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Dimensional control of ring-to-ring casting with a data-driven approach during investment casting

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Abstract

The deformation behavior of the mush zone for superalloy during investment casting directly affects the dimensional control of casting has puzzled many engineers and scientists for years. Numerical simulations are not directly useful to predict the most suitable pattern allowances. A new data-driven approach to be effectively used for pattern allowance and casting process parameters prediction is proposed. The constitutive relationships and deformation parameter from high-temperature mechanical tests on superalloy K4169 is reported. The inputs are alloy temperature, shell temperature, and pattern allowance with the outputs of diameter and ovality of the ring-to-ring casting, respectively. It turns out that the shell temperature is the most momentous factor that governs the dimensional variability in ovality. An RBF-based approximation model is established and the optimized parameters are the alloy temperature 1500.5°C, shell temperature1052.5°C, and the pattern allowance 1.7258%. The optimized results agree well with the observed in practical casting and the ring-to-ring casting tolerance has been optimized as required within CT6 grade. The proposed method is believed to benefit to provide theoretical guidance for casting practice. The data-driven approach used in this research can be easily applied to different materials and different kinds of casting that are subject to dimensional control upon solidification.

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Funding

This work was financially supported by the National Key Research and Development Program of China (2020YFB1710101, 2020YFB1710102), China Postdoctoral Science Foundation (2020M671787), Zhejiang Postdoctoral Foundation (zj2019035), National Natural Science Foundation of China (51821001, 52090042), Major State Basic Research Development Program of Zhejiang (2020C01056, 2021C01157), Equipment Pre-Research Key Laboratory Fund Project (6142903200105), the fund of the State Key Laboratory of Solidification Processing in NWPU (Grant No. SKLSP202015), China Aviation Development Independent Innovation Project (ZZCX-2017-045), Science and Technology Project (K19209), and Major National Science and Technology Projects (2017-VII-008-0102, J2019-VI-0004-0117).

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Authors and Affiliations

  1. College of Chemical Engineering and Materials Science, Institute of Material Forming and Control Engineering, Zhejiang University of Technology, Hangzhou, 310014, China

    Wang Donghong & Lin Zhang

  2. Shanghai Key Laboratory of Advanced High Temperature Materials and Precision Forming, State Key Laboratory of Metal Matrix Composites, School of Materials Science and Engineering, Shanghai Jiao Tong University, 800 Dongchuan RD, Minhang District, Shanghai, 200240, China

    Wang Donghong & Jiangping Yu

  3. Jiashan Xinhai Precision Casting Co., Ltd, Jiaxin, 314100, China

    Wang Donghong & Yinghong Peng

  4. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Jiangping Yu & Changlin Yang

  5. State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an, 710072, China

    Xin Hao

Authors
  1. Wang Donghong
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  2. Jiangping Yu
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  3. Changlin Yang
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  4. Xin Hao
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  5. Lin Zhang
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Contributions

Donghong, Wang: conceptualization, methodology, software, data curation, formal analysis, writing-original draft. Jiangping Yu: conceptualization, formal analysis, validation, writing—review and editing, funding acquisition. Changlin Yang: investigation, data curation. Xin Hao: supervision, writing—review and editing. Lin Zhang: supervision, resources. Yinghong Peng: supervision, funding acquisition.

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Correspondence to Jiangping Yu.

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Donghong, W., Yu, J., Yang, C. et al. Dimensional control of ring-to-ring casting with a data-driven approach during investment casting. Int J Adv Manuf Technol 119, 691–704 (2022). https://doi.org/10.1007/s00170-021-07539-9

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  • DOI: https://doi.org/10.1007/s00170-021-07539-9

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