Preparation of high-strength and low-shrinkage composite salt cores by binder jetting and vacuum impregnation

Abstract

ABSTRACT Binder jetting (BJ) technology was employed combined with vacuum impregnation to fabricate alumina-reinforced Na2SO4-NaCl water soluble composite salt cores (WSCSC), intended for manufacturing aluminum alloy castings featuring intricate cavity structures. The bending strength and sintering shrinkage rate of WSCSC were investigated to discern the influences of alumina content, vacuum impregnation pressure and time, accompanied by a detailed analysis of the microstructure and reinforcement mechanism. The findings reveal that WSCSC containing 40 wt.% alumina exhibits exceptional mechanical properties, demonstrating a bending strength of 29.13 MPa, which is 197% higher than that of WSCSC without alumina. Furthermore, when the vacuum impregnation of saturated brine is conducted at a pressure of 30 KPa for 90 s, the resulting WSCSC possesses a sintering shrinkage rate of 4.94%, reflecting a significant reduction of 73.5% compared to that of WSCSC without vacuum impregnation treatment. Microstructural analyses show that alumina, as a stable secondary phase, can refine the NaCl grains within WSCSC, deflecting cracks and elongating their propagation paths, thereby remarkably enhancing the bending strength. Moreover, the fine inorganic salt particles crystallized and precipitated from saturated brine during the drying process are filled in the internal pores of WSCSC through vacuum impregnation, dramatically reducing the sintering shrinkage rate. Ultimately, the high-strength and low-shrinkage WSCSC parts were successfully manufactured.