光固化增材制造陶瓷型芯尺寸精度控制研究进展

Research progress in dimensional accuracy control of ceramic cores prepared by vat photopolymerization additive manufacturing

摘要

陶瓷型芯是航空发动机空心叶片精密铸造中形成复杂冷却通道的关键部件，其尺寸精度直接影响叶片内腔结构质量与成品率。光固化增材制造技术因具有高分辨率、高效率和无需模具等优势，在复杂陶瓷型芯制备中展现出良好应用前景。然而，其在打印、脱脂烧结及浇注服役过程中，仍存在台阶效应、收缩开裂、相变致裂和高温蠕变等问题，导致型芯尺寸精度严重下降。本文围绕陶瓷型芯“原料—制备—使用”全流程，综述了不同阶段影响光固化增材制造陶瓷型芯尺寸精度的关键因素及其作用机理，重点分析了浆料组成、打印工艺、烧结行为和高温服役对尺寸稳定性的影响。最后对该领域的发展趋势进行了展望，未来研究应重点关注高性能浆料设计、打印与烧结协同调控以及面向工程应用的精度评价与标准体系构建。

Abstract

Ceramic cores are critical components for forming complex cooling channels in the investment casting of hollow aero-engine blades，and their dimensional accuracy directly determines the structural quality of the internal cavities and the casting yield of the blades. Due to its high resolution，high efficiency，and mold-free processing capability，vat photopolymerization additive manufacturing has shown great promise for the fabrication of complex ceramic cores. However，issues such as the stair-step effect，shrinkage-induced cracking，phase-transformation-induced fracture，and high-temperature creep still arise during printing，debinding and sintering，and casting service，thereby severely compromising the dimensional accuracy of the cores. Focusing on the entire lifecycle of ceramic cores，from raw materials to fabrication and service，this paper reviews the key factors affecting the dimensional accuracy of ceramic cores fabricated by vat photopolymerization additive manufacturing at different stages， together with the underlying mechanisms. Particular attention is given to the effects of slurry composition，printing parameters，sintering behavior，and high-temperature service conditions on dimensional stability. Finally，future development trends in this field are discussed，with emphasis on the design of high-performance slurries， the coordinated optimization of printing and sintering， as well as the establishment of dimensional accuracy evaluation methods and standard systems for engineering applications.

关键词

光固化增材制造 / 陶瓷型芯 / 光敏浆料 / 烧结 / 变形机理

Key words

vat photopolymerization additive manufacturing / ceramic core / photosensitive slurry / sintering / deformation mechanism

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基金资助

基础科研(jcky-2024213b002)