CN112222362B - Silicon-based ceramic core resistant to cold and hot impact, high-temperature creep and easy to remove and preparation process thereof - Google Patents

Silicon-based ceramic core resistant to cold and hot impact, high-temperature creep and easy to remove and preparation process thereof Download PDF

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CN112222362B
CN112222362B CN202010946272.6A CN202010946272A CN112222362B CN 112222362 B CN112222362 B CN 112222362B CN 202010946272 A CN202010946272 A CN 202010946272A CN 112222362 B CN112222362 B CN 112222362B
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ceramic core
powder
cold
cristobalite
quartz glass
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CN112222362A (en
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李凯文
姜卫国
肖久寒
董加胜
楼琅洪
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Institute of Metal Research of CAS
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/10Cores; Manufacture or installation of cores
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C1/00Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds

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Abstract

The invention discloses a ceramic core with high cold and hot impact resistance, high temperature creep resistance and easy removal and a preparation process thereof, belonging to the technical field of high-temperature alloy. Quartz glass powder with a certain granularity is used for forming a ceramic core matrix skeleton, so that the ceramic core is ensured to have good cold and hot impact resistance; the sintering density of the ceramic core is improved by the cristobalite and the alumina powder with the granularity of micron and below, so that the high-temperature creep resistance is improved; in the directional solidification process, the cristobalite is used as seed crystals to enable large-particle quartz glass to be easily crystallized and form cracks in the cooling process, and alkali liquor is easily immersed into the cracks when the mold core is removed, so that the removal performance of the ceramic mold core is improved.

Description

Silicon-based ceramic core resistant to cold and hot impact, high-temperature creep and easy to remove and preparation process thereof
Technical Field
The invention relates to the technical field of high-temperature alloy, and particularly provides a silicon-based ceramic core with cold and hot impact resistance, high-temperature creep resistance and easiness in removal for a large-size single crystal/directional hollow guide blade and a preparation process thereof.
Background
Single crystal/directional turbine blades are the most critical hot end components of gas turbines. With the development of gas turbines, power and thermal efficiency are increasing, and the requirement for the temperature bearing capacity of turbine blades is also increasing. In order to improve the temperature bearing capacity, the cooling structure of the blade is increasingly complex, and the preparation difficulty is obviously increased and decreased.
Single crystal/directional turbine blade cooling cavity structures are typically formed using ceramic cores. For the large-size single crystal/directional guide blade of a combustion engine, the ceramic core used for forming the inner cavity has larger size and complex shape, the ceramic core needs to be ensured to have stable size in the blade casting process, and the ceramic core also has good cold and hot impact resistance and high temperature creep resistance, and simultaneously has good decoring capability after the blade is formed. At present, the most common ceramic core base material is silicon base, quartz glass is used as a base material, and mineralizers such as alumina, zirconia, zirconium silicate and the like are added. The precipitation amount of the cristobalite must be controlled during the sintering of the silicon-based ceramic core to ensure that the ceramic core has good comprehensive performance, but the uniformity of the cristobalite precipitation is difficult to ensure only by adjusting process parameters. The ceramic core which is suitable for the large-size blade, has high thermal shock resistance and is easy to remove is selected, and the problem to be solved in the current production is urgent.
Disclosure of Invention
The invention aims to provide a ceramic core which is resistant to cold and hot impact, resistant to high-temperature creep and easy to remove and a preparation process thereof, so as to meet the preparation requirements of single crystal/directional hollow turbine guide blades.
The ceramic core is resistant to cold and hot impact, resistant to high-temperature creep and easy to remove, and comprises the following components in percentage by weight:
cristobalite: 4% -9%;
quartz glass: 42% -76%;
alumina: 20 to 49 percent.
The purity of the quartz glass is more than 99.9 percent, the purity of the aluminum oxide is more than 99.9 percent, and the purity of the cristobalite is more than 99.9 percent.
The granularity of the quartz glass is 100 meshes-200 meshes, the granularity of the cristobalite is 1000 meshes-3000 meshes, and the granularity of the alumina is 600 meshes-1000 meshes.
The preparation process of the ceramic core with cold and hot impact resistance, high temperature creep resistance and easy removal adopts a slurry injection molding method to prepare the ceramic core, and the slurry injection molding method comprises the following steps:
(1) putting quartz glass, alumina and cristobalite into a tank mill according to a ratio, and performing tank milling for 24 hours at a speed of 80r/min to obtain powder for later use;
(2) heating the plasticizer to 70-90 ℃, adding the powder obtained in the step (1) into the plasticizer in batches when the plasticizer is completely melted, wherein the addition amount of each batch accounts for 20-30% of the total powder, continuously stirring in the adding process to ensure that no dry powder exists, obtaining slurry after all the powder is added, and pouring the obtained slurry into slurry ingots for storage;
(3) heating the slurry ingot prepared in the step (2) to 90-110 ℃, preserving heat for 12-24h, and preparing a ceramic core biscuit after the slurry ingot is completely melted;
(4) alumina powder is selected as filler, the ceramic core biscuit is embedded in the filler powder, the temperature is raised to 500 ℃, the heat preservation time is 4-6 h, the temperature is raised to 1220-1250 ℃, the heat preservation time is 2-4 h, and the furnace is cooled to the room temperature.
The ceramic powder material and the plasticizer in the slurry obtained in the step (2) account for 80-85% and 15-20%.
In the step (2), the plasticizer comprises the following components in percentage by weight: 80-90% of paraffin, 1-4% of stearic acid and 5-19% of PVC.
In the step (4), the temperature rising rate is 5 ℃/min when the temperature is raised from the initial furnace temperature (room temperature) to 500 ℃, and the temperature rising rate is 15 ℃/min when the temperature is raised from 500 ℃ to 1220 ℃ -1250 ℃.
In the step (4), the purity of the alumina powder is more than or equal to 99.9%, and the particle size is 150-200 meshes.
The design principle of the invention is as follows:
according to the invention, the quartz glass powder with a certain particle size is used for forming the matrix skeleton of the ceramic core, so that the ceramic core is ensured to have good cold and hot impact resistance; the sintering density of the ceramic core is improved by adopting the cristobalite crystal and the alumina powder with the granularity of micron and below, so that the high-temperature creep resistance is improved; the cristobalite is used as seed crystal, so that large-particle quartz glass is easy to crystallize and forms cracks in the cooling process in the directional solidification process, alkali liquor is easy to immerse the cracks when the mold core is removed, and the removal performance of the ceramic mold core is improved.
In the invention, in order to ensure the formation of a coarse skeleton structure, the quartz glass with the granularity of 100-200 meshes is selected. On one hand, the method can play a good role in resisting cold and hot impact in the blade casting process, and on the other hand, in the depoling process after the blade casting, the depoling liquid can more sufficiently and more quickly enter cracks of quartz glass particles, so that the ceramic core removal performance is improved.
According to the invention, cristobalite with the granularity of less than 3000 meshes is selected, so that the density of the ceramic core is increased; on the other hand, fine cristobalite is used as quartz glass crystallization crystal nuclei and is dispersedly distributed around the quartz glass, so that the contact area between the cristobalite and the quartz glass is increased, the quartz glass can be more effectively and more quickly crystallized in the directional solidification process of the blade, the creep resistance of the core is improved, and the rejection rate of the blade caused by ceramic core eccentricity is reduced.
In the invention, the alumina with the granularity less than 1000 meshes is selected, and the alumina is very stable at a high-temperature stage, so that the high-temperature creep resistance of the ceramic core can be improved;
the invention has the following advantages and positive effects:
1. according to the invention, the quartz glass, the cristobalite and the alumina are reasonably matched in particle size, so that the ceramic core does not lose compactness while forming a more stable framework structure, and has high cold and hot impact resistance, high temperature creep resistance and excellent easy-removal performance;
2. the added fine cristobalite can enable the mold core to be easier to sinter, is beneficial to high-efficiency crystallization of quartz glass, and has good mechanical property and high-temperature creep resistance;
3. in the core components, the alumina with the maximum granularity less than 1000 meshes is matched, and the ceramic core has higher strength, chemical stability and high-temperature creep resistance due to the excellent high-temperature stability of the alumina.
4. The ceramic core obtained by the composition combination can meet the preparation requirement of large-size single crystal/directional hollow turbine guide blades.
Drawings
FIG. 1 is a phase analysis plot of a ceramic core sintered at 1220℃, according to the formulation of example 1;
FIG. 2 is a phase analysis plot of a ceramic core without fine cristobalite added after sintering at 1220 ℃.
Detailed Description
The invention is described in detail below with reference to the figures and examples. All percentages and ratios below are by mass (percent) unless otherwise specified.
In the following examples, the particle size of the quartz glass used was 100 to 200 mesh, the particle size of the cristobalite was 1000 to 3000 mesh, and the particle size of the alumina was 600 to 1000 mesh.
The ceramic core is prepared by the following steps:
(1) putting quartz glass, alumina and cristobalite into a tank mill according to a ratio, and performing tank milling for 24 hours at a speed of 80r/min to obtain powder for later use;
(2) heating the plasticizer to 85 ℃, adding the powder obtained in the step (1) into the plasticizer in 4 batches when the plasticizer is completely melted, wherein the adding amount of each batch accounts for 25% of the total powder, continuously stirring in the adding process to ensure that no dry powder exists, and obtaining slurry after all the powder is added, wherein the ceramic powder accounts for 82% of the slurry, and the plasticizer accounts for 18%. The composition of the plasticizer was (wt.%): 86% of paraffin, 3% of stearic acid and 11% of PVC. Pouring the obtained slurry into slurry ingots for storage;
(3) heating the slurry ingot prepared in the step (2) to 90-110 ℃, preserving heat for 12-24h, and preparing a ceramic core biscuit after the slurry ingot is completely melted;
(4) alumina powder with the purity of more than or equal to 99.9 percent and the particle size of 150-.
Example 1
The ceramic core comprises the following components: quartz glass (100 to 200 mesh): 76%, cristobalite (1000 to 3000 mesh): 4%, alumina (600 to 1000 mesh): 20 percent; the purity of the quartz glass, the purity of the cristobalite and the purity of the alumina are all 99.9 percent; adding plasticizer and pressing into plate-shaped ceramic core biscuit with the size of 12cm by 1cm by 0.4 cm;
selecting alumina powder with the purity of more than or equal to 99.9 percent and the particle size of 150-200 meshes as a filler, embedding a ceramic core biscuit in the filler powder, heating to 500 ℃ at the heating rate of 5 ℃/min, preserving heat for 5h, heating to 1220 ℃ at the heating rate of 15 ℃/min, preserving heat for 2h, calculating the relative content of cristobalite in the ceramic core by analyzing an X-ray map of the sintered ceramic core, continuously heating the ceramic core to 1550 ℃, preserving heat for 1 h, and measuring the high-temperature creep property of the ceramic core. Then the ceramic core is put into the prepared special alkali liquor, and the complete dissolution time is 6 hours.
FIG. 1 is a phase analysis curve of the ceramic core of the present example after being sintered at 1220 ℃, which shows that the ceramic core after being sintered is transformed from quartz glass into a certain amount of cristobalite, and a small amount of amorphous phase of quartz glass still exists.
The performance criteria for the cores of this example are as follows: the room temperature bending strength is 14MPa, the high temperature deflection is 0.6mm, and the shrinkage rate is 2 percent.
Example 2
The ceramic core comprises the following components: quartz glass (100 to 200 mesh): 74%, cristobalite (1000 to 3000 mesh): 6%, alumina (600 to 1000 mesh): 20 percent; the purity of the quartz glass, the purity of the cristobalite and the purity of the alumina are all 99.9 percent; adding plasticizer and pressing into plate-shaped ceramic core biscuit with the size of 12cm by 1cm by 0.4 cm;
selecting alumina powder with the purity of more than or equal to 99.9 percent and the particle size of 150-200 meshes as a filler, embedding a ceramic core biscuit in the filler powder, heating to 500 ℃ at the heating rate of 5 ℃/min, preserving heat for 5h, heating to 1220 ℃ at the heating rate of 15 ℃/min, preserving heat for 2h, calculating the relative content of cristobalite in the ceramic core to be about 15 percent by analyzing an X-ray map of the sintered ceramic core, continuously heating the ceramic core to 1550 ℃, preserving heat for 1 h, and measuring the high-temperature creep property of the ceramic core. Then the ceramic core is put into the prepared special alkali liquor, and the complete dissolution time is 5.5 hours. The performance criteria of the cores were as follows: the room temperature bending strength is 16MPa, the high temperature deflection is 0.4mm, and the shrinkage rate is 2 percent.
Example 3
The ceramic core comprises the following components: quartz glass (100 to 200 mesh): 65%, cristobalite (1000 to 3000 mesh): 8%, alumina (600 mesh to 1000 mesh): 27%; the purity of the quartz glass, the purity of the cristobalite and the purity of the alumina are all more than 99.9 percent; adding plasticizer and pressing into plate-shaped ceramic core biscuit with the size of 12cm by 1cm by 0.4 cm;
selecting alumina powder with the purity of more than or equal to 99.9 percent and the particle size of 150-. Then the ceramic core is put into the prepared special alkali liquor, and the complete dissolution time is 4.5 hours. The performance criteria of the cores were as follows: the room temperature bending strength is 19MPa, the high temperature deflection is 0.3mm, and the shrinkage rate is 1.6%.
Example 4
The ceramic core comprises the following components: quartz glass (100 to 200 mesh): 65%, cristobalite (1000 to 3000 mesh): 8%, alumina (600 mesh to 1000 mesh): 27%; the purity of the quartz glass, the purity of the cristobalite and the purity of the alumina are all more than 99.9 percent; adding plasticizer and pressing into plate-shaped ceramic core biscuit with the size of 12cm by 1cm by 0.4 cm;
selecting alumina powder with the purity of more than or equal to 99.9 percent and the particle size of 150-. Then the ceramic core is put into the prepared special alkali liquor, and the complete dissolution time is 4 hours. The performance criteria of the cores were as follows: the room temperature bending strength is 22MPa, the high temperature deflection is 0.2mm, and the shrinkage rate is 1.3%.
Example 5
The ceramic core comprises the following components: quartz glass (100 to 200 mesh): 52%, cristobalite (1000 to 3000 mesh): 9%, alumina (600 to 1000 mesh): 39 percent; the purity of the quartz glass, the purity of the cristobalite and the purity of the alumina are all more than 99.9 percent; adding plasticizer and pressing into plate-shaped ceramic core biscuit with the size of 12cm by 1cm by 0.4 cm;
selecting alumina powder with the purity of more than or equal to 99.9 percent and the particle size of 150-200 meshes as a filler, embedding a ceramic core biscuit in the filler powder, heating to 500 ℃ at the heating rate of 5 ℃/min, preserving heat for 5h, heating to 1220 ℃ at the heating rate of 15 ℃/min, preserving heat for 2h, calculating the relative content of cristobalite in the ceramic core by analyzing an X-ray map of the sintered ceramic core, continuously heating the ceramic core to 1550 ℃, preserving heat for 1 h, and measuring the high-temperature creep property of the ceramic core. Then the ceramic core is put into the prepared special alkali liquor, and the complete dissolution time is 4 hours. The performance criteria of the cores were as follows: the room temperature bending strength is 23MPa, the high temperature deflection is 0.2mm, and the shrinkage rate is 2.3%.
Comparative example 1:
the difference from the embodiment 1 is that: the ceramic core comprises the following components: quartz glass (100 to 200 mesh): 80%, alumina (600 mesh to 1000 mesh): 20 percent; the rest is the same as the embodiment.
FIG. 2 is a phase analysis plot of the ceramic core of this example without the addition of fine cristobalite after sintering at 1220 ℃.
It can be seen that in the absence of fine cristobalite, the typical diffraction peak intensity of quartz after sintering is low, mostly in the amorphous form of quartz glass.

Claims (5)

1. A ceramic core which resists cold and hot impact, high temperature creep and is easy to remove is characterized in that: the ceramic core comprises the following components in percentage by weight:
cristobalite: 4% -9%;
quartz glass: 42% -76%;
alumina: 20% -49%;
the granularity of the quartz glass is 100 meshes-200 meshes, the granularity of the cristobalite is 1000 meshes-3000 meshes, and the granularity of the alumina is 600 meshes-1000 meshes;
the preparation process of the ceramic core with cold and hot impact resistance, high temperature creep resistance and easy removal comprises the following steps: the method for preparing the ceramic core by adopting the slurry injection molding comprises the following steps:
(1) putting quartz glass, alumina and cristobalite into a tank mill according to a ratio, and performing tank milling for 24 hours at a speed of 80r/min to obtain powder for later use;
(2) heating the plasticizer to 70-90 ℃, adding the powder obtained in the step (1) into the plasticizer in batches when the plasticizer is completely melted, wherein the addition amount of each batch accounts for 20-30% of the total powder, continuously stirring in the adding process to ensure that no dry powder exists, obtaining slurry after all the powder is added, and pouring the obtained slurry into slurry ingots for storage; the plasticizer comprises the following components in percentage by weight: 80-90% of paraffin, 1-4% of stearic acid and 5-19% of PVC;
(3) heating the slurry ingot prepared in the step (2) to 90-110 ℃, preserving heat for 12-24h, and preparing a ceramic core biscuit after the slurry ingot is completely melted;
(4) alumina powder is selected as filler, the ceramic core biscuit is embedded in the filler powder, the temperature is raised to 500 ℃, the heat preservation time is 4-6 h, the temperature is raised to 1220-1250 ℃, the heat preservation time is 2-4 h, and the furnace is cooled to the room temperature.
2. The cold-hot impact resistant, high temperature creep resistant, and release susceptible ceramic core of claim 1, characterized by the following: the purity of the quartz glass is more than 99.9 percent, the purity of the aluminum oxide is more than 99.9 percent, and the purity of the cristobalite is more than 99.9 percent.
3. The cold-hot impact resistant, high temperature creep resistant, and release susceptible ceramic core of claim 1, characterized by the following: the ceramic powder material in the slurry obtained in the step (2) accounts for 80-85 percent, and the plasticizer accounts for 15-20 percent.
4. The process for preparing the ceramic core with cold and hot impact resistance, high temperature creep resistance and easy removal according to claim 1 is characterized by comprising the following steps: in the step (4), the temperature rising speed is 5 ℃/min when the temperature rises from the initial furnace temperature to 500 ℃, and the temperature rising speed is 15 ℃/min when the temperature rises from 500 ℃ to 1220-1250 ℃.
5. The process for preparing the ceramic core with cold and hot impact resistance, high temperature creep resistance and easy removal according to claim 1 is characterized by comprising the following steps: in the step (4), the purity of the alumina powder is more than or equal to 99.9%, and the granularity is 150-200 meshes.
CN202010946272.6A 2020-09-10 2020-09-10 Silicon-based ceramic core resistant to cold and hot impact, high-temperature creep and easy to remove and preparation process thereof Active CN112222362B (en)

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