; and (3) performing single crystal casting in a single crystal furnace to obtain the double-wall hollow turbine blade.
Preparing silicon-based ceramic core slurry with high solid content, high printing performance and more stable and excellent flowing and settling performance in the first step; secondly, obtaining a three-dimensional model of the complex double-wall silicon-based ceramic core according to the single-crystal hollow double-wall engine blade required to be obtained, slicing the three-dimensional model of the core, and performing photocuring 3D printing path programming; step three, importing the STL format file of the mold core into a photocuring 3D printer, and printing layer by combining the silicon-based ceramic mold core slurry prepared in the step one to obtain a photocuring double-wall mold core biscuit; fourthly, drying and sintering the core biscuit to finally obtain the photocuring 3D printed complex double-wall silicon-based ceramic core; fifthly, sticking a wax mold by using the ceramic core and manufacturing a casting mold; sixthly, performing single crystal casting in a single crystal furnace to obtain the double-wall hollow turbine blade. The method can be used for precisely casting the hollow engine blade, and a novel photocuring 3D printing technology is adopted in the process of manufacturing the ceramic core in the intermediate process, so that the whole set of process flow for preparing the single crystal double-wall complex inner cavity blade is integrated.
The method comprises the following specific steps:
(1) taking micron-level and nano-level mixed spherical silicon-based ceramic powder: fused silica with the granularity of 20-40 nm and the purity of 99.9 wt% and silica with the granularity of 100-300 mu m and the purity of 99 wt% are mixed according to a certain proportion, and a certain proportion of gas-phase artificial synthetic hydrophobic silica purchased from Wacker chemical company of Germany is added according to the actual preparation situation, wherein: the nanometer powder accounts for 60-75% of the total mass of the silicon-based ceramic powder, the micron powder accounts for 10-25% of the total mass of the silicon-based ceramic powder, and the gas-phase artificially synthesized hydrophobic silicon dioxide accounts for 5-20% of the total mass of the silicon-based ceramic powder;
(2) taking micron-scale and nano-scale mixed silicon-based ceramic powder, a monomer, a cross-linking agent, a dispersing agent, a photoinitiator, a light absorbing agent and a mineralizing agent;
the volume of the silicon-based ceramic powder accounts for 55-60% of the sum of the volumes of the silicon-based ceramic powder and the monomer;
the monomer is mainly 1, 6-hexanediol diacrylate (HDDA) and is mixed with a part of Hexahydrophthalic Acid Diglycidyl Ester (HADE), and the volume ratio of the 1, 6-hexanediol diacrylate to the hexahydrophthalic acid diglycidyl ester and the dispersing agent in the monomer is (6-6.5): (2.5-3.0): (0.5 to 1.5).
The cross-linking agent is selected from ethoxylated pentaerythritol tetraacrylate (PPTTA), and m (HDDA): m (PPTTA) ((5-10): 1) in mass ratio.
The dispersing agent is 1.0-2.0% of the total mass of the silicon-based ceramic core slurry for photocuring, the dispersing agent is mainly dipentaerythritol hexaacrylate, and sodium polyacrylate, ammonium polyacrylate, stearic acid or oleic acid are mixed, and the mass ratio of the dipentaerythritol hexaacrylate, the sodium polyacrylate, the ammonium polyacrylate, the stearic acid or the oleic acid is (10-20): 2-4): 1: 1.
The photoinitiator is 3 to 6 percent of the total mass of the silicon-based ceramic core slurry for photocuring, and the photoinitiator is a mixture of benzoin dimethyl ether, 2,4, 6-trimethylbenzoyl diphenyl phosphine oxide, diaryl iodonium salt and triaryl sulfonium salt;
the light absorber is 3-7% of the total mass of the silicon-based ceramic core slurry for photocuring, and mainly comprises phenyl o-hydroxybenzoate and one or two of 2, 4-dihydroxy benzophenone and 2- (2 '-hydroxy-5' -methylphenyl) benzotriazole;
the mineralizer is a mixture of alumina and zirconia with the total mass of 5-12% of the silicon-based ceramic powder, and the viscosity and the performance of the slurry are regulated and controlled; the granularity of the alumina is 20nm to 40nm or 100 to 300 mu m, and the granularity of the zirconia is 20 to 40 nm.
(3) Mixing silicon-based ceramic powder and a mineralizer, and carrying out ball milling on the mixture;
(4) sieving the ball-milled mixture, and drying at 55-65 ℃ for 10-12 h to obtain dried and uniformly mixed powder;
(5) placing a photoinitiator, a light absorbent and a dispersant into a prepared monomer, and mixing to form a mixture;
(6) mixing the mixture obtained in the step (5) with the mixed powder obtained in the step (4), stirring the mixture into a viscous mixture by using stirrers with different powers, and gradually adjusting the rotating speed of the stirrer in the stirring process until the photocuring silicon-based ceramic core slurry with high solid content, high printing performance, high reaction efficiency and more stable and excellent flow settling performance is obtained;
wherein the solid content range is 50-60 vol%, the reaction efficiency is 5-15 s for single-layer curing time, the printing performance refers to that standard parts and complex structural parts with small number of gaps, uniform single-layer thickness and similar light transmission and color degree can be printed, the flowing sedimentation performance refers to that the high-solid-content silicon-based ceramic core slurry does not have the layering phenomenon and simultaneously has good fluidity at the discharge port in the printing process, and the shearing rate is 100s-1Viscosity of the slurry in the state<5.5Pa·s。
(7) Establishing a complex double-wall silicon-based ceramic core three-dimensional model by using an Autodesk inventor, slicing the core three-dimensional model by using Simplify3D, programming a 3D printing path G code into an STL format by using C + +, then placing the photocuring silicon-based ceramic core slurry prepared in the step (6) and having high solid content, high printing performance, high reaction efficiency and more stable and excellent flow settling property into a receiving port of photocuring equipment, and importing an operation program into the STL format file to print a silicon-based ceramic core biscuit by using the photocuring 3D equipment.
(8) And (4) cleaning, drying and sintering the silicon-based ceramic core biscuit printed in the step (7) to obtain the final complex double-wall silicon-based ceramic core.
And (3) putting the cleaned silicon-based ceramic biscuit in a drying agent polyethylene glycol for 7-10 hours, carrying out full chemical drying treatment, taking out the silicon-based ceramic core biscuit, washing the silicon-based ceramic core biscuit in water, and putting the silicon-based ceramic core biscuit into a drying box to completely dry the silicon-based ceramic core biscuit.
The sintering process comprises the following specific steps: putting the dried silicon-based ceramic core into a high-temperature sintering furnace, heating the silicon-based ceramic core to 600 ℃ from room temperature for 10 hours, and preserving the heat for 1-2 hours; then raising the temperature from 600 ℃ to 1200 ℃ for 8 hours, and preserving the heat for 4 hours; and then cooling to room temperature along with the furnace, and taking out the sintered sample.
(9) And (4) carrying out wax mold pasting treatment on the silicon-based ceramic core sintered in the step (8), and then manufacturing a hollow blade casting mold shell.
(10) And (4) placing the shell prepared in the step (9) into a single crystal furnace to cast the turbine blade with the complex double-wall inner cavity of the single crystal.
The present invention will be described in detail below with reference to the drawings and examples.
Examples
In this embodiment, the preparation method of the single crystal double-walled hollow turbine blade based on the photo-curing technology is as follows:
(1) 100g (46 mL v, 2g/cm p) of micron-sized and nano-sized mixed spherical silicon-based ceramic powder is weighed3) (ii) a Monomer (b): 20g (18mL) of 1, 6-hexanediol diacrylate, and 10g (11mL) of diglycidyl hexahydrophthalate; dispersing agent: 4g (3.5mL) of dipentaerythritol hexaacrylate (DPHA), and 0.8g of sodium polyacrylate, 0.2g of ammonium polyacrylate and 0.2g of oleic acid are mixed; photoinitiator (2): benzoin bis methyl ether 0.8g, 2,4, 6-trimethylbenzoyldiphenylphosphine oxide 0.12g, diarylsulfonium salt 0.12g, triarylsulfonium salt 0.12 g; light absorbers: 0.21g of 2, 4-dihydroxybenzophenone, 0.15g of 2- (2 '-hydroxy-5' -methylphenyl) benzotriazole; mineralizing agent: 8g of alumina and 6g of zirconia, wherein the granularity of the alumina is 20-40 nm, and the granularity of the zirconia is 20-40 nm.
(2) Mixing micron-scale and nano-scale mixed spherical silicon-based ceramic powder with a mineralizer, and carrying out ball milling treatment, wherein the milling ball is 10mm, 100g is added, the ball milling parameter is the rotating speed of 330r/min, and the ball milling is carried out for 5.5 hours;
(3) and (3) sieving the ball-milled mixture, drying, and putting in a drying oven at 60 ℃ for 11 hours to obtain dried and uniformly mixed powder. Adding a photoinitiator, a light absorbent and a dispersing agent into a monomer, stirring and dissolving the mixture in the monomer, adding the dried mixed powder, stirring the mixture into a viscous state while adding the mixture, putting the mixture into a homogenizing mixer, fully mixing the mixture for 60s with the set parameter of 1200r/min, and mixing the mixture for 40s with the set parameter of 1800r/min to obtain the silicon-based ceramic core slurry with the solid content of 56.6 vol%.
(4) The method comprises the steps of establishing a complex double-wall silicon-based ceramic core three-dimensional model by using an Autodesk inventor, slicing the core three-dimensional model by using Simplify3D, programming a 3D printing path G code into an STL format by using C + +, then putting prepared silicon-based ceramic core slurry with high solid content, high printing performance, high reaction efficiency and more stable and excellent flow settlement performance into a receiving port, and leading an operation program into an STL format file to print the ceramic core by using photocuring 3D equipment.
(5) And (3) putting the cleaned silicon-based ceramic biscuit in a drying agent polyethylene glycol for 7-10 hours, and carrying out sufficient chemical drying treatment until the mold core is taken out, washed in water and then put in a drying box to be thoroughly dried. The sintering process comprises the following specific steps: putting the dried silicon-based ceramic core into a high-temperature sintering furnace, heating the silicon-based ceramic core to 600 ℃ from room temperature for 10 hours, and preserving the heat for 1-2 hours; then raising the temperature from 600 ℃ to 1200 ℃ for 8 hours, and preserving the heat for 4 hours; and then cooling to room temperature along with the furnace, taking out a sintered sample as shown in figure 1, carrying out wax mold sticking treatment on the sintered silicon-based ceramic core, then manufacturing a hollow blade casting mold shell as shown in figures 2 and 3, and carrying out single crystal casting by using the technological parameters of DD5 single crystal material, 2.2Kg, 1470 ℃ in the upper region, 1520 ℃ in the lower region, 1520 ℃, standing time 5min and 5mm/min drawing speed as shown in figure 4.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and the inventive concepts thereof according to the present invention should be equivalent or changed within the scope of the present invention.
Claims (7)
1. A method for preparing a single crystal double-wall hollow turbine blade based on a photocuring technology is characterized by mainly comprising the steps of preparing silicon-based ceramic core slurry; manufacturing a complex double-wall silicon-based ceramic core three-dimensional model; slicing the three-dimensional model of the mold core, programming a 3D printing path, importing an STL format file, and adding silicon-based ceramic mold core slurry to perform photocuring 3D printing of the mold core; drying and sintering the core biscuit; carrying out wax mold sticking treatment by using a ceramic core and manufacturing a casting mold; and (3) performing single crystal casting in a single crystal furnace to obtain the double-wall hollow turbine blade.
2. The method for preparing a single crystal double-walled hollow turbine blade based on the photo-curing technique as claimed in claim 1, wherein the first step is to prepare a silica-based ceramic core slurry having a high solid content, a high printing performance, and a more stable and excellent flow settling performance; secondly, obtaining a three-dimensional model of the complex double-wall silicon-based ceramic core according to the single-crystal hollow double-wall engine blade required to be obtained, slicing the three-dimensional model of the core, and performing photocuring 3D printing path programming; step three, importing the STL format file of the mold core into a photocuring 3D printer, and printing layer by combining the silicon-based ceramic mold core slurry prepared in the step one to obtain a photocuring double-wall mold core biscuit; fourthly, drying and sintering the core biscuit to finally obtain the photocuring 3D printed complex double-wall silicon-based ceramic core; fifthly, sticking a wax mold by using the ceramic core and manufacturing a casting mold; sixthly, performing single crystal casting in a single crystal furnace to obtain the double-wall hollow turbine blade.
3. The method for preparing a single crystal double-walled hollow turbine blade based on the photo-curing technique as claimed in claim 1, wherein the method comprises the following steps:
(1) taking micron-level and nano-level mixed spherical silicon-based ceramic powder: fused silica with the granularity of 20-40 nm and the purity of 99.9 wt%, silica with the granularity of 100-300 mu m and the purity of 99 wt%, and gas-phase synthetic hydrophobic silica, wherein: the nanometer powder accounts for 60-75% of the total mass of the silicon-based ceramic powder, the micron powder accounts for 10-25% of the total mass of the silicon-based ceramic powder, and the gas-phase artificially synthesized hydrophobic silicon dioxide accounts for 5-20% of the total mass of the silicon-based ceramic powder;
(2) taking micron-scale and nano-scale mixed silicon-based ceramic powder, a monomer, a cross-linking agent, a dispersing agent, a photoinitiator, a light absorbing agent and a mineralizing agent;
(3) mixing silicon-based ceramic powder and a mineralizer, and carrying out ball milling on the mixture;
(4) sieving the ball-milled mixture, and drying to obtain dried and uniformly mixed powder;
(5) placing a photoinitiator, a light absorbent and a dispersant into a prepared monomer, and mixing to form a mixture;
(6) mixing the mixture obtained in the step (5) with the mixed powder obtained in the step (4), stirring the mixture into a viscous mixture by using stirrers with different powers, and gradually adjusting the rotating speed of the stirrer in the stirring process until the silicon-based ceramic core slurry for photocuring is obtained;
(7) establishing a complex double-wall silicon-based ceramic core three-dimensional model by using an Autodesk inventor, slicing the core three-dimensional model by using Simplify3D, programming a 3D printing path G code into an STL format by using C + +, then placing the photocuring silicon-based ceramic core slurry prepared in the step (6) and having high solid content, high printing performance, high reaction efficiency and more stable and excellent flow settlement performance into a receiving port of photocuring equipment, and leading an operation program into an STL format file to print a silicon-based ceramic core blank by using the photocuring 3D equipment;
(8) cleaning, drying and sintering the silicon-based ceramic core biscuit printed in the step (7) to obtain a final complex double-wall silicon-based ceramic core;
(9) carrying out wax mold sticking treatment on the silicon-based ceramic core sintered in the step (8), and then manufacturing a hollow blade casting mold shell;
(10) and (4) placing the shell prepared in the step (9) into a single crystal furnace to cast the turbine blade with the complex double-wall inner cavity of the single crystal.
4. The method for preparing a single crystal double-walled hollow turbine blade based on the photocuring technique as set forth in claim 3, wherein the volume of the silicon-based ceramic powder is 50 to 60% of the sum of the volumes of the silicon-based ceramic powder and the monomer;
the monomer is mainly 1, 6-hexanediol diacrylate and is mixed with a part of Hexahydrophthalic Acid Diglycidyl Ester (HADE), and the volume ratio of the 1, 6-hexanediol diacrylate to the hexahydrophthalic acid diglycidyl ester and the dispersing agent in the monomer is (6-6.5): (2.5-3.0): (0.5 to 1.5);
the cross-linking agent is selected from ethoxylated pentaerythritol tetraacrylate (PPTTA), and m (HDDA) and m (PPTTA) are 5-10: 1 in mass ratio;
the dispersing agent is 1-2% of the total mass of the silicon-based ceramic core slurry for photocuring, the dispersing agent is mainly dipentaerythritol hexaacrylate, and is mixed with sodium polyacrylate, ammonium polyacrylate, stearic acid or oleic acid, the mass ratio of the dipentaerythritol hexaacrylate, the sodium polyacrylate, the ammonium polyacrylate, the stearic acid or the oleic acid is (10-20): 2-4): 1: 1;
the photoinitiator is 3 to 6 percent of the total mass of the silicon-based ceramic core slurry for photocuring, and the photoinitiator is a mixture of benzoin dimethyl ether, 2,4, 6-trimethylbenzoyl diphenyl phosphine oxide, diaryl iodonium salt and triaryl sulfonium salt;
the light absorber is 3-7% of the total mass of the silicon-based ceramic core slurry for photocuring, and mainly comprises phenyl o-hydroxybenzoate and one or two of 2, 4-dihydroxy benzophenone and 2- (2 '-hydroxy-5' -methylphenyl) benzotriazole;
the mineralizer is a mixture of alumina and zirconia with the total mass of 5-12% of the silicon-based ceramic powder, and the viscosity and the performance of the slurry are regulated and controlled; the granularity of the alumina is 20nm to 40nm or 100 to 300 mu m, and the granularity of the zirconia is 20 to 40 nm.
5. The method for preparing a single crystal double-walled hollow turbine blade based on the photo-curing technique as claimed in claim 3, wherein in the step (6), the rotation speed of the stirrer is gradually adjusted during stirring until a silicon-based ceramic core slurry for photo-curing is obtained; wherein the solid phase content range is 50-60 vol%, the reaction efficiency is 5-15 s for single-layer curing time, the silicon-based ceramic core slurry can not be layered in the printing process,simultaneously, the material has good fluidity at the discharge port and the shear rate is 100s-1Viscosity of the slurry in the state<5.5Pa·s。
6. The method for preparing a single crystal double-walled hollow turbine blade based on the photocuring technology as claimed in claim 3, wherein in the step (8), the cleaned silicon-based ceramic biscuit is placed in a drying agent polyethylene glycol for 7-10 hours, sufficient chemical drying treatment is carried out, the silicon-based ceramic core biscuit is taken out, washed clean in water and then placed in a drying box, and the silicon-based ceramic core biscuit is completely dried.
7. The method for preparing a single crystal double-walled hollow turbine blade based on the photo-curing technique as claimed in claim 3, wherein in the step (8), the sintering process comprises the following specific steps: firstly, putting a dried silicon-based ceramic core into a high-temperature sintering furnace, heating the silicon-based ceramic core to 600 ℃ from room temperature for 8-12 hours, and preserving heat for 1-2 hours; then, heating from 600 ℃ to 1200 ℃ for 6-10 hours, and preserving heat for 3-5 hours; finally, the furnace is cooled to room temperature.
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