Andrzej Nowotnik

Rapid prototyping in manufacturing of core models of aircraft engine blades

Purpose – The purpose of this paper is to present the advantages of computer-aided design/rapid prototyping (CAD/RP) usage in designing and manufacturing of the core models used for precise casting with direct and single solidification of aircraft engine turbine blade cores. Design/methodology/approach – The process of modelling three-dimensional CAD geometry of research blade in relation to the model of the core was presented with different wax types used in the RP technique. Findings – The geometry of the blade model has been designed in a way which allows making a silicon mould on the basis of a base prototype in the process of rapid tooling (RP/RT). Filing by different wax types was investigated in mean of the impact on filling accuracy of the mould cavity. Originality/value – The resulting models were used to make ceramic moulds and carry further work on the development of casting technology in the process of directional solidification and single crystal solidification of core blades of aircraft engines.

The effect of TMCP parameters on the microstructure and mechanical properties of Ti–Nb microalloyed steel

The aim of this work was to study the influence of thermo‐mechanical controlled process parameters on the refinement of microstructure during processing as well as the final microstructure and mechanical properties of Nb microalloyed steel. The steel was investigated and thermo‐mechanical controlled process simulations were carried out using the material testing system 810. The effect of deformation sequences with constant finish rolling temperature and accelerated controlled cooling rate were studied with regard to strength and microstructure of heavy plate. The optimized thermo‐mechanical controlled process parameters will be discussed in relation to the microstructure and precipitate evolution, as well as the mechanical properties of high‐strength steel, microalloyed with Nb and Ti. The best results for strength were obtained for accelerated controlled cooling rates >5°C s−1 in the present cases where the finishing temperature was 850°C, for both light and heavy reductions.

Investigation of the effect of solidification velocity on the quality of single crystal turbine blades

The occurrence of high temperatures in combustion chambers of jet engines and gas turbines has led to the demand for new technologies and new materials for the manufacture of one of the most critical elements of these systems - the turbine blades. These elements have to withstand extreme temperatures for extended periods without loss of mechanical strength, conditions under which many alloys fail. Such failure is ascribed to the combination of high temperatures and high centrifugal forces, resulting in creep. This is especially prevalent in multi-crystalline structures in which grain boundaries present weaknesses in the structure. High temperature resistant alloys formed as single crystal (SX) structures offer the necessary material properties for safe performance under such extreme conditions. Modelling and simulation techniques were first used to study the directional solidification (DS) of crystal structures during vacuum investment casting. These models allowed the study of the dendritic growth rate, the formation of new grains ahead of the solid/liquid interface and the morphology of the dendritic microstructure. These studies indicated the opportunity to optimise the velocity of the solidification front (solidification rate) for single crystal structures. The aim of this study was therefore to investigate the effect of the solidification rate on the quality of SX castings. The investigations were carried out for nickel-based superalloy CMSX-4 turbine blade casts and rods using the Bridgman process for vacuum investment casting.

The assessment of geometric accuracy of aircraft engine blades with the use of an optical coordinate scanner

Purpose The purpose of this paper is to present coordinate measuring system possibilities in the meaning of the geometric accuracy assessment of hot zone elements in aircraft engines. The aim of the paper is to prove that this method, which uses blue light and is most sufficient and cost-saving method, can to be used in the production line for serial manufacturing of elements, for which a high level of accuracy is required. Design/methodology/approach The analysis of the geometric accuracy of the blades was performed using non-contact optical coordinate scanner ATOS Triple Scan II Blue Light, manufactured by GOM Company, at the Department of Mechanical Engineering, Rzeszow University of Technology. Geometric analysis was conducted for blades manufactured from different waxes (A7Fr/60 and RealWax VisiJet CPX200), thus comparing injection technique and rapid prototyping (RP) method, and for casting made of Inconel 713C nickel-based superalloy. Findings The analysis of the criteria for the method of blades’ measuring selection showed that the chosen system successfully met all criteria for the verification of blades’ geometry at the selected stages of the process. ATOS II optical scanner with blue light technology allows measurement almost regardless of daylight or artificial (white) light. This allows the application of the measurement system in the production cycle, thus eliminating the need to create special conditions for measurements. Practical implications Requirements related to the accuracy of measured values, diversity and allowable measurement time are linked with the methods of production. Modern manufacturing methods based on computer-aided design systems/manufacturing/engineering systems require a non-contact optical measurement method based on the computer-aided-based coordinate measuring technique. In case of the non-contact optical scanning method based on the ATOS GOM measuring system, time and measurement costs depend on the methodology of measurement and the possibility of its automation. This is why the presented paper has a practical impact on possibilities for the automation of geometric accuracy measurements of obtained elements in the series production line. Social implications The use of ATOS Triple Scan II Blue Light by GOM Company allows the reduction of cost and time of production because of the possibility of the introduction of this system in an automated production line. Additionally, the measurement of hot section blades of aircraft engines by using the blue light method is much more accurate and has implication as it impacts safety of further used manufactured elements. Originality/value This paper presents the possibility of using the ATOS Triple Scan II Blue Light measuring system for geometric accuracy measurements in case of hot section blades of aircraft engines. This research is original because it describes three model geometric accuracy measurements, wax model obtained using the injection technique, wax model obtained using the I RP process and casting made of Inconel 713C nickel-based superalloy.

Development of Nickel Based Superalloys for Advanced Turbine Engines

Superalloys have been developed for specific, dedicated properties and applications. One of the main application for this material is advanced, high-performance aircraft engines elements. Turbine engine creates harsh environments for materials due to the high operating temperature and stress level. Hence, as described in this article, many alloys used in the turbine section of these engines are very complex and highly optimized. This article provides an overview of structural changes that occur during the aging process of wrought and cast alloys and provides insight into the use of precipitated particles to achieve desired structures. Example will focus on alloy Inconel 718 and CMSX-4. Functional properties of these alloys can be achieved by choosing proper heat treatment parameters to obtain required rate between secondary phases. The paper also attempts to determine structural perfection and changes of crystallographic orientation along the axis of growth of single crystal nickel superalloys cast using X-ray topography and Laue diffraction method. Single crystal bars and turbine blades were manufactured in VIM furnace using the Bridgeman method. Withdrawing rates typical for CMSX-4 superalloy were used. It has been found that with increasing withdrawing rate the nature of distribution along the axis of growth of the angle of [001] direction deviation from the axis of single crystal blades growth had changed. The change of the withdrawing rate results also in the rotation of γ’ phase in the form of cubes against the axis of single crystal blades growth.

Bi-velocity model of mass transport in two-phase zone of ternary system

Bi-velocity (Darken) method, which includes material drift and diffusion fluxes, is for the first time applied to describe mass transport in multiphase materials. The respective model is formulated in details and then applied for a ternary diffusion couple in which a two-phase zone can grow during isothermal diffusion. Thanks to the use of a phase-field order parameter, identified here with volume fraction of a chosen phase, the mass transport throughout both phases within a two-phase zone can be considered. The model allows smooth crossing of the type 1 boundary, which makes the mass transport equations valid in both single- and two-phase regions. The solution obtained for 1D geometry provides: (1) a diffusion path in the concentration triangle, (2) element-concentration profiles, (3) volume fractions of the phases in the two-phase zone and (4) drift-velocity distribution along x axis parallel to the mass transport. As an example, the interdiffusion in the diffusion couple of Type 0 boundary is modelled. The zigzag diffusion path is predicted and the profiles of the element concentrations are simulated. For the first time, the drift velocity for the diffusion in two-phase system is determined and correlated with the changes in volume fractions of the phases.

High temperature deformation of superalloy Inconel 718

Experimental results on hot deformation and dynamic structural processes of nickel based alloy Inconel 718 are reviewed. The focus is the analysis of dynamic precipitation processes which operate during hot deformation of these materials at elevated temperatures. Hot compression tests were performed on the solution treated precipitation hardenable nickel based superalloy Inconel 718 at 720-1150°C with a constant true strain rates of 10-4 and 4x10-4s-1. True stress - true strain curves and microstructure analysis of the deformed nickel based superalloy is presented. The properties and dynamic behaviour are explained through observation of the microstructure using standard optical, scanning and transmission electron microscopy. Structural observations of solution treated Inconel 718 deformed at high temperatures, reveal non uniform deformation effects. The distribution of niobium-rich carbides were affected by localized flow within the strain range investigated at relatively low deformation temperatures 720 - 850°C.

Process Temperature Effect on Surface Layer of Vacuum Carburized Low-Alloy Steel Gears

Gears, due to their complex shape, carried load and required accuracy are ones of most complex aircraft engine parts. Single tooth damage usually breaks the power transmission and causes failure of the entire gear system. Adequate sustainability and guarantees of transmission is therefore a condition for secure operation of whole device. Particularly high requirements for reliability are put to transmissions used in the aerospace industry. Due to the loads which are transmitted through the gears, the materials used by the manufacturer must have not only high strength but also show the abrasion resistance of the surface layer and the ductility of the core. Thermo-chemical treatment of industrial gears is a fundamental process, which gives them adequate mechanical properties regarding loads they carry and the surface conditions of work. The most promising method in the discussed field is vacuum carburizing, which by its specification of work significantly reduce the emission of CO2 and the duration of the process, without reducing the quality of the final product. The main aim of the paper is to present criteria for selection of carburizing parameters (mainly temperature increase) as a part of thermo-chemical treatment process performed using vacuum methods. Proper (higher to compare with conventional methods) carburizing process temperature is crucial in programming of carbon diffusion process meaning in process time and final carburized layer characteristics as carbon profile and homogeneity of the carburized layer.

Dynamic precipitation of nickel-based superalloys undergoing severe deformation below the solvus temperature

Abstract The authors performed uniaxial compression tests of nickel-based superalloys: single crystal CMSX–4, also precipitation hardened; Inconel 718 and X750, at temperatures below the γ′ solvus, in order to study the effect of temperature and strain rate on their flow stress and microstructural development. On the basis of the obtained flow stress values, the activation energy of a high-temperature deformation process was estimated. Microstructural observations of the deformed samples at high temperatures, previously solution heat treated and aged CMSX–4 and Inconel alloys revealed non-uniform deformation effects. Distribution of either molybdenum- or niobium-rich carbides was found to be affected by localized flow within the investigated strain range at relatively low deformation temperatures, 720–850 °C. Microstructural examination of the alloys also showed that shear banding and cavity growth were responsible for the decrease in flow stress and a specimen fracture at larger strains.

The chemical phenol extraction of intermetallic particles from casting AlSi5Cu1Mg alloy

This paper presents a chemical extraction technique for determination of intermetallic phases formed in the casting AlSi5Cu1Mg aluminium alloy. Commercial aluminium alloys contain a wide range of intermetallic particles that are formed during casting, homogenization and thermomechanical processing. During solidification, particles of intermetallics are dispersed in interdendritic spaces as fine primary phases. Coarse intermetallic compounds that are formed in this aluminium alloy are characterized by unique atomic arrangement (crystallographic structure), morphology, stability, physical and mechanical properties. The volume fraction, chemistry and morphology of the intermetallics significantly affect properties and material behaviour during thermomechanical processing. Therefore, accurate determination of intermetallics is essential to understand and control microstructural evolution in Al alloys. Thus, in this paper it is shown that chemical phenol extraction method can be applied for precise qualitative evaluation. The results of optical light microscopy LOM, scanning electron microscopy SEM and X‐ray diffraction XRD analysis reveal that as‐cast AlSi5Cu1Mg alloy contains a wide range of intermetallic phases such as Al4Fe, γ‐ Al3FeSi, α‐Al8Fe2Si, β‐Al5FeSi, Al12FeMnSi.