Sand-burning Reaction of Ceramic Shell for Directional Solidification of Nickel-based Superalloy

doi:10.11901/1005.3093.2020.244

Chinese Journal of Materials Research

2021, Vol. 35

Issue (4): 251-258 DOI: 10.11901/1005.3093.2020.244

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Sand-burning Reaction of Ceramic Shell for Directional Solidification of Nickel-based Superalloy

SHI Zhenwei¹^,²(

), ZHENG Wei¹, LU Yuzhang¹, ZHANG Gong¹, SHEN Jian¹(

)

^1.Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
^2.Nano Science and Technology Institute, University of Science and Technology of China, Suzhou 215123, China

Cite this article:

SHI Zhenwei, ZHENG Wei, LU Yuzhang, ZHANG Gong, SHEN Jian. Sand-burning Reaction of Ceramic Shell for Directional Solidification of Nickel-based Superalloy. Chinese Journal of Materials Research, 2021, 35(4): 251-258.

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Abstract

The influence of the particle size ratio of the ceramic shell for directional solidification of superalloy and the Cr₂O₃ additive on the surface quality of castings was investigated by means of multi-index orthogonal experiment and the range analysis while taking the sand-burning on the surface quality and roughness of the resulted castings as the calibration. The results show that the main components of the sand-burning layer on the casting surface includes Al₂O₃and elements Cr, Ni of the alloy. Adjusting the particle size gradation can reduce the porosity of the ceramic shell surface layer and then yield a dense shell surface layer, thereby reducing the penetration of the molten alloy into the ceramic shell surface layer during the directional solidification process and reducing the physical adhering sand on the surface of the casting. The addition of Cr₂O₃ additive can induce the reaction of Cr₂O₃ with Al₂O₃in the shell resulting in the formation of the binary compound Al₂O₃-Cr₂O₃ or ternary compound Al₂O₃-SiO₂-Cr₂O₃, which can inhibit the active elements (Ni, Ti, Al, etc.) in the casting react with free SiO₂ in the ceramic shell to reduce the formation of Al₂O₃ on the casting surface, thereby reducing the chemical adhering sand on the casting surface and improving the casting surface quality.

Key words: metallic materials sand-burning reactions ceramic shell orthogonal experiment superalloy

Received: 19 June 2020

ZTFLH:

TG245

Fund: National Natural Science Foundation of China(51631008);National Science and Technology Major Project(2017-VII-0008-0101);Key Deployment Projects of the Chinese Academy of Sciences(ZDRW-CN-2019-01)

About author: SHI Zhenwei, Tel: 18655950521, E-mail: 785251495@qq.com

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https://www.cjmr.org/EN/10.11901/1005.3093.2020.244 OR https://www.cjmr.org/EN/Y2021/V35/I4/251

Table 1 Nominal compositions of nickel-based superalloy(mass fraction, %)

Table 2 Chemical composition of EC95 powders (mass fraction, %)

Table 3 Particle size distribution of ceramic shell surface powders

Table 4 Factors and levels graph

Table 5 Experiment scheme and results

Table 6 Range analysis of various indicators

Fig.1 Porosity of ceramic shell surface

Fig.2 Microstructures of ceramic shell surface (a) optimization shell and (b) regular shell

Fig.3 Surface of casting. (a) casting with optimization shell and (b) casting with regular shell

Fig.4 SEM and EDS analysis of sand-burning layer on casting surface. (a) micromorphology, (b) Al element, (c) O element, (d) Si element and (e) EDS elemental analysis

Fig.5 Cross section SEM images of casting surface layer. (a) sand-burning layer on casting surface of regular shell, (b) sand-burning layer on casting surface of optimization shell, (c) smooth area of casting surface of regular shell, (d, e) EDS surface scan of the smooth area of conventional casting shell casting and (f) smooth area of casting surface of optimization shell

Fig.6 Ceramic shell surface and XRD pattern of shell surface (a) ceramic shell surface, (b) XRD pattern of shell surface

Fig.7 EDS line scan of the sand-burning layer

Table 7 Gibbs free energy of related interfacial reaction

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