Professional Documents
Culture Documents
Motivation
Prototype Optimization
Summary
2
SFB/Transregio 103 / B1 SUPERALLOY SINGLE CRYSTALS
Matthias Hofmeister, 14th World Conference on Investement Casting, April 18th 2016, Paris, WCIC - 40
Project Mission
[1]
[1] M. M. Franke, results from numerical investigation on the influence of the Baffle on the as cast subgrain structure (2013)
3
SFB/Transregio 103 / B1 SUPERALLOY SINGLE CRYSTALS
Matthias Hofmeister, 14th World Conference on Investement Casting, April 18th 2016, Paris, WCIC - 40
Advantages of Inert Gas Fluidized Bed for IC Process
[2] ~
U
A
u
θ0
θB
air
Particle bed behaves fluid-like, as gas input exceeds minimum fluidization limit.
Inert gas atmosphere is beneficial for heat flux off the casting [3].
Alloying element evaporation is reduced during partial pressure solidification.
Buoyancy allows the application of the Dynamic Baffle.
[2] H. Martin, M5 Wärmeübergang in Wirbelschichten: VDI-Wärmeatlas, Springer Berlin Heidelberg, Berlin, Heidelberg (2013)
p. 1493
[3] M. Konter, E. Kats, N. Hofmann, A novel casting process for single crystal gas turbine components, Superalloys 2000
Proceedings of the 9. International Symposium on Superalloys, 2000, Seven Springs, PA pp. 189–200
4
SFB/Transregio 103 / B1 SUPERALLOY SINGLE CRYSTALS
Matthias Hofmeister, 14th World Conference on Investement Casting, April 18th 2016, Paris, WCIC - 40
Fluidized Bed Investment Casting Attempts in Literature
Nakagawa et al. [4] Quested et al. [5] Graham [6,7]
500 µm
Superalloy compatibility:
Glassy carbon bed material
Low density graphite Dynamic Baffle
material
7
SFB/Transregio 103 / B1 SUPERALLOY SINGLE CRYSTALS
Matthias Hofmeister, 14th World Conference on Investement Casting, April 18th 2016, Paris, WCIC - 40
FCBC Process Animation
Process Animation
8
SFB/Transregio 103 / B1 SUPERALLOY SINGLE CRYSTALS
Matthias Hofmeister, 14th World Conference on Investement Casting, April 18th 2016, Paris, WCIC - 40
FCBC Bed Material Choice & Property Engineering
9
SFB/Transregio 103 / B1 SUPERALLOY SINGLE CRYSTALS
Matthias Hofmeister, 14th World Conference on Investement Casting, April 18th 2016, Paris, WCIC - 40
FCBC Potential Assessment - Theory
Lohmüller [8] provides means to compare process potentials based on 1-D heat
flux calculations. However, ...
influence of the baffle is not considered. Franke [1] showed the significance
of the Dynamic Baffle.
approach is partly based on simplifying assumptions.
[8] A. Lohmüller, W. Eßler, J. Großmann, M. Hördler, J. Preuhs, R. F. Singer, Improved quality and economics of investment casting by
liquid metal cooling - the selection of cooling media, Superalloys 2000 Proceedings of the 9. International Symposium on Superalloys,
10 2000, Seven Springs, PA pp. 181–188
Gas filled
in FCBC
FCBC profits from the presence of gas in mold pores and the solidification gap.
Al2O3 shelled Cu sphere directly considers the situation during solidification
(gap, ceramic mold insulation, ...)
Experimental temperature is limited by probe’s melting temperature;
extrapolation seems reasonable
11
SFB/Transregio 103 / B1 SUPERALLOY SINGLE CRYSTALS
Matthias Hofmeister, 14th World Conference on Investement Casting, April 18th 2016, Paris, WCIC - 40
Prototype FCBC Device of Industrial Relevance
Dynamic
Baffle
H
G
F
E
D
C
B
A TC instrumented reference
casting in an industrial casting
device at RZUT / Poland
Casting design by D.
Szeliga, RZUT / Poland
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SFB/Transregio 103 / B1 SUPERALLOY SINGLE CRYSTALS
Matthias Hofmeister, 14th World Conference on Investement Casting, April 18th 2016, Paris, WCIC - 40
Optimization: The Essentiality of the Dynamic Baffle
14
SFB/Transregio 103 / B1 SUPERALLOY SINGLE CRYSTALS
Matthias Hofmeister, 14th World Conference on Investement Casting, April 18th 2016, Paris, WCIC - 40
Outcome from the Ongoing Optimization
H
G
F
E
D
C
B
A
[K]
15
SFB/Transregio 103 / B1 SUPERALLOY SINGLE CRYSTALS
Matthias Hofmeister, 14th World Conference on Investement Casting, April 18th 2016, Paris, WCIC - 40
Summary
16
SFB/Transregio 103 / B1 SUPERALLOY SINGLE CRYSTALS
Matthias Hofmeister, 14th World Conference on Investement Casting, April 18th 2016, Paris, WCIC - 40
Thank you for your attention!