Krzysztof Kubiak

The effect of microstructure on the mechanical properties of two-phase titanium alloys

Abstract This paper presents the results of investigations of the microstructure and mechanical properties of two-phase α+β titanium alloys after different heat treatment. The influence of the morphology of lamellar microstructure and phase composition on the tensile properties and fracture toughness of the alloys was studied. Static tensile, hardness and fracture toughness tests and microstructure investigations were performed. It was noticed that the cooling rate from the β-phase range and ageing conditions had an effect on the microstructure parameters, volume fraction and chemical composition of the β-phase, and has a significant effect on the mechanical properties of the alloys tested.

Microstructure of Haynes ® 282 ® Superalloy after Vacuum Induction Melting and Investment Casting of Thin-Walled Components

The aim of this work was to characterize the microstructure of the as-cast Haynes® 282® alloy. Observations and analyses were carried out using techniques such as X-ray diffraction (XRD), light microscopy (LM), scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray spectroscopy (EDS), wave length dispersive X-ray spectroscopy (WDS), auger electron spectroscopy (AES) and electron energy-loss spectrometry (EELS). The phases identified in the as-cast alloy include: γ (gamma matrix), γʹ (matrix strengthening phase), (TiMoCr)C (primary carbide), TiN (primary nitride), σ (sigma-TCP phase), (TiMo)2SC (carbosulphide) and a lamellar constituent consisting of molybdenum and chromium rich secondary carbide phase together with γ phase. Within the dendrites the γʹ appears mostly in the form of spherical, nanometric precipitates (74 nm), while coarser (113 nm) cubic γʹ precipitates are present in the interdendritic areas. Volume fraction content of the γʹ precipitates in the dendrites and interdendritic areas are 9.6% and 8.5%, respectively. Primary nitrides metallic nitrides (MN), are homogeneously dispersed in the as-cast microstructure, while primary carbides metallic carbides (MC), preferentially precipitate in interdendritic areas. Such preference is also observed in the case of globular σ phase. Lamellar constituents characterized as secondary carbides/γ phases were together with (TiMo)2SC phase always observed adjacent to σ phase precipitates. Crystallographic relations were established in-between the MC, σ, secondary carbides and γ/γʹ matrix.

Modeling of Directional Solidification of Columnar Grain Structure in CMSX-4 Nickel-Based Superalloy Castings

The paper presents the analysis of numerical simulation of the Bridgman directional solidification process performed on CMSX-4 rods. The numerical simulation was studied applying the ProCAST software. The constitutive law parameters of the normal Gaussian distribution were used to describe the nucleation process. The coefficients of the equation were determined and used to calculate the growth rate of dendrite tip. The analysis of the as-cast microstructure was carried out with the use of Aphelion software in order to determine the average area of grains and their quantity. The experimental verification of both nucleation and grain growth coefficients used for the simulation of the directional solidification process confirmed that the model was correct and described well the investigated process of directional solidification using the Bridgman method.

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.

Modelling of Grain Microstructure of IN-713C Castings

This paper provides an analysis of experimental research results and numerical simulation of grain microstructure of turbine blade castings made of the IN-713C nickel superalloy. The numerical simulation was carried out by applying the ProCAST program. The geometric description of model assemblies and three-dimensional ceramic mould enclosure was developed. The boundary conditions as well as the thermal and physical coefficients for alloy and ceramic shell mould were selected for simulation purposes. The parameters of nucleation law based on normal (Gaussian) distribution as well as the values of equation coefficients were established in order to determine the growth rate of dendrite tips for the IN-713C alloy, depending on the undercooling. The experimental verification of boundary conditions for numerical simulation was carried out by comparison with the results of temperature distribution measurements performed in the castings. The analysis of grain microstructure was conducted on the surface and cross-sections of castings. The forecasted grain microstructure was determined using the CAFE module (ProCAST software). The cast microstructure as well as the value of grain growth and nucleation coefficients, which were used for numerical simulation of solidification process, were experimentally verified.

Correlation between SEM and X-Ray Diffraction Imaging of Defect Structure in Single-Crystal Ni-Based Superalloy

In the work the single-crystalline alloy CMSX-4 was studied. The main aim of the study was an attempt to find correlations between images of X-Ray topography, X-ray diffraction maps of lattice parameter and misorientation angle and Scanning Electron Microscopy (SEM) images obtained by back-scattered electron (BSE) technique. Topography images were obtained by Auleytner method with wide beam. Diffractometer provided by EFG company was used for obtaining orientation and lattice parameter maps. Material for research was produced in Research and Development Laboratory for Aerospace Materials of Rzeszów University of Technology. Casts were obtained in ALD furnace by the Bridgman technique. It was found that X-ray topograms were correlated with SEM images of microstructures as well as with orientation and lattice parameter maps. X-Ray topograms showed high contrast bands which corresponded to dendrite arms. There was a correlation between low angle boundary and lattice parameter map.

Influence of silicon carbide chills on solidification process and shrinkage porosity of castings made of nickel based superalloys

Abstract The paper presents the manufacturing methodology of IN713C castings by application of investment casting method and silicon carbide (SiC) chills. On the basis of numerical simulation and conducted microstructure analysis, it was established that the application of SiC chills results in significant decrease in shrinkage porosity, in comparison to castings without chills. The temperature measurement was carried out, and the influence of chills on the kinetics of solidification process was established. It was determined that the application of SiC chills causes the increase in cooling rate (∼0·1 K s−1), in comparison to the casting without chills. The authors carried out numerical optimisation with the use of ProCAST software and established which parameters have the largest influence on the solidification process of castings with and without chills. In addition to SiC, the graphite and Al2O3 were analysed as chill material in terms of influence on the predicted kinetics of cooling process and the shrinkage porosity of castings. The conditions of solidification process for castings, which are equipped with chills and are free from shrinkage porosity, were determined on the basis of obtained results.

Characterization of Single-Crystal Dendrite Structure and Porosity in Nickel-Based Superalloys Using X-Ray Micro-Computed Tomography

X-ray micro-computed tomography system has been used for visualization in two- (2-D) and three dimensions (3-D) of the dendrite structure and pores in single-crystals fabricated by Bridgman investment casting technique. The system described in the paper reconstructs 3-D geometry from a set of 2-D images obtained by multiple slicing of an X-ray radiography image. The results obtained in this study demonstrate the effect of withdrawal rate on the primary dendrite arm spacing and porosity in single-crystal made of CMSX-4 alloy.

X-Ray Topography Study of the Nickel Superalloy CMSX-4 Single Crystals

The paper attempts to determine structural perfection of monocrystalline nickel superalloys using X-ray topography. Monocrystalline bars and turbine blades were manufactured in an ALD Vacuum Technologies furnace using the Bridgman method. Pulling out rates typical for CMSX-4 nickel superalloys were used. It has been found that in the case of monocrystalline bars the structural perfection determined based on X-ray topograms does not depend on the distance from the selector. Instead, for blades the structural perfection significantly decreases with increasing distance from the selector.

The Unidirectional Crystallization of Metals and Alloys (Turbine Blades)

Abstract In the work, ceramics (zirconium silicate, aluminosilicates, mullite, zirconium dioxide), waxes, and binders used in investment casting of nickel-based superalloys have been characterized. Additionally, methodology of wax model pattern and ceramic molds for investment casting process have been discussed. The manufacturing methods (Bridgman, liquid metal cooling (LMC), gas cooling casting (GCC)) of single crystal and directionally solidified (DS) castings (mainly of aircraft engine and gas turbine blades) from nickel-based superalloys were presented. Moreover, the geometry of starter and selector in single crystal (SC) castings has been characterized. In the work, chemical composition of nickel-based superalloys (DS and SC), heat treatment technology, and test methods (macro-and microstructure, mechanical properties, crystalline perfection by Laue method, EBSD, and diffractometry) of nickel-based superalloys casting were shown and the principles of modeling the process of directional solidification (nucleation and grain growth) by finite element method (FEM) method has been described.