Microstructure Evolution and High-Temperature Dimensional Stability of Silica-Based Ceramic Cores via Modification of Alumina Nanopowder in Digital Light Processing 3D Printing

3D printing represents a promising fabrication technology for silica-based ceramic cores, which are essential components in the casting of turbine blades, but it is faced with poor high-temperature dimensional stability. Herein, alumina nanopowder was utilized as a modifier agent in digital light processing (DLP) 3D printing of silica-based ceramic cores, and systematic investigations were conducted on the microstructure and properties of ceramic cores throughout sintering and casting dependent on the content of alumina nanopowder (0–1.0 wt.%). Alumina nanopowder increased the sintering barrier of fused silica, significantly reducing the shrinkage in sintering and simulated casting, while improving high-temperature dimensional stability. Even though the alumina nanopowder led to decreased room-temperature and high-temperature flexural strengths attributed to inhibited densification and crystallization, the strengths met investment casting requirements after PVA solution strengthening. Excessive alumina nanopowder (0.8–1.0 wt.%) resulted in poor interlayer bonding and particle spalling, unfavorable to the structural integrity in casting. The optimal alumina content was 0.6 wt.%, which balanced sintering shrinkage of 1.86%, shrinkage of 4.41% after simulated casting, room-temperature flexural strength of 11.13 MPa, high-temperature flexural strength of 31.29 MPa, high-temperature creep deformation of 0.55 mm, and surface roughness of 1.815 μm. This research proposes an effective strategy for the optimization of 3D-printed silica-based ceramic cores in the manufacture of complex hollow turbine blades.