MANUFACTURING CASTINGS FROM HEAT-RESISTANT ALLOYS FOR CRITICAL PART
Procesi littâ, 2024, Vol 1 (155), 48-57
DOI:
https://doi.org/10.15407/plit2024.01.048Keywords:
Nickel-based superalloys, Gas turbine engines (GTE), blade, directional crystallizationAbstract
The development of the latest gas turbine engines (GTEs) requires improvements and innovations in production processes, including the introduction of advanced methods and processing tools that meet the growing standards of quality and operational reliability. The main causes of GTE failure are often related to wear or damage to key turbine elements, especially during operation in conditions of intense vibration, high temperatures, corrosive environments and abrasive wear. The article discusses modern solutions and manufacturing technologies of castings for parts of responsible purpose from heat-resistant alloys. The quality of castings depends on many factors, such as alloy composition, melting point, pouring speed, as well as the quality of the casting mold. Optimization of existing heat-resistant alloys is a necessity, as it is due to the increase in the resource and efficiency of the functioning of industrial equipment, such as gas turbine engines (GTE). The article considers the influence of various technological parameters on the quality of castings from heat-resistant alloys. A review of a number of scientific works and publications in the field of development and casting of heat-resistant alloys for parts of responsible purpose was carried out. Determined parameters that have a significant impact on the structural and phase characteristics of castings in the production of parts of responsible use from heat-resistant alloys by the method of directional hardening. In particular, the article analyzes in detail such aspects as the influence of the chemical composition of alloys on their heat resistance and resistance to oxidation, the role of heat treatment modes in the process of obtaining castings, as well as the importance of precise control of technological casting parameters. Special attention is paid to the newest methods of casting quality control. The effect of adding alloying elements on the properties of heat-resistant alloys and on the quality of final castings for complex-profile parts of gas turbines is also considered.
References
Superalloys for gas turbine engines. (2012). © Woodhead Publishing Limited. (originally published 2001 y.)
Патон Б.Е., Строганов Г.Б., Кишкин С.Т. и др. Жаропрочность литейных никелевых сплавов и защита их от окисления. Киев: Наукова думка, 1987. 256 с.
Sims, C.T.; Stoloff, N.S.; Hagel, W.C. Superalloys II: High-Temperature Materials for Aero- space and Industrial Power; John Wiley & Sons: New York, NY, USA, 1987; 640p. Available online: https://www.wiley.com/en-us/Superalloys+II%3A+High+Temperature+Materials+- for+Aerospace+and+Industrial+Power-p-9780471011477.
Olorunfemi, O. (2015). Nickel Based Super Alloys For Gas turbine Applications. Research- Gate, 1(1), 4–15.
Патон Б., Халатов А., Костенко Д., Білека Б., Письменний О., Боцула А., Парафійник В., Коняхін В. Концепція (проект) державної науково-технічної програми «Створення промислових газотурбінних двигунів нового покоління для газової промисловості та енергетики». Вісник НАН України. 2008. No 4. С. 3–9.
H Weber. (2016). Nickel-Based Superalloys: Alloying. Special Metals Corporation, Hunting- ton, WV, USA. MK Banerjee, Malaviya National Institute of Technology, Jaipur, India, 1(1), 1–3.
Balyts’kyi, A.I.; Kvasnyts’ka, Y.H.; Ivas’kevich, L.M.; Myal’nitsa, H.P. Corrosion and Hydro- gen-ResistanceofHeat-ResistantBladeNickel-CobaltAlloys.Mater.Sci.2018,54,230–239. https://doi.org/10.1007/s11003-018-178-z.
Reed, R. C. (2006). The superalloys fundamentals and applications. Cambridge. (originally published 2006 y.)
Harris K., Erickson G.L., Sikkenga S.L., Brentnall W.D., Aurrecoechea J.M., and Kubarysh K.G., Development of the Rhenium containing superalloy CMSX-4&CM186LC for single crystal blade and directionally solidified vane applications in advanced turbine engines. Superalloys. 1992. TMS. 1992. 297.
Kuznetsov, P.; Lesnikov, V.P.; Konakova, I.P.; Popov, N.A.; Kvasnitskaya, Y.G. Structural and phase transformations in single-crystal rhenium- and ruthenium-alloyed nickel alloy under testing for long-term strength. Met. Sci. Heat Treat. 2015, 57, 503–506. https://doi. org/10.1007/s11041-015-9912-4
X. Wu, S. K. Makineni, C. H. Liebscher, G. Dehm, and J. R. Mianroodi Unveiling the Re effect in Ni-based single crystal superalloys. Nature communications. 2020. 11: 389. https://doi. org/10.1038/s41467-019-14062-9
L. Ivaskevich, A. Balitskii, I. Kvasnytska, K. Kvasnytska, H. Myalnitsa Thermal Stability, Cyclic Durability and Hydrogen Resistance of Cast Nickel-cobalt Alloys for Gas Turbine Blades. CAMPE 2021: Advances in Mechanical and Power Engineering, pp 147–155 https://doi. org/10.1007/978-3-031-18487-1_15
Migas, D., Gradoń, P., Mikuszewski, T., & Moskal, G. (2020). Crystallization behavior of ter- nary γ–γ′ Co–Al–W alloy. Journal of Thermal Analysis and Calorimetry. https://link.springer. com/article/10.1007/s10973-020-10279-9
Korsmik, R., Turichin, G., Zadykyan, G., & Zhitenev, A. (2019). Investigation of Crystallization Process of a Single Crystal Nickel-Based Alloy during the Laser Multilayer Cladding. Trans Tech Publications Ltd, Switzerland, 822, 481–488.
Peachey, D. D., Carter, C. P., Garcia-Jimenez, A., Mukundan, A., Leonard, D. N., Charpagne, M.-A., & Cordero, Z. C. (2022). Directional recrystallization of an additively manufactured Ni-base superalloy. Additive Manufacturing, 60. https://www.sciencedirect.com/science/ article/pii/S2214860422005875
Zhang Weiguo, and LiuLin. Progress in directionally solidified superalloys. Foundry. 2009. 58(1):1.
Plancher E., Gravier aP., Chauvet E., Blandin J., Boller E., Martin G., Salvo L., Lhuissier P. Tracking pores during solidification of a Ni-based superalloy using 4D synchrotron microtomography. Acta Materialia, Vol. 181, December 2019, P. 1–9. https://doi. org/10.1016/j.actamat.2019.09.040
XU Qingyan,YANG Cong,YAN Xuewei,LIU Baicheng. Development of Numerical Simulation in Nickel-Based Superalloy Turbine Blade Directional Solidification. Acta Metall Sin, 2019, 55(9): 1175-1184. https://doi.org/10.11900/0412.1961.2019.00126
Giamei A.F., Tschinkel J.G. Liquid Metal Cooling: A New Solidification Technique. Metallurgical Transction A. 1976. Vol. 7A. P. 1427–1434.
Broomfield R.W., Ford D.A., Bhangu J.K., Thomas M. C., Frasier D. J., Burkholder P. S., Harris K., Erickson G. L., and Wahl J. B., Development and turbine performance of three advanced rhenium containing superalloys for single crystal and directionally solidified blades and vanes. Journal of Engineering for Gas Turbines and Power. 1998. 120(7): 595.
Калюкин Ю.Н. Современные методы управления кристаллизацией турбинных лопаток из жаропрочных сплавов. Газотурбинные технологии. 2007. No 5. С. 6–11.
Harris K. J. B. Wahl Developments in superalloy castability and new applications for ad- vanced superalloys. Materials Science and Technology. 2009. 25(2): 147–153. https://doi. org/10.1179/174328408X355442
StanfordN.,DjakovicA.,ShollockB.,McLeanM.,D’SouzaN.,JenningsP.Seedingofsingle crystal superalloys. Role of seed melt-back on casting defects/2004, Scripta Materialia 50(1). P. 159–163. https://doi.org/10.1016/j.scriptamat.2003.08.029
Makineni, S.K.; Lenz, M.; Neumeier, S.; Spiecker, E.; Raabe, D.; Gault, B. Elemental segregation to antiphase boundaries in a crept CoNi-based single crystal superalloy. Scr. Mater. 2018, 157, 62–66. https://doi.org/10.1016/j.scriptamat.2018.07.042.
Dexin MA Novel casting processes for single-crystal turbine blades of superalloys. Front. Mech. Eng. 2018, Vol. 13 , 3–16. https://doi.org/10.1007/s11465-018-0475-0
Jian-Jun Xu , Yong-Qiang Chen. Steady spatially-periodic eutectic growth with the effect of triple point in directional solidification. // Acta Materialia, Volume Vol. 80, November 2014, Pages P. 220–238. https://doi.org/10.1016/j.actamat.2014.06.047
Ажажа В.М., Свердлов В.Я., Ладыгин А.Н., Богуслаев А.В., Клочихин В.В., Лысенко Н.А. Перспективные направления в совершенствовании структуры монокристаллических лопаток газотурбинных двигателей. http://ptsm.donntu.org/arhiv%20nambe/36%20 pdf/003-009.pdf
Гайдук C.B., Кононов В.В., Петрик И.А., Налесный Н.Б. Влияние скорости кристаллизации и термической обработки на структуру и свойства монокристаллов жаропрочных никелевых сплавов. Вестник двигателестроения. 2005. No 1. С. 150–153.
Горічок І. В., Криськов Ц. А., Рачковський О. М., Фреїк Д. М., Люба Т.С. Пристрій зі змінним градієнтом температури в області кристалізації для вирощування кристалів з розплаву. Патент України 78465 (2013) https://uapatents.com/5-78465-pristrijj-zi- zminnim-gradiehntom-temperaturi-v-oblasti-kristalizaci-dlya-viroshhuvannya-kristaliv-z- rozplavu.html
Plancher E., Gravier aP., Chauvet E., Blandin J., Boller E., Martin G., Salvo L., Lhuissier P.Tracking pores during solidification of a Ni-based superalloy using 4D synchrotron microtomography. Acta Materialia. Vol. 181, December 2019, P. 1–9. https://doi. org/10.1016/j.actamat.2019.09.040
Hengzhi Fu and Xingguo Geng. High rate directional solidification and its application in single crystal superalloys/Science and Technology of Advanced Materials.. Adv. Mater. 2 // 2001 197-204. https://iopscience.iop.org/article/10.1016/S1468-6996(01)00049-3/pdf
Иванов В.Н., Казенов С.А., Курчман Б.С. и др. Литье по выплавляемым моделям / Под общ. ред. Шкленника Я.И., Озерова В.А. Москва: Машиностроение, 1984. 408 с.
Иванина Е.С., Батышев К.А. Модернизация установки УВНК-8П для направленной кристаллизации отливок из Ni-жаропрочных сплавов. Литейное производство. 2017. No1. С. 34–36.
Денисов А, Савин В, Зеленцов А., Авдюхин С. Монокристаллические турбинные ло- патки. Газотурбинные технологии. Май-июнь 2000. С. 24–25.
Franke M.M., Hilbinger R.M., Lohmüller A., Singer R.F.The effect of liquid metal cooling on thermal gradients in directional solidification of superalloys: Thermal analysis. Journal of Materials Processing Technology. Vol. 213, Issue 12 Issue 12, December 2013, P. 2081– 2088. https://doi.org/10.1016/j.jmatprotec.2013.06.001
Наумик В.В., Бялик Г.А. Упрощенный метод контроля загрязненности жидко- металлического кристаллизатора. Вестник двигателестроения. 2006. No 4. С. 123–125.
Жеманюк П.Д, Яценко В.К., Рубель О.В., Орлов М.Р. Регламентация выбора КГО лопаток турбины, полученных методом направленной кристаллизации. Вестник двигателестроения. 2002. No 1. С. 157–164.
Гранкин С.С., Свердлов В.Я. Исследование градиента температуры на фронте кристаллизации монокристаллов Ni-W-сплавов. Вопросы атомной науки и техники. 2008. No 1. Серия: Вакуум, чистые материалы, сверхпроводники (17). С. 162–165. http://vant.kipt.kharkov.ua/ARTICLE/VANT_2008_1/article_2008_1_162.pdf
StanfordN.,DjakovicA.,ShollockB.,McLeanM.,D’SouzaN.,JenningsP.Seedingofsingle crystal superalloys — Role of seed melt-back on casting defects/2004, Scripta Materialia 50(1). P. 159–163. https://doi.org/10.1016/j.scriptamat.2003.08.029
Konter M., Kats E., Hofmann N. Аnovel casting process for single crystal gas turbine components. Superalloys. 2000. P.189–200.
Krzysztof Kubiak, Dariusz Szeliga, Jan Sieniawski, Arkadiusz Onyszko, The Unidirectional Crystallization of Metals and Alloys (Turbine Blades). Handbook of Crystal Growth (Second Edition)2015, P. 413–457. https://doi.org/10.1016/B978-0-444-63303-3.00011-0
Jingying Xu a, Jinwu Kang b, Lele Zheng b c, Weimin Mao a, Jiwu Wang Numerical simulation of the directional solidification process with multi-shell mold being gradually immersed in water. Journal of Materials Research and Technology, Volume 19, July–August 2022, Pages 2705-2716. https://doi.org/10.1016/j.jmrt.2022.06.037
Pat. 6311760US, B22D27/04. Publ. 06.11.2001
Espacenet EP2921244A1. Method of the directional solidification of the castings of gas turbine blades and a device for producing the castings of gas turbine blades of the directional solidified and monocrystalline structure / A. Wiechczynski, M. Lisiewicz, J. Kwasnicka, and W. Kostrica. Application number EP 20150000675, 6.03.2015. Priority PL/13.03.14.
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2024 В.О. Нога
This work is licensed under a Creative Commons Attribution 4.0 International License.
