Investment Casting Technology and Development Trend of Superalloy Ultra Limit Components
SUN Baode1,2(), WANG Jun1,2(), KANG Maodong1, WANG Donghong1, DONG Anping1, WANG Fei3, GAO Haiyan1, WANG Guoxiang1, DU Dafan1
1.Shanghai Key Lab of Advanced High-Temperature Materials and Precision Forming, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China 2.State Key Lab of Metal Matrix Composites, Shanghai Jiao Tong University, Shanghai 200240, China 3.Research Center of High-Temperature Alloy Precision Forming, School of Materials Engineering, Shanghai University of Engineering Science, Shanghai 201620, China
Cite this article:
SUN Baode, WANG Jun, KANG Maodong, WANG Donghong, DONG Anping, WANG Fei, GAO Haiyan, WANG Guoxiang, DU Dafan. Investment Casting Technology and Development Trend of Superalloy Ultra Limit Components. Acta Metall Sin, 2022, 58(4): 412-427.
Superalloy casting is an important hot component in major aerospace equipment. It is being developed for larger and more complex structures and thinner wall thickness than traditional superalloy casting. The requirements of its internal metallurgical quality and external dimensional accuracy are becoming increasingly stringent, gradually exceeding the manufacturing limit of traditional investment casting technology. Shrinkage porosity defect control, thin-walled complete filling, dimensional accuracy, and surface quality control have become key challenges in the manufacturing of large and complex thin-walled superalloy castings. This paper systematically summarizes the research status of the superalloy casting process design, mold shell preparation, whole process dimensional accuracy, and adjusted pressure casting technique at home and abroad. This paper also analyzes and predicts the development trend of intelligent casting based on big data.
Fund: National Science and Technology Major Project of China(J2019-VI-0004-0117);National Natural Science Foundation of China(51821001);National Natural Science Foundation of China(52090042);National Natural Science Foundation of China(52031012)
About author: WANG Jun, professor, Tel: (021)54745387, E-mail: junwang@sjtu.edu.cn SUN Baode, professor, Tel: (021)54747421, E-mail: bdsun@sjtu.edu.cn
Fig.1 Image of wetting angle (θ) experiment and schematic of θ measurement[40] (a) alloy drop on the ceramic (b) schematic illustration of the measurement of h and d (θ was calculated by using the geometric parameters h and d of the solidified alloy droplets, where h means the drop height and d is the base diameter of the alloy drop. The relationship expression between h, d, and θ is θ = 2arctan(2h / d). L—apex of the alloy drop, r—base radius of the alloy drop, α = arctan(r / h), β =arctan(h / r))
Fig.2 Photograph and thickness comparison of full fused silica mold and needle coke modified mold[47] (a) photograph of two mold samples (b) thickness comparison of two mold samples on flat piece and at trailing edge
Fig.3 Ceramic shell prepared by digital light processing (DLP) technology and its casting[53] (a) as-printed green shell (b) sintered shell (c) impeller casting
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