Fabrication of Y2O3–CaO composite ceramics with controllable hydration resistance by a novel gel casting method

Y 2 O 3 and CaO are ideal ceramic materials for precision casting of TiAl alloy, overcoming challenges associated with intricate component removal, such as turbine blades, leveraging the stability of Y 2 O 3 and the water solubility of CaO. To address these challenges, we employed Isobam104 in a novel gel casting method, serving as both a dispersant and a gelling agent. This method enabled us to create a stable Y 2 O 3 –CaCO 3 slurry with high solid content (up to 55 vol%) and low viscosity (101.51 mPa·s at a shear rate of 10 s −1 ). Following sintering at 1500 °C for 2 h, Y 2 O 3 –CaO composite ceramics were produced. Surprisingly, two distinct characteristics of CaO were noted. One showed a rod-shaped morphology with high chemical reactivity crucial for water solubility, while the other displayed a flat-like feature, forming a well-maintained interface due to its coherent or semi-coherent matching relationship with Y 2 O 3 , thereby providing excellent hydration resistance. Ultimately, we acquired composite ceramics showcasing a 30-day “shelf life" alongside exceptional water solubility. This establishes the theoretical groundwork for storing and employing soluble ceramic cores in the precision casting of TiAl alloy.