Dimensional changes and creep of silica core ceramics used in investment casting of superalloys

Dimensional changes and creep deformation of a silica/zircon (74%/24%, respectively) and a high silica (93% silica and 3% zircon) ceramic were characterized and compared. All specimens were tested with a thermal profile that consisted of a 300°C/h heating rate to 1475 or 1525°C, followed by a one-hour isothermal hold (where each specimen was compressively crept under a static stress of 2.07, 4.14, or 6.21 MPa). The specimens were cooled at a rate of 900°C/h under stress. Dimensional changes were interpreted from apparent thermal expansion behavior during heating as well as before-and-after dimensional measurements. The silica/zircon ceramic generally exhibited less total contraction than the high silica ceramic for a specific test condition even though it crept faster at all stresses and temperatures during the one-hour isothermal/isostress segment. This indicates that the total contraction for both was dominated by reinitiated sintering and subsequent cristobalite formation that occurred during the heating segment. Minimum creep rate during the one-hour isothermal/isostress segment was examined as a function of stress and temperature for both ceramics using a power-law creep model. Creep-rate stress exponents (n) and activation energies (Q) were equivalent (within 95% confidence) for both ceramics showing that their different contents of zircon (3 vs. 24%) did not affect them. Lastly, n ≈ 1.3–1.4 and Q ≈ 170 kJ/mol indicate that diffusion-assisted crystallization of cristobalite, combined with power-law sintering owing to the high concentration of porosity (28–30%) was likely the rate-limiting mechanism in the creep deformation for both ceramics.