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Investment casting of nozzle guide vanes from nickel-based superalloys: part I – thermal calibration and porosity prediction

  • Agustín Jose Torroba
  • Ole Koeser
  • Loic Calba
  • Laura Maestro
  • Efrain Carreño-Morelli
  • Mehdi Rahimian
  • Srdjan Milenkovic
  • Ilchat Sabirov
  • Javier LLorcaEmail author
Research article

Abstract

Investment casting is the only commercially used technique for fabrication of nozzle guide vanes (NGVs), which are one of the most important structural parts of gas turbines. Manufacturing of NGVs has always been a challenging task due to their complex shape. This work focuses on development of a simulation tool for investment casting of a new generation NGV from MAR-M247 Ni-based superalloy. A thermal model is developed to predict thermal history during investment casting. Experimental casting trials of the NGV are carried out and the thermal history of metal, mold, and insulation wrap is recorded. Inverse modeling of the casting trials is used to define accurately some thermophysical parameters and boundary conditions of the thermal model. Based on the validated thermal model, another model is developed to predict porosity in the as-cast NGVs. The porosity predictions are in good agreement with the experimental results in the as-cast NGVs. The advantages and shortcomings of the developed modeling tool are discussed.

Keywords

Ni-based superalloys Investment casting Nozzle guide vanes Thermal model Thermal history Porosity 

Notes

Acknowledgements

This investigation was carried out in frame of the VANCAST project (EU, FP7, ERA-NET MATERA+). SM and IS acknowledge gratefully the Spanish Ministry of Economy and Competitiveness for financial support through the Ramon y Cajal fellowships. Prof. A. Zryd (Maxwell Technologies SA) and Dr. A. Faes (CSEM SA) are greatly acknowledged for the inverse simulations of experimental casting trials of easy geometry parts as those results constituted the seed for experimental work which had led to this manuscript.

Supplementary material

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Copyright information

© Torroba et al.; licensee Springer. 2014

This article is published under license to BioMed Central Ltd. This is an Open Access article distributed under the terms of the Creative Commons Attribution License (http://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly credited.

Authors and Affiliations

  • Agustín Jose Torroba
    • 1
  • Ole Koeser
    • 2
  • Loic Calba
    • 2
  • Laura Maestro
    • 3
  • Efrain Carreño-Morelli
    • 1
  • Mehdi Rahimian
    • 4
  • Srdjan Milenkovic
    • 4
  • Ilchat Sabirov
    • 4
  • Javier LLorca
    • 4
    • 5
    Email author
  1. 1.University of Applied Sciences and Arts Western SwitzerlandSionSwitzerland
  2. 2.CALCOM-ESILausanneSwitzerland
  3. 3.Precicast BilbaoBilbaoSpain
  4. 4.IMDEA Materials InstituteGetafeSpain
  5. 5.Department of Materials SciencePolytechnic University of MadridMadridSpain

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