Abstract
Ni-based superalloys are currently used as materials for single-crystal (SC) or directionally solidified (DS) turbine blades produced in Bridgman or Liquid Metal Cooling (LMC) furnaces. Valid selection of the process parameters providing proper quality of the casting depends on casting geometry and furnace design. Process parameters should vary with the solidified cross section of the casting. Withdrawal rate is the most important parameter which affects solidification process more severely than the heater temperature. The technique providing for a valid withdrawal rate selection is based on the critical solidification rate calculation from experimental or numerical modeling data. A range of withdrawal rates providing for the required type and quality of the macrostructure is an output of the technique application. Full-scale and computing experiments were carried out to validate the optimization technique. The performance capability of the optimization technique is demonstrated in terms of the in situ composite solidification process. As a result of the solidification process, a real turbine blade was obtained at the desired temperature gradient and solidification rate supporting conditions of the planar solidification front.
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