Effects of Process Related Variations on Fillablity Simulation of Thin-Walled IN718 Structures

Mohsin Raza,Anders E W Jarfors,Björn Fägerström,Mark Irwin,Roger Svenningsson

doi:10.1007/s40962-017-0189-9

Abstract

Simulation tools have improved significantly and are now capable of accurately predicting mould filling behavior. The quality of prediction is highly dependent on material properties and set-up of boundary conditions for the simulation. In this work material properties were measured and casting conditions were analyzed to accurately replicate the casting process in simulation. The sensitivity of the predictions to minor process variations commonly found in foundries was evaluated by comparing simulation and cast samples. The observed discrepancies between simulation and cast samples were evaluated and discussed in terms of their dependency on process variations. It was concluded that the simulation set-up was capable of reasonable predictions and could replicate the asymmetry of the filling however did not accurately predict the absolute value of the unfilled area. It was discovered that asymmetric flow due to variations in the orientation of the casting mould during filling could have greater influence on the predictions than the actual variation in fill time. The quality of simulation is dependent on equipment and techniques used in the foundry as well as the metallurgical model to simulate the process.

Highlights

Due to the ability to produce net shape parts that maintain tight dimensional tolerances, investment casting has been widely used to manufacture components used in the hot gas path in gas turbines since 1950’s.1 In the power generation and aerospace industries, the overall weight reduction of engineering systems is much sought after, especially for turbines
The second phase of this study focused on performing casting trials according to the experimental plan, as described in Table 1 and using test geometries shown in Figure 1, as well as analyzing and comparing casting to the simulated results
In the current study empirically measured thermo-physical properties of the mould material and the alloy were used in the simulation to achieve maximum accuracy

Summary

Introduction

Due to the ability to produce net shape parts that maintain tight dimensional tolerances, investment casting has been widely used to manufacture components used in the hot gas path in gas turbines since 1950’s.1 In the power generation and aerospace industries, the overall weight reduction of engineering systems is much sought after, especially for turbines. Due to the ability to produce net shape parts that maintain tight dimensional tolerances, investment casting has been widely used to manufacture components used in the hot gas path in gas turbines since 1950’s.1. In the power generation and aerospace industries, the overall weight reduction of engineering systems is much sought after, especially for turbines. Weight reduction of an engineering system can be achieved by using integrated multifunction components or by reducing component weight either by improving component design or using lightweight materials. Increased demands have been put on investment casting foundries by the turbine industry to produce complex thin-walled components.[2] Weight reduction of components is essential to lower fuel consumption and reduce environmental impact.[3] Casting of thin-sections is challenging due to premature solidification in thin-walled sections and long feeding

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Conclusion