Simulation and Experimental Investigation of a Combined Control Method for Stray Grain During Single Crystal Blade Solidification

IF 2.6 3区 材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING International Journal of Metalcasting Pub Date : 2024-05-11 DOI:10.1007/s40962-024-01357-x
Haoyu Zhao, Kun Bu, Binqiang Wang, Sheng Mou, Pengguo Duan
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Abstract

It is of great significance to effectively prevent the stray grain defect at the edge plate of nickel-based superalloy single crystal blades. In this study, the evolution of the mushy zone and the growth of grain adjacent to the edge plate was first simulated by the temperature field and cellular automaton-finite element (CAFÉ) model, combined with a single crystal blade solidification experiment; it was proved that modifying the withdrawal rate alone was insufficient to prevent the stray grain formation. Then, the formation reason of the heat barrier zone and the irregular distribution pattern of the mold shell thickness were revealed by quantifying the present mold shell thickness near the edge plate through an industrial conical beam computed tomography. Based on these results, a combined control method for stray grain was proposed, which involves the use of precise measures such as non-uniform mold design, exact addition of process bars, and variable withdrawal rate. Simulation analysis demonstrated that this method can substantially reduce the undercooling range and average undercooling at the edge plate by 45.5% and 31.6%, respectively, and then eliminate the isolated undercooling zone. The macrostructure and microstructure of the blade cast by this method verified the effectiveness in inhibiting stray grain, and it will be a promising approach to manufacturing single crystal blades.

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单晶叶片凝固过程中杂散晶粒组合控制方法的模拟与实验研究
有效防止镍基超合金单晶叶片边缘板的杂散晶粒缺陷具有重要意义。本研究首先通过温度场和单元自动机-有限元(CAFÉ)模型,结合单晶叶片凝固实验,模拟了叶片刃板附近的粘滞区和晶粒生长的演变过程;实验证明,仅通过改变退模速率不足以防止杂散晶粒的形成。然后,通过工业锥形束计算机断层扫描对边缘板附近的现有模壳厚度进行量化,揭示了热障区的形成原因和模壳厚度的不规则分布模式。在此基础上,提出了游离晶粒的组合控制方法,包括使用非均匀模具设计、精确添加工艺棒和可变退模率等精确措施。仿真分析表明,该方法可将边缘板的欠冷范围和平均欠冷量分别大幅降低 45.5% 和 31.6%,进而消除孤立的欠冷区。用这种方法铸造的叶片的宏观结构和微观结构验证了抑制杂散晶粒的有效性,它将是制造单晶叶片的一种有前途的方法。
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来源期刊
International Journal of Metalcasting
International Journal of Metalcasting 工程技术-冶金工程
CiteScore
4.20
自引率
42.30%
发文量
174
审稿时长
>12 weeks
期刊介绍: The International Journal of Metalcasting is dedicated to leading the transfer of research and technology for the global metalcasting industry. The quarterly publication keeps the latest developments in metalcasting research and technology in front of the scientific leaders in our global industry throughout the year. All papers published in the the journal are approved after a rigorous peer review process. The editorial peer review board represents three international metalcasting groups: academia (metalcasting professors), science and research (personnel from national labs, research and scientific institutions), and industry (leading technical personnel from metalcasting facilities).
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