Effects of surface-active elements on wettability and interfacial reaction between DD5 superalloy and Al2O3-based ceramic shell

The study investigates the effects of oxygen-sulfur content, holding temperature, and time on the wettability and interfacial reactions between DD5 superalloy and Al2O3-based ceramic shells through non-in-situ sessile drop experiments. Lowering the oxygen-sulfur content in the DD5 master alloy, as well as reducing the holding temperature and time, leads to an increase in the wetting angle and a mitigation of interfacial reactions. Improved wettability promotes interfacial reactions, while intensified interfacial reactions further spread the alloy melt, enhancing its wettability. The main products of the interfacial reaction between the DD5 alloy and Al2O3-based ceramic shells are Al2O3 and Si, with the process being influenced by the presence of Al. When the oxygen-sulfur content is controlled within 6 ppmw, the wettability will undergo a characteristic transformation, resulting in a sharp increase in the wetting angle. It demonstrates that the ultra-pure DD5 master alloy plays a crucial role in reducing wettability and interfacial reaction, as well as slowing down the tendency of the heterocrystal formation. Therefore, it is of great engineering significance to further reduce the content of oxygen-sulfur impurity elements in DD5 superalloy.