Key Takeaways & Executive Findings
- •• Achieved silica-based ceramic core slurries with solid loading up to 68 vol.% by optimizing monomer ratio and dispersant content, overcoming viscosity limitations. • Optimal slurry formulation (monomer mass ratio 3:2, 4 wt.% BYK111) exhibited superior curing and rheological performance, enabling high-quality VPP 3D printing. • Increasing solid loading led to denser microstructure and improved flexural strength (19.5 MPa), while sintering shrinkage became more uniform, meeting casting requirements. • Provides a practical guide for preparing high solid loading ceramic slurries, advancing the fabrication of complex ceramic cores for aero-engine applications.
Abstract
Vat photopolymerization (VPP) 3D printing is an optimized technology for complex-shaped ceramic cores, in which the solid loading of ceramic slurries greatly influences the microstructure and property of the final ceramic parts. However, the high solid loading of slurries is highly limited by the high viscosity. In this study, silica-based ceramic core slurries with solid loading up to 68vol.% were achieved by the composition design to optimize the performance, considering the curing, rheological, and double bond conversion rate. The slurries demonstrate superior curing and rheological performance with mass ratio of monomers being 3:2 and mass fraction of BYK111 being 4wt.%. Afterwards, the impact of solid loading on the morphology and mechanical properties was investigated. As the solid loading increases, the microstructure becomes gradually dense, leading to an improved flexural strength of 19.5 MPa. Additionally, the sintering shrinkage becomes more uniform, satisfying the casting requirements effectively. This work serves as a guide for the preparation of ceramic slurries with a high solid loading.
1. Introduction
Ceramic cores serve as crucial components in aero-engine turbine blades, enabling the formation of complex internal structures that facilitate air-cooling for the blades [1-5]. The advancement of the aerospace industry has called for higher and higher temperature of the engine inlet to enhance the thrust-to-weight ratio [6, 7]. Consequently, the requirements for the internal cooling structure must be increasingly strict. As a result, the design of ceramic cores has evolved towards being multi-layered and complex [8]. Currently, hot injection molding is the traditional process used for fabricating ceramic cores; nevertheless, it is mostly dependent on molds and faces challenges in producing ceramic cores with intricate structures [9,10]. The high cost of molds and the long research and development cycle consistently hinder the progress of ceramic core development [11]. Hence, the fabrication of ceramic cores featuring complex, three-dimensional structures necessitates the establishment of a novel preparation process tailored to their geometrical intricacies.
The ceramic cores can now be manufactured via an innovative approach due to the rapid development of ceramic additive manufacturing, which can break through the restrictions of molds for ceramic molding, and significantly shorten the research and development cycle and reduce production costs [12-15]. Among various additive manufacturing technologies, vat photopolymerization (VPP) 3D printing is relatively mature with the benefits of high accuracy and excellent surface quality [16, 17]. Li et al. [18] employed an Ar atmosphere to regulate the oxidation of Al powders and utilized liquid-phase sintering to enhance the performance of alumina-based cores, which led to low linear shrinkage of 0.3%. Niu et al. [19] doped mullite fibers into a silica-based ceramic core to enhance the dimensional accuracy, and the high-temperature deflection was decreased to 1.79 mm. Li et al. [20] revealed the anisotropy mechanism of VPP-3D printing through finite element simulation and optimized the physical properties of the ceramic cores via designed sintering regime. The above research demonstrates the viability of producing ceramic cores through VPP-3D printing technology.
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Yong-kang Yang, Bo-ran Wang, Zi-qi Jia, Shu-xin Niu, Xin Li, Ya-jie Guo, Xi-qing Xu (2025). Vat photopolymerization of silica-based ceramic cores using high solid loading slurry with performance optimization. China Foundry. https://doi.org/10.1007/s41230-025-4178-y
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Frequently Asked Questions
What is the maximum solid loading achieved for silica-based ceramic slurries in this study?
The study achieved silica-based ceramic core slurries with solid loading up to 68 vol.% by optimizing the composition, including monomer ratio and dispersant content.
How does solid loading affect the mechanical properties of the ceramic cores?
As solid loading increases, the microstructure becomes denser, leading to improved flexural strength. The study reported a flexural strength of 19.5 MPa at the highest solid loading.
What are the optimal parameters for the slurry formulation?
The optimal slurry formulation uses a monomer mass ratio of 3:2 and a mass fraction of BYK111 dispersant of 4 wt.%, which provides superior curing and rheological performance.
Why is high solid loading important for VPP 3D printing of ceramic cores?
High solid loading not only provides reliable strength for sintered parts but also reduces shrinkage, which is particularly important for ceramic cores to meet dimensional accuracy requirements.
What is the significance of this work for the aerospace industry?
This work provides a guide for preparing high solid loading ceramic slurries, enabling the fabrication of complex-shaped ceramic cores with improved performance, which is essential for advanced aero-engine turbine blades.
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