Abstract
Alumina (Al2O3) suspensions were prepared for the effective application in the stereolithography three-dimensional (3D) printing process. Thermal treatment of -Al2O3 could optimize the ceramic slurries to meet the requirements of stereolithography 3D printing technique. In this study, alumina powders were modified by thermal treatment at different temperatures for the preparation of well dispersed ceramic slurries. The influence of thermal treatment on the raw powder, printed green bodies, and sintered alumina parts was systematically studied. Thermogravimetric analysis indicated that the decomposition temperature of photosensitive resin was between 390C and 460C. The alumina powders became denser, the crystal grains changed from round sphere-shaped to long cylinder-shaped, and the pores disappeared with increasing thermal treatment temperature. After the 3D printing process, the microstructure of green bodies and sintered alumina ceramics exhibited significant variation. Decomposition and removal of photosensitive resin led to higher water absorption, higher porosity, and lower bulk density of alumina ceramics compared to the printed green bodies. The scattering phenomenon in ceramic slurries and layer-by-layer forming characteristic determined the different shrinkage in three directions. Experimental results suggested that 1500C was considered as the optimal thermal treatment temperature, with the water absorption of 107%, open porosity of 91%, and bulk density of 0.67g·cm3. The higher thermal treatment temperatures would cause alumina powders to clump and agglomerate.
Highlights
Aero-engines pursue extreme performance in extremely limited space and under extreme conditions to ensure long-term stability (Lukin et al, 1993; Xiao and Huang, 2016; Williams, 2017; Salpingidou et al, 2018)
The inorganic alumina powder was previously treated at high temperature (1,300–1,500◦C), which prevented its decomposition at TGA temperature (50–600◦C)
The peaks of the DSC curves are located at 430◦C, which means that the photosensitive resin reacts mostly at this temperature
Summary
Aero-engines pursue extreme performance in extremely limited space and under extreme conditions (high temperature, high pressure, and high stress) to ensure long-term stability (Lukin et al, 1993; Xiao and Huang, 2016; Williams, 2017; Salpingidou et al, 2018). In order to meet the requirements of temperature, innovative design advances for efficient and reliable cooling systems is the key problem (Kim et al, 2016; Popoola et al, 2016; Uysal et al, 2018). This technology utilizes the internal cooling channels to cool down the hightemperature blades in working conditions, which indirectly boosts the required utilization temperature of the blade. The ceramic cores could shape the complex cooling passage inside the blade, improve the blade cooling structures, and continuously improve the blade cooling efficiency. Ceramic cores play an extremely important role in molding hollow blades with complex cavities
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