Id Wcic - 40 - M Hofmeister WTM

B1
Single Crystal Solidification with Enhanced Microstructure:

Development and Optimization of the Fluidized Carbon Bed
Cooling Process
M. Hofmeister, M. M. Franke, R. Rettig, R. F. Singer
University of Erlangen-Nuremberg FAU, Erlangen, Germany
14th World Conference in Investment Casting,

Paris, 18.04.2016 WCIC - 40
Outline
FCBC Process Development & Optimization
 Motivation
 Former Fluidized Bed Attempts
 FCBC Process Idea and Potential Study
 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]
 Improvement in casting quality (e.g. segregation, pores) and costs

 Provide processability for new, high d-shell element containing
superalloys
[1] M. M. Franke, results from numerical investigation on the influence of the Baffle on the as cast subgrain structure (2013)
3
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
Fluidized Bed Investment Casting Attempts in Literature
Nakagawa et al. [4] Quested et al. [5] Graham [6,7]
1979 1986 1998 2005 TIME

[4] Y.G. Nakagawa, M. Nemoto, Growth and Thermal Stability of γ/γ'-α Eutectic Composite, MRS Proc. (1981) pp. 143–153
[5] P. N. Quested, Northwood J.E., inventor; The Secretary of State of Defense in Her Britannic Majesty's Government of the
United Kingdom of Great Britain and North Ireland, assignee. Method and apparatus for casting directionally solidified articles.
United States patent US 4573516. 1986 Mar. 4.
[6] L. D. Graham, inventor; PCC Airfoils, Inc., assignee. Method of casting a metal article. United States patent US 6035924.
2000 Mar. 14.
[7] L. D. Graham, inventor; PCC Airfoils, Inc.; assignee. Fluidized Bed with Baffle. United States patent US 6889747.
2005 May 10.
5
Hypothetical Drawbacks of Former Fluidized Bed Attempts
 Choice of ceramic process materials:
 Wear of setup
 Contamination of castings with oxide ceramic particles
Alumina sand (mesh 120) used in fluidized

bed applications.
 Restriction of excess gas flow rate:

 Particle blow out
 Detrimental cooling of shell mold heater
 Control of the fluidized bed filling level

6
FCBC: Fluidized Carbon Bed Cooling
 Counter pressure concept for ...

 wide process window Argon
 smoothly agitated Dynamic Baffle kept
at constant level
500 µm
 Superalloy compatibility:
 Glassy carbon bed material
 Low density graphite Dynamic Baffle
material
7
FCBC Process Animation
Process Animation
8
FCBC Bed Material Choice & Property Engineering
 Bed material is intrinsically free from

fine fraction.
 Heat treatment for improvement of ...
 oxidation and wear resistance.
 applicability in vacuum.
500 µm
9
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

FCBC Potential Assessment - Experiment
Pore
Gas filled
in FCBC
µCT image of the heat flux

probe setup. Cu ball packed
in typical Al2O3 shell mold.
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
Prototype FCBC Device of Industrial Relevance
Dynamic
Baffle
Argon fluidized bed
 FCBC and HRS mode implemented

 10 kg casting capacity
 Ø 200 mm shell mold clusters
12
Reference Casting (industrial furnace)
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
 Reference for acceptance test

(v = 3mm/min)
 λ1 ≈ 450 µm
13
Optimization: The Essentiality of the Dynamic Baffle
No Dynamic Baffle Dynamic Baffle
 Shielding against parasitic heat input to heat sink

 Improvement of temperature gradient
 Reduction of mold heater power consumption
 Smooth fluidized bed start up
 Barrier against particle ejection
14
Outcome from the Ongoing Optimization
H
G
F
E
D
C
B
A
[K]
15
Summary
Advanced method designed and implemented:
 Potential for high temperature gradient demonstrated
 Commissioning of prototype plant completed; basis

for resilient comparison with HRS
 Applicability of HRS shell mold system demonstrated
 Potential for casting microstructure revealed
16
Thank you for your attention!


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B1

Single Crystal Solidification with Enhanced Microstructure:

M. Hofmeister, M. M. Franke, R. Rettig, R. F. Singer

University of Erlangen-Nuremberg FAU, Erlangen, Germany

14th World Conference in Investment Casting,

FCBC Process Development & Optimization

 Former Fluidized Bed Attempts

 FCBC Process Idea and Potential Study

 Improvement in casting quality (e.g. segregation, pores) and costs

1979 1986 1998 2005 TIME

Alumina sand (mesh 120) used in fluidized

 Restriction of excess gas flow rate:

 Control of the fluidized bed filling level

 Counter pressure concept for ...

 Bed material is intrinsically free from

SFB/Transregio 103 / B1 SUPERALLOY SINGLE CRYSTALS

µCT image of the heat flux

Argon fluidized bed

 FCBC and HRS mode implemented

 Reference for acceptance test

No Dynamic Baffle Dynamic Baffle

 Shielding against parasitic heat input to heat sink

Advanced method designed and implemented:

 Potential for high temperature gradient demonstrated

 Commissioning of prototype plant completed; basis

 Applicability of HRS shell mold system demonstrated

 Potential for casting microstructure revealed

SFB/Transregio 103 / B1 SUPERALLOY SINGLE CRYSTALS

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