Investigation of Shrinkage Porosity in a Nickel Based Super Alloy Blade by Using Computer Simulation

M.R. Alizadeh¹ , Y. Miladi² , A. Khedmati³

1. MavadKaran Engineering Company, Mapna Group, Tehran, Iran.
2. MavadKaran Engineering Company, Mapna Group, Tehran, Iran.
3. MavadKaran Engineering Company, Mapna Group, Tehran, Iran.

Section:Research Paper, Product Type: Journal-Paper
Vol.10 , Issue.1 , pp.1-6, Mar-2023

Online published on Mar 31, 2023

Copyright © M.R. Alizadeh, Y. Miladi, A. Khedmati . This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
 

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Abstract :
In all experimental researches in investment casting process, real foundry experiences in producing a gas turbine blade has always been time consuming. In addition, cost of its production is very high. Therefore, using other beneficial way like software simulation investigation is a key step to design a suitable gating system before starting the casting process. In this research a simulation of gas turbine blade has been studied by ProcCAST software which is based on the Finite Element Method. For this reason, two different gates were simulated and compared to each other. Both systems had similar pouring cup and identical sprue. Casting condition such as casting temperature, method of wrapping insulators and the alloy were identical. In the first gating system volume fraction of feed to blade was 0.17 while in the second system this amount increase to 0.28. The results showed that in the first system the molten metal that exist in the pouring cup initiates its solidification stage before the gate; in effect, computer results showed that in this system after 14 minutes of pouring the molten metal, the gates’ pass was closed and was not able to fed the blade. In other words, simulated results displayed that contour of temperature in the pouring cup is completely below the contour of casting parts. As a result, shrinkage porosity was observed in the root of the blade. In the second gating system, however, the blockage of the gate was not observed and the correct thermal gradient lead to the producing a non-shrinkage porosity part. In fact, contour of temperature in the pouring cup is completely above the contour of casting parts.

Key-Words / Index Term :
- Computer simulation, Gating system, Investment Casing, Nickel Based Super alloy

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