DEVELOPMENT OF SINGLE CRYSTAL SOLIDIFICA- TION TECHNOLOGY FOR PRODUCTION OF SUPERALLOY TURBINE BLADES

doi:10.11900/0412.1961.2015.00380

Acta Metall Sin

2015, Vol. 51

Issue (10): 1179-1190 DOI: 10.11900/0412.1961.2015.00380

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DEVELOPMENT OF SINGLE CRYSTAL SOLIDIFICA- TION TECHNOLOGY FOR PRODUCTION OF SUPERALLOY TURBINE BLADES

MA,Dexin,^1,²(

)

1 Material R&D Center, Dongfang Turbine Co., LTD, Deyang 618000
2 State Key Laboratory of Long-Life High Temperature Materials, Deyang 618000

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MA,Dexin,. DEVELOPMENT OF SINGLE CRYSTAL SOLIDIFICA- TION TECHNOLOGY FOR PRODUCTION OF SUPERALLOY TURBINE BLADES. Acta Metall Sin, 2015, 51(10): 1179-1190.

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Abstract

Based on the analysis of solidification processing in complex turbine blades, a new idea of 3-dimensional and precise control of single crystal (SC) growth was proposed. A series of new techniques were presented,exhibiting the new development in the production of SC blades of superalloys. The heat conductor (HC)technique was developed to minimize the hot barrier effect which hindered the lateral SC growth. This method promotes the successful transition of SC growth from the blade body into the platform extremity prior to the nucleation of stray grains. To achieve symmetric thermal conditions for solidifying the SC blades, the PHC (parallel heating and cooling) system has been employed. With this technique, both sides of a shell mold can be both symmetrically heated in the heating zone as well as cooled in the cooling zone. The negative shadow effect in the current Bridgman process and the related defects are hence removed. With the H&D (dipping and heaving) technique using thin shell, the main problems of the Bridgman process, such as the ineffective radiative heat exchange and the large thermal resistance in thick ceramic molds, can be effectively resolved. This technique enables the establishment of a high temperature gradient at solidification front. By combining targeted cooling and heating technique, a 3-dimensionalcontrol of SC growth in large components can be achieved.

Key words: superalloy directional solidification single crystal turbine blade

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https://www.ams.org.cn/EN/10.11900/0412.1961.2015.00380 OR https://www.ams.org.cn/EN/Y2015/V51/I10/1179

Fig.1 Formation principle of three typical grain structures in turbine blade (Q—heat flow, G—temperature gradient)

(a) equiaxed crystal (EQ) (b) directionally solidified crystal (DS) (c) single crystal (SC)

Fig.2 Typical blade geometry (a), schematic illustration of undercooling sequence (b) and SC solidification path in a platform (c)

Fig.3 Transverse section of a CMSX-6 blade platform showing the lateral growth of SC dendrite

Fig.4 Macromorphology of turbine blade of a superalloy having low undercoolability showing stray grains on the platform

Fig.5 Sketch of the grain continuator method (a) and a produced blade with low angle boundaries (LABs) (b)

Fig.6 Principle of heat conductor (HC) technique (a), application of HC in a turbine blade (b) and the structure improvement compared to conventionally produced blade (c) (T_L—liquidus isotherm)

Fig.7 Single crystal blade used for power station gas turbine

Fig.8 Sketchs of the cylindrical Bridgman furnace currently used for manufacturing SC blades (T_S—solidus isotherm, arrows indicate heat radiation)

(a) top view (b) side view

Fig.9 Sketchs of the new furnace with parallel heating and cooling (PHC) system (Arrows indicate heat radiation)

(a) top view (b) side view

Fig.10 Sketch of combination of targeted cooling and heating technique to precisely control SC solidification

Fig.11 Schematic of the dipping and heaving (D&H) process using thin shell (V_dip—dipping velocity, V_pull—pulling velocity)

(a) dipping the shell mold into the melt bath

(b) mold filling

Fig.12 D&H experiment using thin shell to manufacture SC blade of Al alloy in the air (a), as-cast blade with residual shell (b) and macro- and microstructure (right corner) of the SC blade (c)

Fig.13 Schematic of D&H process combined with targeted cooling and heating technique

Fig.14 Setup for D&H process in vacuum (a), a produced SC blade of superalloy CMSX-4 (b) and transverse section of the SC blade showing the fine microstructure (c)

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