Abstract
The investment casting process is widely used in the aerospace industry to produce complex engine parts. The article determines the properties of quartz powders, nanosilica dioxide binders, and multilayer samples of ceramic casting molds. The properties of spherical molds obtained using an alcohol-water system derived from hydrolyzed ethyl silicate (ZKE) and LUDOX PX-30 (type Q1) were compared with those obtained in water systems derived from Remasol Plus and Remasol Premium binders (type Q2). The spherical samples are composed of seven layers made with the use of an immersion-sprinkling method. To assess the properties of the molds, X-ray microscopy (µCT), scanning electron microscopy (SEM), and gas permeability analysis over a temperature range of 20–950 °C were utilized. The binder type is proven to affect the properties of the casting mold samples. The material obtained in the water system, Q2, has advantageous properties such as a high porosity and gas permeability.
Highlights
Precision casting has been widely developed by the arms industry, for the production of aircraft engine components
We address the possibility of replacing hydrolyzed ethyl silicate (ZKE) with commercial water binders such as Remasol Plus and Remasol Premium
Performedbinders calculations, of the solid and the porosity, were properties of the foundry areboth presented in phase based on the numerical 3D analysis of chosen volumes in the reconstructed tomographic views of samples, allowed by the CTAn software
Summary
Precision casting has been widely developed by the arms industry, for the production of aircraft engine components. Ceramic molds with firmly specified properties, made from alloys such as CMSX4 and CMSX6, allow manufacturing precision castings with the Bridgman method This method allows to obtain a specific microstructure in the mold, in the form of mono- or poly-crystalline castings with specific grain orientation [2,3]. This type of approach is used for manufacturing heavily stressed parts for aircraft engine sections, such as high-pressure turbines. Ceramic molds, which are properly constructed and manufactured, allow a directional heat absorption from the volume of the crystallizing alloy This allows to achieve a custom microstructure with the desired fraction of the particles in the desired orientation. It is possible to obtain equiangular column grains or whole elements consisting of a single crystal
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