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Simulation of Thermal Stress Distribution in Ceramic Shell upon Heat

Treatment Process

Conference Paper · October 2015

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ADVANCES IN APPLIED PLASMA SCIENCE, Vol.10,2015 ISAPS '15, Nara

simulation of Thermal stress Distribution in ceramic shell

upon Heat Treatment Process

Tomasz Bolekl, Ryszard Sitek1, Romuald Doboszl, Paulina Wawulska-Marekl,

Joanna Zdunekl, Rafal Cygan2, Krzysztof Jan Kurzydlowskil

tFaculty of Materials science and Engineering, Warsaw University of Technology

2lnvestment Casting WSK, PZL-Rzeszów'' S.A

Warsaq 02-524, Poland

ABSTRACT
Contemporary investment casting process in its advanced form is commonly used in
industly where cąsting metals with high temperątures. Production of turbine blades for tttrbojet
engines is an example of applying this technology into manufacturing process, Complicated
shape of cruciąl components such ąs blades requires high qualit1,* elelnents ttsed in the
production process. Ceramic shell is decidingfactor on qualiĘ of Jinal procłucts iłl investment
casting. Therefore, choicely prepared process of heat treątment of ceramic shell is needed before
pouring with melted metal. Although heat treątment is an indispensable step in the process, apart
from desired effects, results can be accompanied by unwanted elfects such as lov, łłlateriąl
strength or a lack of toughness which can lead in conseqLlence to crack forłnation. Thus, it is
important to evaluate mąteriąl effort during this step. For this reason a lhree dimensioncłl finite
element model of the shell was prepared to investigate the heąt treąttnent process. Rest on
numericąl simulątion results it can be predicted the stress concentration regions in the model
ąnd the temperature distribution in the shell ąs well. Numerical model can be used ąs a CAD tool
in the designing step in investment casting technology for selectioł,t adecluate paralneters of the
proCeSS.

KEYWORDS: Numerical Simulation, FEM, Ceramic Mold, Investment Casting

l. INTRODUCTION by firing. Subsequently, sintering of the ceramlc

The investment casting process consists of
rnaking wax patterns by injecting wax into metal
dies, building of ceramic shell molds around the
rvax patterns, dewaxing of ceramic shell molds, and
casting of alloys into the shell molds. Nowadays
this process is widely used in the industry for
producing finished components of ferrous and non-
lerrous materials [1,6]. Investment casting offers
solution for manufacfuring manifold parts with
complicated shape, smooth surfaces and accurate
dimensions including turbine blades for aircraft
engines [2,5]. Production of crucial components of
alrcraft engines require high quality elements used
in the manufacturing process. Ceramic shell is
deciding factor on quality of final product in
investment casting process. During the process shell
is cleaned from the pattem residue and strengthened
takes place to deliver the shell a strucfure sufficient
to withstand the pressure of liquid metal. Prior to
molten metal pouring, shell is preheated between
700 and 1000'C in heat treatment operation [3,16].
Heat treatment allows to modify the behavior of
material and in consequence provide desired
properlies in ceramic mold [4,5]. Quality of final
product, particularly one with complex shape,
greatly depends on temperature difference between
mold and melted metal in every point of inner
surface of the ceramic shell. Therefore steadily
preheated mold have strong influence onto degree
of filling with liquid metal.
Contemporary many researchers use computer
simulation as inseparable paft to examine
investment casting process U -9,14-16l. However,
majority of numerical research in this field focus on

21
ADVANCES IN APPLIED PLASMA SCIENCE Vol.10.201_<

last step of the process: pouring shell with melted
metal U-9l. In this work numerical model of
ceramic mold was built and used to simulate heat
treatment process. Main pulpose of this research
was to investigate temperature distribution in
ceramic mold during heat treatment process and
directly before filling with liquid metal.
2. EXPERIMENTAL PROCEDURE
2.1 Geometry and FE Model
In order to investigate temperature distribution
at each point of the ceramic mold during
treatment numerical model was built [Fig. 2].
Firstly geometry of the wax pattern was transfened
to CAD software (Autodesk Inventor) where mold
shape was prepared [Fig. 1]. Geometry of ceramic
shell is different than normally used in production.
In par1 of thę model where final product exist,
instead of blades system of gores was used. This
modification enable to examine mold with very
nalTow internal surfaces. Base on experimental
measurements of cross section of the ceramic shell.
thickness of the model was set on 10mm.
The discretization of the finite element model
have been done using ANSYS Software. As an
element for the model three dimension S-node.
SOLIDI85, has been selected. Meshing density in
numerical model have an important effect on the
obtained results [10,11]. Most notably on the studr
of temperature and stress distribution at region with
nalTow internal surfaces such as final product or
blades. To avoid adverse influence of small acute
angles, those part of the numerical model has been
discretized with lesser element size than main areas.
heat These technique should provide more accurate
results from numerical simulation [1 1,12].
2.2 Material Data
ceramic mold in numerical model is treated as
isotropic material. Its termo-mechanical properties
in function of temperature are given in Table 1 and
Table 2.
It is assumed that density, young modulus and
Poisson's ratio of the mold remain constant during
thermal process [3].
2.3 Heat Treatment
Heat treatment operation is standard thermal
plocess in investment casting. Firing ceramic shell

T a tlle 1 Mate na of mold.

Temperature Therma1 Specific Thermal
I"C] Conductivity Heat Expansion
I lJ/ke+Kl t 1 0-ó/K l

20 0.672 846 2.80

200 0.705 960
400 0.736 o7ż J.oJ
600 0.7 65 68 3.84
800 0,835 ż49 4.00
l 000 0.94ż 313 3.78

Fig. 1 Wax Pattern with of the ceramic shęll Tabl 2M ęclralucal DroDęrlleS of
()I cera m mold
Density [g/cmJ] Young Modulus poisson's ratio
built on.
lMPa'l
1.413 3.4E5 0.23

Temperatrrre [.C]

l
f,o..
,, ł]

Fig. 2 Numerical modęl of the cęramic mold with |'ime [s]

mesh division,
Fig. 3 Heat treatment process.

22
 Simulation of Thermal Stręss Distribution in Ceramic Shell upon Heat Treatment Process

casting and allows to remove chemically combined

water, also last particles of wax pattern can be
removed [5]. In this study characteristic of the
process is similar to those used in production.
Process consist of several steps of heating and
cooling at different temperatures I l6]. For
numerical simulation pulposes this operation has
been divided into four stages, accordingly to Fig.3.
Stage 1 and 3 is responsible for preheating ceramic
shell in temperafure below 500"C. Afterwards mold
is fired at stage 2 and eventually at stage 4 in
temperature close to melted metal. Time of ffi
heating/cooling operation at steps 2-4 is identical,
whereas first step with starling point at room Fig. 5 Temperature in thę model is even out.
temperafure is longer.

3. RESULTS AND DISCUSSION Prior this point temperature variations in heat

3.1 Numerical Simulations
In this
section the results of numerical
calculations will be presented. Simulations have
been carried out with transient finite elęment
procedure with temperafure dependent thermal and
material properlies U,12,14). Heat treatment
process of Fig.3 have been performed in one
calculation divided into four load stages. Results
obtained in last step from first stage are initial loads
in second stage. This provide continuiĘ of the
calculations and enhance simulation outcomes
[12, l 5].
Although entire model have identical material
properties, slightly variations in temperafure occur
among some regions Fig. 4 and 6. Mainly, it may
be caused by geometry distinction between parts of
the model. However, it has to be pointed out that
difference is 1ess than loń. Thus, it is assumed that
numerical model is heated steadily in entire volume.
From the moment when temperature in the
model even out at every point of the ceramic mold,
until the end of the heating operation temperature
variations not occur Fio.5
operation of each stage were observed. Fig 6
presents zoomed in region of inside part of the
model. Base on this results it can be deduced that
temperature growth from outside to inside of the
model. Heating in furnace is simulated as heat
transfer from surfaces exposed to hot air stream in
real process [l3,14]. Those lead to conclusion that
par-t of the model remaining farther form the stream
are heated slower.
Comparison of two point called "Nodel" and
"Node2", respectively, is showed on F'ig. 7. Highest
distinction between those points reach almost 15C.
Nonetheless this value occurs solely at beginning of
the calculations. Variation estimated in stage 2-4
does not exceęd 10'C and in majority of the heating
plocess significantly lower than 5"C. With regard to
the process temperature up to 1000'C differencę is
under 1o%. Characteristic of the direct comparison
among the "Nodes" confirm previous assumption,
when temperature in the model even out differences
does not occur.

Fig. 4 Temperature distribution at heating operation in Fig. 6 Regions with temperature variations.
step 2.

23
 ADVANCES iN APPLIED PLASMA SCIENCE Vol.10,2015

15 Developed numerical model may be useful to

0
o
ciT
iil TernperatureDifference consider either other effects (associated with
g,*
material) or different factors influence (terms of the
10
x3 process, geometry of mold) in investment casting
Yz
l l, proceSS.
60 t,

c-
1,, i' \ ;"\ ACKNOWLEDGEMENTS
F 1'',",i]j',.' ! The research has been carried out under the
"'l
Time [s] project ,Optimizatton of technology for production
Fig. 7 Temperature comparison betwęen the nodes from of multilayer ceramic shell mold for precision
Fig.6. casting of critical parts of gas turbines for aircraft
industry" No PBSllB5l6lż0I2 funded by the
National Centre for Research and Development.
Numerical simulations allow to perform
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