Novel casting processes for single-crystal turbine blades of superalloys

Dexin MA

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Front. Mech. Eng. ›› 2018, Vol. 13 ›› Issue (1) : 3-16. DOI: 10.1007/s11465-018-0475-0
RESEARCH ARTICLE

Novel casting processes for single-crystal turbine blades of superalloys

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Abstract

This paper presents a brief review of the current casting techniques for single-crystal (SC) blades, as well as an analysis of the solidification process in complex turbine blades. A series of novel casting methods based on the Bridgman process were presented to illustrate the development in the production of SC blades from superalloys. The grain continuator and the heat conductor techniques were developed to remove geometry-related grain defects. In these techniques, the heat barrier that hinders lateral SC growth from the blade airfoil into the extremities of the platform is minimized. The parallel heating and cooling system was developed to achieve symmetric thermal conditions for SC solidification in blade clusters, thus considerably decreasing the negative shadow effect and its related defects in the current Bridgman process. The dipping and heaving technique, in which thin-shell molds are utilized, was developed to enable the establishment of a high temperature gradient for SC growth and the freckle-free solidification of superalloy castings. Moreover, by applying the targeted cooling and heating technique, a novel concept for the three-dimensional and precise control of SC growth, a proper thermal arrangement may be dynamically established for the microscopic control of SC growth in the critical areas of large industrial gas turbine blades.

Keywords

superalloy / investment casting / Bridgman process / directional solidification / single crystal / turbine blade

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Dexin MA. Novel casting processes for single-crystal turbine blades of superalloys. Front. Mech. Eng., 2018, 13(1): 3‒16 https://doi.org/10.1007/s11465-018-0475-0

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Acknowledgement

This work was funded by the Science and Technology Innovation Commission of Shenzhen Municipality (Grant No. JSGG20141016141652366) and the Economic, Trade and Information Commission of Shenzhen Municipality (Grant No. 2016-122), the Program for Guangdong Introducing Innovative and Enterpreneurial Teams.

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2018 The Author(s) 2018. This article is published with open access at link.springer.com and journal.hep.com.cn
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