RESEARCH ON THE INTERFACIAL HEAT TRANSFER COEFFECIENT BETWEEN CASTING AND CERAMIC SHELL IN INVESTMENT CASTING PROCESS OF Ti6Al4V ALLOY

doi:10.11900/0412.1961.2015.00037

Acta Metall Sin

2015, Vol. 51

Issue (8): 976-984 DOI: 10.11900/0412.1961.2015.00037

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RESEARCH ON THE INTERFACIAL HEAT TRANSFER COEFFECIENT BETWEEN CASTING AND CERAMIC SHELL IN INVESTMENT CASTING PROCESS OF Ti6Al4V ALLOY

Heng SHAO¹,Yan LI²,Hai NAN²,Qingyan XU¹(

)

1 Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, School of Materials Science and Engineering, Tsinghua University, Beijing 100084
2 Beijing Institute of Aeronautical Materials, Beijing 100095

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Heng SHAO,Yan LI,Hai NAN,Qingyan XU. RESEARCH ON THE INTERFACIAL HEAT TRANSFER COEFFECIENT BETWEEN CASTING AND CERAMIC SHELL IN INVESTMENT CASTING PROCESS OF Ti6Al4V ALLOY. Acta Metall Sin, 2015, 51(8): 976-984.

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Abstract

Investment casting process is an important way to get complex parts of titanium alloy. However there are few research on the interfacial heat transfer coefficient (h) between casting and shell thus the temperature simulation of investment casting process of titanium alloy is often inaccurate. In order to get a relatively accurate h, a one-dimensional mathematical model for the reverse calculation of h between casting and shell in investment casting process of Ti6Al4V alloy was built and the analytic relationship between temperature and time/heat flux was established. Considering the calculated h is significantly affected by the error of parameters such as the specific heat capacity and thermal diffusivity of shell and position of thermocouples, research on the error of these parameters is essential. The relationship between the error of these parameters and the temperatures in the casting and shell was studied and it was found that the effect of different kind of error on the temperature field was obviously different. An experiment based on the one-dimensional mathematical model was done and temperatures of different positions were measured. Based on the effect of different kind of error and the difference between the calculate temperature field and the measured temperatures, the proportion of effect of each kind of error was assessed. These errors were revised on the basis of the assessment, thus a relatively accurate h between the casting and shell was obtained. The relationships between h and thickness of the solidified layer on the casting/temperature at the surface of casting can be divided into 4 stages: (1) Metal was liquid and h kept about 440 W/(m²K); (2) Solid layer appeared on the surface, and h declined nearly 60%; (3) Solid layer grew up before metal became completely solid and h declined nearly 20% of its maximum; (4) After metal solidified, h declined slowly as temperature on the surface of casting dropped. These relationships were applied in a three-dimensional model for numerical simulation of the temperature field. Temperatures of different positions in casting and shell were calculated and calculated temperatures agreed with measured ones well. Thus the accuracy of h was identified and it can help solve problems in the production in investment casting process of Ti6Al4V alloy.

Key words: titanium alloy investment casting interfacial heat transfer coefficient

Fund: Supported by China-EU (European Union) Science & Technology Cooperation in Aviation, 7th Framework Programme of EU, National Basic Research Program of China (No.2011CB706801), National Natural Science Foundation of China (Nos.51171089 and 51374137), National Science and Technology Major Project (No.2012ZX04012011) and High Technology Research and Development Program of China (No.2007AA04Z141)

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	Heng SHAO
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https://www.ams.org.cn/EN/10.11900/0412.1961.2015.00037 OR https://www.ams.org.cn/EN/Y2015/V51/I8/976

Fig.1 Schematics of one-dimensional heat transfer model (a) and temperature field in the model (b) (q₁—interfacial heat flux between casting and mold; q₂—heat flux across the surface of mold; x—distance from the interface between casting and mold; d—thickness of mold; T—temperature)

Fig.2 Schematic of the cavity and the positions of the thermocouples (TC)

Fig.3 Variation of specific heat capacity (c) of shell with temperatures (T)

Fig.4 Variations of c (a) and thermal conductivity l (b) of Ti6Al4V with temperatures

Fig.5 Measured temperatures at different positions in mold and casting (t—time)

Fig.6 Calculated interfacial heat transfer coefficient (h) between 0~4000 s and between 0~200 s (inset)

Fig.7 Calculated h based on conditions A and B (when assumed c is 20% smaller and bigger than the real c) (a) and temperatures based on condition A (b)

Fig.8 Calculated h based on conditions C and D (when assumed the thermal diffusivity of the shell deviate (a) is 20% smaller and bigger than the real a) (a) and temperatures based on condition C (b)

Fig.9 Calculated h based on conditions E and F (when real distances between the interface and thermocouples are 2.5, 5.5, 8.5 mm, and 3.5, 6.5, 9.5 mm) (a) and temperatures based on condition E (b)

Fig.10 Comparison between measured and calculated temperatures

Fig.11 Calculated h between 0~4000 s and between 0~200 s (inset) (a), comparison between measured and calculated temperatures with specific heat capacity, thermal diffusivity of shell and positions of thermocouples adjusted (b)

Fig.12 Relationship between h and the thickness of solidified layer d

Fig.13 Relationship between h and T of the casting after solidification

Fig.14 Simulated temperatures of casting and shell based on the fitted h

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