View in EDS HTML Full Text PDF Full Text

Ecofriendly Water-Soluble Binders for Precision Ceramic Moulds in Aerospace Turbine Casting: Process Development and Performance Evaluation.

Saved in:
Bibliographic Details
Title: Ecofriendly Water-Soluble Binders for Precision Ceramic Moulds in Aerospace Turbine Casting: Process Development and Performance Evaluation.
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]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
Full text is not displayed to guests.
FullText Links:
  – Type: pdflink
Text:
  Availability: 1
Header DbId: egs
DbLabel: Engineering Source
An: 185475302
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
PreciseRelevancyScore: 0
IllustrationInfo
Items – Name: Title
  Label: Title
  Group: Ti
  Data: Ecofriendly Water-Soluble Binders for Precision Ceramic Moulds in Aerospace Turbine Casting: Process Development and Performance Evaluation.
– Name: Author
  Label: Authors
  Group: Au
  Data: <searchLink fieldCode="AR" term="%22Małek%2C+Marcin%22">Małek, Marcin</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> marcin.malek@wat.edu.pl</i><br /><searchLink fieldCode="AR" term="%22Wachowski%2C+Marcin%22">Wachowski, Marcin</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Kluczyński%2C+Janusz%22">Kluczyński, Janusz</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)
– Name: TitleSource
  Label: Source
  Group: Src
  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. May2025, Vol. 18 Issue 10, p2329. 29p.
– Name: Subject
  Label: Subjects
  Group: Su
  Data: <searchLink fieldCode="DE" term="%22Precision+casting%22">Precision casting</searchLink><br /><searchLink fieldCode="DE" term="%22Ethyl+silicate%22">Ethyl silicate</searchLink><br /><searchLink fieldCode="DE" term="%22Occupational+hazards%22">Occupational hazards</searchLink><br /><searchLink fieldCode="DE" term="%22Bending+strength%22">Bending strength</searchLink><br /><searchLink fieldCode="DE" term="%22Surface+morphology%22">Surface morphology</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: 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]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
PLink https://search.ebscohost.com/login.aspx?direct=true&site=eds-live&db=egs&AN=185475302
RecordInfo BibRecord:
  BibEntity:
    Identifiers:
      – Type: doi
        Value: 10.3390/ma18102329
    Languages:
      – Code: eng
        Text: English
    PhysicalDescription:
      Pagination:
        PageCount: 29
        StartPage: 2329
    Subjects:
      – SubjectFull: Precision casting
        Type: general
      – SubjectFull: Ethyl silicate
        Type: general
      – SubjectFull: Occupational hazards
        Type: general
      – SubjectFull: Bending strength
        Type: general
      – SubjectFull: Surface morphology
        Type: general
    Titles:
      – TitleFull: Ecofriendly Water-Soluble Binders for Precision Ceramic Moulds in Aerospace Turbine Casting: Process Development and Performance Evaluation.
        Type: main
  BibRelationships:
    HasContributorRelationships:
      – PersonEntity:
          Name:
            NameFull: Małek, Marcin
      – PersonEntity:
          Name:
            NameFull: Wachowski, Marcin
      – PersonEntity:
          Name:
            NameFull: Kluczyński, Janusz
    IsPartOfRelationships:
      – BibEntity:
          Dates:
            – D: 15
              M: 05
              Text: May2025
              Type: published
              Y: 2025
          Identifiers:
            – Type: issn-print
              Value: 19961944
          Numbering:
            – Type: volume
              Value: 18
            – Type: issue
              Value: 10
          Titles:
            – TitleFull: Materials (1996-1944)
              Type: main
ResultId 1