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Particle Grading and Anisotropy Control of Ceramic Cores Formed by Digital Light Processing |
LI Xin1,2, LI Jie3, WANG Ke1, XU Xiqing3, SHI Zhenmei1, NIU Shuxin1, JIAO Qi2 |
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Abstract 3D printing is an ideal technology to prepare complex-shaped ceramic cores, however, due to the layerby-layer molding of 3D printing, the as-prepared ceramic cores exhibit significant anisotropy in microstructure and properties. Silica-based ceramic cores were prepared using digital light processing, and anisotropy in microstructure and properties was adjusted through particle grading. When the mass ratio (particle grading) of coarse powder to fine powder is 8∶ 2, the ceramic slurry exhibits good fluidity and stability, and interlayer gap of the ceramic core almost disappears, exhibiting uniform microstructure with surface roughness of 2.9 μm. The shrinkage rates in X, Y, Z three-dimensional directions are 3.15%, 3.08%, and 3.07%, indicating that the inhomogeneous shrinkage is alleviated. Interlayer strength is significantly lower than intralayer strength of ceramic cores. As particle grading changes from 6∶4 to 8∶2, the ratio of interlayer to intralayer strength increases from 0.40 to 0.62, indicating that the anisotropy of mechanical properties is alleviated. It is demonstrated that the structural and property anisotropy of 3D printed ceramic cores can be effectively controlled by particle grading, which provides a new technology to fabricating high-performance ceramic cores.
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