Ecofriendly Water-Soluble Binders for Precision Ceramic Moulds in Aerospace Turbine Casting: Process Development and Performance Evaluation.
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| Title: | Ecofriendly Water-Soluble Binders for Precision Ceramic Moulds in Aerospace Turbine Casting: Process Development and Performance Evaluation. |
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| Authors: | Małek, Marcin1 (AUTHOR) marcin.malek@wat.edu.pl, Wachowski, Marcin2 (AUTHOR), Kluczyński, Janusz1,2 (AUTHOR) |
| Source: | Materials (1996-1944). May2025, Vol. 18 Issue 10, p2329. 29p. |
| Subjects: | Precision casting, Ethyl silicate, Occupational hazards, Bending strength, Surface morphology |
| Abstract: | The paper presents the development of an ecofriendly ceramic moulding system for the precision casting of aircraft turbine components from nickel superalloys using water-soluble binders. The motivation was to eliminate hydrolysed ethyl silicate (HES) due to its environmental and occupational hazards. Two water-based binders (K + M)—Keysol (for the primary layer) and Matrixsol (for the backup layers)—were evaluated against the standard HES-based system. A comprehensive comparative analysis was conducted including microstructure, phase composition, wettability, mechanical, thermal, and gas permeability properties. The developed K + M ceramic moulds achieved a bending strength of 12.4 MPa after annealing, average surface roughness (Ra) below 5 µm, and open porosity of 29.1%, indicating excellent strength and permeability. Thermal conductivity increased from 0.3 W/mK to 2.0 W/mK between 22 °C and 1400 °C. The wetting angle of water-based binders was higher (Keysol: ~36°) compared to HES (~5°), resulting in more stable surface morphology. Gas permeability was maintained at 5.6 × 10−9 cm2 at 1100 °C, ensuring effective degassing during casting. The results demonstrate that the K + M system can replace HES in production while improving safety and reducing environmental impact, making it suitable for industrial-scale implementation in the aerospace sector. [ABSTRACT FROM AUTHOR] |
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| Database: | Engineering Source |
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| Abstract: | The paper presents the development of an ecofriendly ceramic moulding system for the precision casting of aircraft turbine components from nickel superalloys using water-soluble binders. The motivation was to eliminate hydrolysed ethyl silicate (HES) due to its environmental and occupational hazards. Two water-based binders (K + M)—Keysol (for the primary layer) and Matrixsol (for the backup layers)—were evaluated against the standard HES-based system. A comprehensive comparative analysis was conducted including microstructure, phase composition, wettability, mechanical, thermal, and gas permeability properties. The developed K + M ceramic moulds achieved a bending strength of 12.4 MPa after annealing, average surface roughness (Ra) below 5 µm, and open porosity of 29.1%, indicating excellent strength and permeability. Thermal conductivity increased from 0.3 W/mK to 2.0 W/mK between 22 °C and 1400 °C. The wetting angle of water-based binders was higher (Keysol: ~36°) compared to HES (~5°), resulting in more stable surface morphology. Gas permeability was maintained at 5.6 × 10−9 cm2 at 1100 °C, ensuring effective degassing during casting. The results demonstrate that the K + M system can replace HES in production while improving safety and reducing environmental impact, making it suitable for industrial-scale implementation in the aerospace sector. [ABSTRACT FROM AUTHOR] |
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| ISSN: | 19961944 |
| DOI: | 10.3390/ma18102329 |
