CN111892399B - Curved surface gradient ceramic part and manufacturing method thereof - Google Patents

Curved surface gradient ceramic part and manufacturing method thereof Download PDF

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CN111892399B
CN111892399B CN202010628726.5A CN202010628726A CN111892399B CN 111892399 B CN111892399 B CN 111892399B CN 202010628726 A CN202010628726 A CN 202010628726A CN 111892399 B CN111892399 B CN 111892399B
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ceramic
curved surface
curved
ceramic part
manufacturing
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CN111892399A (en
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吴甲民
何俊宏
刘荣臻
陈双
陈安南
陆路
史玉升
李晨辉
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Huazhong University of Science and Technology
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Abstract

The invention belongs to the technical field related to additive manufacturing, and discloses a curved surface gradient ceramic part and a manufacturing method thereof, wherein the manufacturing method comprises the following steps: (1) slicing along the model curved surface of the curved surface gradient ceramic part to be manufactured so as to realize the layering of the model along the curved surface; (2) the method comprises the steps of taking a plurality of ceramic paste bodies with different components as raw materials, firstly paving the ceramic paste body with a first component along a model curved surface and curing by ultraviolet irradiation by combining a layering result, then paving the ceramic paste body with a second component along the model curved surface and curing by ultraviolet irradiation, and repeating the steps until the paving and curing of the ceramic paste bodies with all the components are completed, thereby obtaining a biscuit of the curved gradient ceramic part to be manufactured and further obtaining the curved gradient ceramic part. The invention adopts the ceramic paste spread on the curved surface and adopts ultraviolet irradiation to cure layer by layer, thus well solving the problem that the curved surface gradient ceramic part is difficult to manufacture.

Description

Curved surface gradient ceramic part and manufacturing method thereof
Technical Field
The invention belongs to the technical field related to additive manufacturing, and particularly relates to a curved surface gradient ceramic part and a manufacturing method thereof.
Background
The curved surface gradient ceramic is a novel structural ceramic, and combines a curved surface structure with a material gradient, so that the ceramic has more excellent comprehensive properties of mechanics, biology, wave transmission and the like. The manufacturing problem of the missile radome is mainly that good wave-transmitting performance, mechanical strength, corrosion resistance, high temperature resistance and other excellent performances are difficult to combine together. The curved surface gradient ceramic can well solve the problem, the radome can have various excellent performances by utilizing different laminated layers, but the forming of the curved surface and the gradient combined ceramic is the problem which is not solved at present, and therefore, a novel ceramic additive manufacturing method is required to be adopted to manufacture the curved surface gradient ceramic.
Additive Manufacturing (AM) is a Manufacturing method using computer aided design (cad) to build up layer by layer, and is different from the traditional "constant material Manufacturing" and "material reduction Manufacturing", and has great advantages in Manufacturing complex and precise parts. Ceramic Stereolithography (SL) is one of the mainstream ceramic additive manufacturing technologies at present, and compared with other methods, the ceramic Stereolithography can manufacture more compact and fine ceramic parts. The ceramic has the characteristics of high strength, high temperature resistance, corrosion resistance, good wave-transmitting performance and the like and the characteristics of the ceramic three-dimensional photocuring technology, and the popularization and the application of the high-performance ceramic in various fields can be greatly improved. The ceramic three-dimensional light curing generally uses two raw materials of ceramic paste and slurry, and the ceramic paste has certain intensity before ultraviolet light irradiation curing compared with the slurry and can keep a specific shape before the shaping is finished and the curing is not finished. Curved gradient ceramics have wide application, but the manufacturing of the ceramics has great challenges, and the current planar slice additive manufacturing technology is difficult to realize.
Disclosure of Invention
Aiming at the defects or improvement requirements of the prior art, the invention provides a curved surface gradient ceramic part and a manufacturing method thereof, wherein ceramic paste bodies with different components are used as raw materials, photocuring is adopted to coat the ceramic paste body with a first component along the curved surface of a model of the curved surface gradient ceramic to be prepared and finish curing, then a ceramic paste body with a second component is coated and cured, the steps are repeated until the ceramic paste bodies with all components are coated and cured to obtain a biscuit of the curved surface gradient ceramic part, then glue discharging and sintering are carried out on the biscuit to obtain the curved surface gradient ceramic part, and therefore the ceramic has certain strength, the ceramic paste bodies are coated on the curved surface, and the problem that the curved surface gradient ceramic part is difficult to manufacture can be well solved by adopting ultraviolet irradiation layer-by layer curing.
To achieve the above object, according to one aspect of the present invention, there is provided a manufacturing method of a curved gradient ceramic part, the manufacturing method including the steps of:
(1) slicing along the model curved surface of the curved surface gradient ceramic part to be manufactured so as to realize the layering of the model along the curved surface;
(2) the method comprises the steps of taking a plurality of ceramic paste bodies with different components as raw materials, firstly paving the ceramic paste body with a first component along a model curved surface and curing by ultraviolet irradiation by combining a layering result, then paving the ceramic paste body with a second component along the model curved surface and curing by ultraviolet irradiation, and repeating the steps until the paving and curing of the ceramic paste bodies with all the components are completed, thereby obtaining a biscuit of the curved gradient ceramic part to be manufactured and further obtaining the curved gradient ceramic part.
Further, step (1) is preceded by the following steps: dissolving a photoinitiator and a dispersant in photosensitive resin to obtain photosensitive premixed liquid, adding one or more ceramic powders into the photosensitive premixed liquid, performing ball-milling mixing and degassing to obtain a plurality of ceramic pastes with different components.
Further, the photosensitive resin is acrylic resin and/or epoxy resin; the photoinitiator is a free radical photoinitiator and/or a cationic photoinitiator; the dispersant is one or more of ammonium polyacrylate, ammonium citrate, sodium polyacrylate, tetramethyl ammonium hydroxide, oleic acid, stearic acid and polyethylene glycol.
Further, the mass of the photoinitiator is 1 wt% -3 wt% of that of the photosensitive resin; the mass of the dispersant is 1 to 4 weight percent of the mass of the ceramic powder; the ceramic paste comprises the following components in percentage by volume: 30 vol% -70 vol% of ceramic powder and 30 vol% -70 vol% of photosensitive premixed liquid.
Furthermore, the wavelength of the ultraviolet light is 355nm or 405nm, the power of the ultraviolet light is 300 mW-500 mW, the scanning speed is 50 mm/s-3000 mm/s, and the scanning interval is 0.05 mm-0.2 mm.
And further, carrying out glue discharging and sintering on the biscuit to obtain the curved surface gradient ceramic part.
Further, the glue discharging temperature is 600-700 ℃, the heating rate is 0.2-1 ℃/min, and the heat preservation time is 6-12 h; the sintering temperature is 1400-2000 ℃, and the heat preservation time is 2 h.
According to another aspect of the present invention, there is provided a curved gradient ceramic part manufactured by the method for manufacturing a curved gradient ceramic part as described above.
Generally, compared with the prior art, the curved gradient ceramic part and the manufacturing method thereof provided by the invention have the following beneficial effects:
1. ceramic paste bodies with different components are used as raw materials, photocuring is adopted to spread and cure the ceramic paste body with a first component along the curved surface of a model of curved gradient ceramic to be prepared, then a ceramic paste body with a second component is spread and cured, the steps are repeated until the ceramic paste bodies with all the components are spread and cured to obtain a biscuit of the curved gradient ceramic part, and then glue discharging and sintering are carried out on the biscuit to obtain the curved gradient ceramic part, so that the ceramic has certain strength, the ceramic paste bodies are spread on the curved surface, and the problem that the curved gradient ceramic part is difficult to manufacture can be well solved by adopting ultraviolet irradiation layer-by-layer curing.
2. The method adopts a method of manufacturing the ceramic parts by stacking along the curved surface layer by layer, cuts the curved surface gradient ceramic model along the curved surface by using related software, utilizes the different special properties of the ceramic paste and the slurry, and combines a three-dimensional photocuring technology, so that the curved surface gradient ceramic parts can be effectively formed.
3. Different layers of the curved surface gradient ceramic part can contain ceramics with different components, the excellent performances of different ceramics are combined together, various application requirements of the curved surface gradient ceramic part such as strength, hardness, wave transmission, corrosion resistance, high temperature resistance and the like can be met, the curved surface gradient ceramic part with the combined structure and performance is directly manufactured, and the curved surface gradient ceramic part has wide application prospects in the fields of aerospace, electronic information and the like.
4. The manufacturing method does not need a mould, and overcomes the defect that the prior art depends on the mould.
Drawings
FIG. 1 is a schematic diagram of a method for manufacturing a curved gradient ceramic part according to the present invention;
fig. 2 (a), (B), and (c) are schematic structural diagrams of the obtained a-type interlayer structure, B-type interlayer structure, and gradient-structure ceramic radome, respectively;
FIG. 3 is a schematic flow chart of a method for manufacturing a curved gradient ceramic part according to the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
Referring to fig. 1, fig. 2 and fig. 3, the method for manufacturing a curved gradient ceramic component according to the present invention mainly includes the following steps:
dissolving a photoinitiator and a dispersant in photosensitive resin to obtain photosensitive premixed liquid, adding one or more ceramic powders into the photosensitive premixed liquid, performing ball-milling mixing and degassing to obtain a plurality of ceramic pastes with different components.
Specifically, the ceramic powder may be common oxide ceramic powder, non-oxide ceramic powder, or the like, and mainly includes alumina (Al)2O3) Ceramic powder and quartz (SiO)2) Ceramic powder and zirconium oxide (ZrO)2) Ceramic powder, cordierite ceramic powder, Boron Nitride (BN) ceramic powder, silicon nitride (Si)3N4) Ceramic powder, silicon carbide (SiC) ceramic powder and silicon carbide whisker (SiC)(w)) Boron nitride particles (BN)(p)) Boron nitride whisker (BN)(w)) Boron nitride fiber (BN)(f)) And (c) equal reinforcing phases, including one or more thereof.
The photosensitive resin is acrylic resin and/or epoxy resin, the photoinitiator is a free radical photoinitiator and/or a cationic photoinitiator, and the dispersant is one or more of ammonium polyacrylate, ammonium citrate, sodium polyacrylate, tetramethylammonium hydroxide, oleic acid, stearic acid and polyethylene glycol.
In the embodiment, the mass of the photoinitiator is 1-3 wt% of that of the photosensitive resin; the mass of the dispersing agent is 1-4 wt% of the mass of the ceramic powder; the ceramic paste comprises the following components in percentage by volume: 30-70 vol% of ceramic powder and 30-70 vol% of photosensitive premixed liquid.
And step two, designing a model of the curved surface gradient ceramic part to be manufactured with the curved surface gradient characteristics by adopting computer-aided software, and slicing the model along the curved surface of the model by adopting modeling software so as to realize the layering of the model along the curved surface.
Specifically, the computer-aided software used may be modeling software such as NX, Print 3D, or autonomously developed software. The curved surface gradient ceramic part is formed by overlapping a plurality of curved surface gradient ceramic layers with similar structures but different material components, and in order to enable the curved surface gradient ceramic part to use an additive manufacturing method, the curved surface gradient ceramic part to be manufactured is layered along a curved surface by using the software.
And step three, using the ceramic pastes of the different components as raw materials, combining the layering result, firstly spreading the ceramic paste of the first component along the curved surface of the model, curing by ultraviolet irradiation, then spreading the ceramic paste of the second component along the curved surface of the model, curing by ultraviolet irradiation, and repeating the steps until the spreading and curing of the ceramic pastes of all the components are completed, thereby obtaining the biscuit of the curved gradient ceramic part to be manufactured.
Specifically, the wavelength of the ultraviolet light is 355nm or 405nm, the power of the ultraviolet light is 300 mW-500 mW, the scanning speed is 50 mm/s-3000 mm/s, and the scanning interval is 0.05 mm-0.2 mm.
And step four, carrying out glue removal and sintering on the biscuit to obtain the curved surface gradient ceramic part.
Specifically, the glue discharging temperature is 600-700 ℃, the heating rate is 0.2-1 ℃/min, and the heat preservation time is 6-12 h; the sintering temperature adopted by the sintering process is 1400-2000 ℃, and the heat preservation time is 2 hours.
The invention also provides a curved surface gradient ceramic part which is prepared by adopting the manufacturing method of the curved surface gradient ceramic part.
The present invention is further described in detail below with reference to several specific examples.
Example 1
The manufacturing method of the curved gradient ceramic part provided by the embodiment 1 of the invention mainly comprises the following steps:
step (a): acrylic resin, 2-dimethoxy-2-phenylacetophenone and ammonium polyacrylate are uniformly mixed according to a proportion to prepare a photosensitive premixed solution, wherein the mass of a photoinitiator is 1 wt% of the mass of the photosensitive resin, and the mass of a dispersing agent is 2 wt% of the mass of ceramic powder. Next, an appropriate amount of Al was weighed2O3、ZrO2Adjusting the proportion of each component of the ceramic powder, then ball-milling and mixing the ceramic powder and the photosensitive premixed liquid in a planetary ball mill respectively, degassing to finally obtain Al2O3The ceramic powder in the ceramic paste accounts for 40 vol% and the photosensitive premixed liquid accounts for 60 vol%; ZrO (ZrO)2The ceramic powder in the ceramic paste accounts for 60 vol%, and the photosensitive premixed liquid accounts for 40 vol%.
Step (b): a model of the curved surface gradient part to be manufactured with the curved surface characteristics is designed by adopting computer-aided software, and the model is sliced along the curved surface of the model by using modeling software.
Step (c): al prepared as described above2O3、ZrO2Ceramic paste is used as raw material, and light-curing equipment is adopted to cure Al2O3Spreading ceramic paste along curved surface of model, ultraviolet irradiating for curing, and spreading ZrO2And solidifying the ceramic paste to obtain the biscuit of the curved gradient ceramic part. The ultraviolet wavelength of the photocuring equipment is 355nm or 405nm, the ultraviolet power is 300 mW-500 mW, the scanning speed is 500mm/s, and the scanning interval is 0.05 mm.
Step (d): and carrying out glue removal and sintering on the biscuit to obtain the high-performance curved surface gradient ceramic part. Wherein the glue discharging temperature adopted by the glue discharging process is 600 ℃, the heating rate is 0.2 ℃/min, and the heat preservation time is 6 h; the sintering temperature adopted by the sintering process is 1600 ℃, the heat preservation time is 2 hours, and finally the Al is prepared2O3-ZrO2Curved gradient ceramics.
Example 2
The manufacturing method of the curved gradient ceramic part provided by the embodiment 2 of the invention mainly comprises the following steps:
step (a): mixing acrylic resin, 1-hydroxycyclohexyl phenyl ketone and sodium polyacrylate uniformly according to a certain proportion to obtain the photosensitive premixed materialThe mass of the photoinitiator is 2 wt% of that of the photosensitive resin, and the mass of the dispersant is 3 wt% of that of the ceramic powder. Next, an appropriate amount of Al was weighed2O3、ZrO2Adjusting the proportion of each component of the ceramic powder, then ball-milling and mixing the ceramic powder and the photosensitive premixed liquid in a planetary ball mill respectively, degassing to finally obtain Al2O3The ceramic powder in the ceramic paste accounts for 50 vol%, and the photosensitive premixed liquid accounts for 50 vol%; al (Al)2O3/ZrO2Al in composite ceramic paste2O3And ZrO2The ceramic powder accounts for 50 vol% in total, and the photosensitive premixed liquid accounts for 50 vol%.
Step (b): designing a model of the curved surface gradient ceramic part to be manufactured with curved surface characteristics by adopting computer-aided software, and slicing along the curved surface of the model by using modeling software;
step (c): al obtained by the above preparation2O3、Al2O3/ZrO2The composite ceramic paste is used as raw material, and light-curing equipment is adopted to cure Al2O3Spreading ceramic paste along curved surface of model, ultraviolet irradiating for curing, and spreading Al2O3/ZrO2Compounding the ceramic paste and curing to obtain the biscuit of the curved gradient ceramic part. The ultraviolet wavelength of the photocuring equipment is 355nm or 405nm, the ultraviolet power is 300 mW-500 mW, the scanning speed is 1000mm/s, and the scanning interval is 0.1 mm.
Step (d): and carrying out glue removal and sintering on the biscuit to obtain the high-performance curved surface gradient ceramic part. In the embodiment, the glue discharging temperature adopted by the glue discharging process is 650 ℃, the heating rate is 0.3 ℃/min, and the heat preservation time is 8 hours; the sintering temperature adopted by the sintering process is 1500 ℃, the heat preservation time is 2 hours, and the ZrO is finally prepared2、Al2O3/ZrO2Curved gradient ceramics.
Example 3
The manufacturing method of the curved gradient ceramic part provided by the embodiment 3 of the invention mainly comprises the following steps:
step (a): mixing epoxy resin, 2,4, 6-trimethyl benzoyl diphenyl phosphine oxide and tetraAnd uniformly mixing the methyl ammonium hydroxide according to a proportion to prepare the photosensitive premixed liquid, wherein the mass of the photoinitiator is 3 wt% of the mass of the photosensitive resin, and the mass of the dispersing agent is 4 wt% of the mass of the ceramic powder. Next, an appropriate amount of Si was weighed3N4Adjusting the proportion of each component of the ceramic powder, then ball-milling and mixing the ceramic powder and the photosensitive premixed liquid in a planetary ball mill respectively, degassing to finally obtain the component A, namely Si3N4The ceramic powder in the ceramic paste accounts for 60 vol%, and the photosensitive premixed liquid accounts for 40 vol%; b component Si3N4The ceramic powder in the ceramic paste accounts for 40 vol%, and the photosensitive premixed liquid accounts for 60 vol%.
Step (b): a model of the curved surface gradient ceramic part to be manufactured with curved surface characteristics is designed by adopting computer-aided software, and the model is sliced along the curved surface of the model by using modeling software.
Step (c): different components Si obtained by the above preparation3N4Ceramic paste is used as raw material, and component A, Si, is solidified by light3N4Spreading ceramic paste along curved surface of model, ultraviolet irradiating for curing, and spreading component B Si3N4Ceramic paste is solidified and finally the component A Si is spread and coated3N4And (4) solidifying the ceramic paste to obtain a biscuit of the curved gradient ceramic part. In this embodiment, the ultraviolet wavelength of the light curing device is 355nm or 405nm, the ultraviolet power is 300-500 mW, the scanning speed is 1500mm/s, and the scanning distance is 0.15 mm.
Step (d): and carrying out glue removal and sintering on the biscuit to obtain the high-performance curved surface gradient ceramic part. In the embodiment, the glue discharging temperature adopted by the glue discharging process is 700 ℃, the heating rate is 0.4 ℃/min, and the heat preservation time is 9 h; the sintering temperature adopted by the sintering process is 1800 ℃, the heat preservation time is 2 hours, and finally the Si is prepared3N4The sandwich structure curved surface gradient ceramic.
Example 4
The manufacturing method of the curved gradient ceramic part provided by the embodiment 4 of the invention mainly comprises the following steps:
step (a): epoxy resin, 2,4, 6-trimethyl benzoyl-diphenyl phosphine oxide,The tetramethyl ammonium hydroxide is uniformly mixed according to a proportion to prepare the photosensitive premixed liquid, wherein the mass of the photoinitiator is 1 wt% of the mass of the photosensitive resin, and the mass of the dispersant is 2 wt% of the mass of the ceramic powder. Next, an appropriate amount of Si was weighed3N4Ceramic powder and SiC crystal whisker, regulating the proportion of each component, and mixing pure Si3N4Ceramic powder and SiC of different compositions(w)/Si3N4Respectively ball-milling and mixing the ceramic powder and the photosensitive premixed liquid in a planetary ball mill, and degassing to finally obtain pure Si3N4The ceramic powder in the ceramic paste accounts for 70 vol%, and the photosensitive premixed liquid accounts for 30 vol%; c component SiC(w)/Si3N4Si in ceramic paste3N445 vol% of ceramic powder, 5 vol% of SiC whisker and 50 vol% of photosensitive premixed liquid; d component SiC(w)/Si3N4Si in ceramic paste3N4The ceramic powder accounts for 40 vol%, the SiC whisker accounts for 10 vol%, and the photosensitive premixed liquid accounts for 50 vol%.
Step (b): designing a model of the curved surface gradient ceramic part to be manufactured with curved surface characteristics by adopting computer-aided software, and slicing along the curved surface of the model by using modeling software;
step (c): pure Si obtained by the above preparation3N4Ceramic paste and different components of SiC(w)/Si3N4Ceramic paste is used as raw material, pure Si is added by adopting light curing equipment3N4Spreading ceramic paste along the curved surface of the model, irradiating with ultraviolet light to complete curing, and spreading C-component SiC(w)/Si3N4Ceramic paste is solidified and finally D component SiC is spread and coated(w)/Si3N4And (4) solidifying the ceramic paste to obtain a biscuit of the curved gradient ceramic part. In this embodiment, the ultraviolet wavelength of the light curing device is 355nm or 405nm, the ultraviolet power is 300mW to 500mW, the scanning speed is 2000mm/s, and the scanning distance is 0.2 mm.
Step (d): and carrying out glue removal and sintering on the ceramic part biscuit to obtain the high-performance curved surface gradient ceramic part. In this embodiment, the glue discharging temperature adopted by the glue discharging process is 750 ℃, and the heating rate is 0.5 ℃/minThe heat preservation time is 10 hours; the sintering temperature adopted by the sintering process is 1750 ℃, the heat preservation time is 2 hours, and finally the SiC whisker reinforced Si is prepared3N4The gradient ceramic part of the gradual change structure curved surface.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.

Claims (6)

1. A method of manufacturing a curved gradient ceramic part, comprising the steps of:
(1) dissolving a photoinitiator and a dispersant in photosensitive resin to obtain photosensitive premixed liquid, adding one or more ceramic powders into the photosensitive premixed liquid, performing ball-milling mixing and degassing to obtain a plurality of ceramic pastes with different components;
(2) slicing along the model curved surface of the curved surface gradient ceramic part to be manufactured so as to realize the layering of the model along the curved surface;
(3) the method comprises the steps of taking a plurality of ceramic paste bodies with different components as raw materials, firstly paving the ceramic paste body with a first component along a model curved surface by combining a layering result, curing by ultraviolet irradiation, then paving the ceramic paste body with a second component along the model curved surface, curing by ultraviolet irradiation, repeating the steps until the paving and curing of the ceramic paste bodies with all the components are completed, thus obtaining a biscuit of the curved gradient ceramic part to be manufactured, and carrying out glue discharging and sintering on the biscuit to obtain the curved gradient ceramic part.
2. The method of manufacturing a curved gradient ceramic part according to claim 1, wherein: the photosensitive resin is acrylic resin and/or epoxy resin; the photoinitiator is a free radical photoinitiator and/or a cationic photoinitiator; the dispersant is one or more of ammonium polyacrylate, ammonium citrate, sodium polyacrylate, tetramethyl ammonium hydroxide, oleic acid, stearic acid and polyethylene glycol.
3. The method of manufacturing a curved gradient ceramic part according to claim 1, wherein: the mass of the photoinitiator is 1 to 3 weight percent of that of the photosensitive resin; the mass of the dispersant is 1 to 4 weight percent of the mass of the ceramic powder; the ceramic paste comprises the following components in percentage by volume: 30 vol% -70 vol% of ceramic powder and 30 vol% -70 vol% of photosensitive premixed liquid.
4. The method of manufacturing a curved gradient ceramic part as set forth in any one of claims 1 to 3, wherein: the wavelength of the ultraviolet light is 355nm or 405nm, the power of the ultraviolet light is 300 mW-500 mW, the scanning speed is 50 mm/s-3000 mm/s, and the scanning interval is 0.05 mm-0.2 mm.
5. The method of manufacturing a curved gradient ceramic part according to claim 1, wherein: the glue discharging temperature is 600-700 ℃, the heating rate is 0.2-1 ℃/min, and the heat preservation time is 6-12 h; the sintering temperature is 1400-2000 ℃, and the heat preservation time is 2 h.
6. A curved gradient ceramic part produced by the method for producing a curved gradient ceramic part according to any one of claims 1 to 5.
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