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Effect of Al Powder on Property and Microstructure of Silica-based Ceramic Core

: Silica-based ceramic core was produced by fused silica as matrix material, corundum powder as miner-alizer, and Al powder as additive. Effects of aluminum powder contents on the ceramic core regarding shrinkage rate, physical performance, and microstructure were investigated. Results showed that through sintering process, aluminum powder was oxidized to alumina, accompanying with volume expansion and weight gain, which reduced sintering and casting shrinkages of silica-based ceramic core. There is no obvious inhibitory effect on devitrification by Al powder in the sintering process. Due to increased looseness of core skeleton structure in the casting process, the high temperature creep deformation increased. The sample with 1wt% Al showed good comprehensive properties, of which three-dimensional direction of sintering shrinkage rate were 0.01%, 0.03%, 0.03%, respectively, and porosity rate, deflection bending strength were 28.58%, 0.57 mm, 12.1 MPa, respectively. All these data demon-strated that the new core materials can meet the requirement of directional solidification and be expected to improve the dimensional accuracy of the hollow turbine blade.