Chinese Journal of Lasers, Volume. 49, Issue 12, 1202002(2022)

Research Progress of Ceramic Cores and Shells Prepared by Laser Additive Manufacturing

Dong Sun1,2, Shuang Chen1,2, Yusheng Shi1,2、*, Chunze Yan1,2, Jiamin Wu1,2, and Shifeng Wen1,2
Author Affiliations
  • 1State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, Hubei, China
  • 2Engineering Research Center of Ceramic Materials for Additive Manufacturing, Ministry of Education, Wuhan 430074, Hubei, China
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    Figures & Tables(12)
    Internal structure of turbine blades. (a) Development trend of turbine blade internal structure[5]; (b) typical gas-cooled structure inside gas turbine blades[6]
    Design of ceramic core/shell for superalloy airfoil[9]. (a) Ceramic core for complex internal cooling passages; (b) cross-section of integrally cored ceramic mold; (c) profile of integrally cored ceramic mold
    Preparation of ceramic core/shell by SLS process
    Al2O3-SiO2 ceramic parts prepared by SLS[17]
    Surface morphology of alumina ceramic parts prepared by SLS. (a) Before debinding; (b) after debinding
    Two main process routes for preparation of ceramic core/shell by SLA process
    Effect of particle size distribution on segregation in layers of green body fabricated by SLA process[66].(a) Regions representing segregation and no segregation in layers; (b) bimodal powder; (c) coarse powder
    Green bodies under different drying conditions[44]. (a) Air drying; (b) freeze drying
    Ceramic shell/core fabricated by SLA+gel casting[77]. (a) CAD model of simplified ceramic impingement hole cores (CIHCs); (b) CIHCs prototype fabricated by SLA process; (c) CIHCs mold; (d) cross-section of double wall blade; (e) deformation of double-wall ceramic core from finite element simulation; (f) cross-section of fabricated metal double-wall blade
    Integrally cored ceramic mold for turbine airfoil with complex internal hollow structure[9]. (a) Three-dimensional model; (b) green body; (c) sintered body without any cracks
    • Table 1. Typical properties of ceramic cores and shells prepared by conventional processes and laser additive manufacturing processes

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      Table 1. Typical properties of ceramic cores and shells prepared by conventional processes and laser additive manufacturing processes

      MethodFeedstockSintering temperature /℃Sintering shrinkagePorosity /%Strength@room temperature /MPaStrength /MPa(1550 ℃)Reference No.
      Hot die castingAl2O3(AC-1)14502.1%32-369.0-12.05.0-7.0[7]
      Hot die castingAl2O3(AC-2)14-50<1%-9.0-11.06.0-8.0[8]
      SLA+gel castingAl2O31550-41.35-4.61[87]
      SLA+gel castingAl2O314000.36%32.6-20.4[91]
      SLASiO213004%(X/Y),5.7%(Z)33.512.1-[92]
      SLASiO212001.64%39.520.3821.43[84]
      SLAAl2O311502.3%(X),2.4%(Y),5.3%(Z)37.933.7-[85]
      SLAAl2O312802.1%(X),2.3%(Y),3.8%(Z)37.624.0-[93]
      SLAAl2O315506.4%(X/Y), 11.4%(Z)30.1278.15-[68]
      SLS3Al2O3·2SiO21600-1238±3.18-[40]
      SLSSiO212000.6%397.4515.04[39]
    • Table 2. Characteristics of different laser additive manufacturing processes used for ceramic core/ shell manufacturing

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      Table 2. Characteristics of different laser additive manufacturing processes used for ceramic core/ shell manufacturing

      CharacteristicSLSSLA+Gel castingSLA
      Precision~500 μm50-200 μm50-200 μm
      Size100-1000 mm50-600 mm50-300 mm
      Surface qualityMediumHighHigh
      Forming efficiencyHighMediumMedium
      Support needNoYesYes
      FeedstockPowderResinCeramic slurry
      Feedstock recycleEasyEasyMedium
      Sintering shrinkageLowLowHigh
      Range of applicationMedium-large turbine bladeSmall-medium turbine bladeSmall-medium turbine blade
      PerformanceMediumHighHigh
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    Dong Sun, Shuang Chen, Yusheng Shi, Chunze Yan, Jiamin Wu, Shifeng Wen. Research Progress of Ceramic Cores and Shells Prepared by Laser Additive Manufacturing[J]. Chinese Journal of Lasers, 2022, 49(12): 1202002

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    Paper Information

    Category: laser manufacturing

    Received: Jan. 11, 2022

    Accepted: Mar. 7, 2022

    Published Online: Jun. 13, 2022

    The Author Email: Yusheng Shi (shiyusheng@hust.edu.cn)

    DOI:10.3788/CJL202249.1202002

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