S. Roskosz

Effect of microstructure on properties of sintered carbides

Abstract The paper presents the methodology and results of a quantitative description of sintered carbides of WC–Co type. Quantitative relationships between the sintered carbide microstructures and properties have been determined. A set of quantitative metallography parameters has been identified which constitutes structural criteria for quality evaluation and criteria of selection for sintered carbides.

Non-Metallic Inclusions in Castings Made of Nickel-Base Superalloys

The paper presents investigations concerning causes of non-metallic inclusions forming in castings made of nickel-base superalloys. The most common reason of inclusions forming is erosion and thermal decomposition of crucibles and molds by the action of liquid alloy. In case of superalloys containing reactive elements (Hf), many reactions at the alloy-crucible and alloy-mold interfaces take place.

Evaluation of Porosity of Precision Castings Made of High-Temperature Creep Resisting Nickel Superalloys

Abstract The subject matter of the paper is the quantitative evaluation of gaseous and shrinkage porosity in construction elements of a low-pressure aircraft engine turbine using quantitative metallography methods. The research material consisted of blades and blade segments with a polycrystalline structure made of IN 713C and MAR M247 superalloys. One of the major problems that occur in the precision castings is their porosity: gaseous, which is the result of emission of dissolved gases from the superalloy during solidification, and shrinkage, being the result of shrinkage of the superalloy and from a lack of feeding of the interdendritic space. The comprehensive procedure of porosity evaluation includes: an automatic decimal-to-binary conversion of pores, a selective quantitative evaluation of gaseous and shrinkage porosity, the development of measuring conditions of quantitative metallography parameters, and the application of structural maps showing the varied porosity distribution over the cross-sections of castings of blades and blade segments. The developed practical procedure of selective measurement of gaseous and shrinkage porosity in the examination of precision castings made of high-temperature creep resisting nickel superalloys is presented.

Influence of Mould Cooling Rate on the Microstructure of AZ91 Magnesium Alloy Castings

Magnesium alloys are the lightest, widely used structural material. They are often used in aeronautical and automotive industries, where the weight savings are essential. Due to high responsibility of the elements made from magnesium alloys it is important to achieve high quality castings without any defects. The paper presents results of investigations on impact of sand mould cooling rate on microstructure and quality of the castings. Six identical castings, fed and cooled in different ways were investigated. Studies consisted of: RTG investigations and SEM and LM observations. Microstructure was evaluated qualitatively and quantitatively. RTG investigations showed that casting without feeder and cooler, casting only with feeder and castings cooled with 20mm and 40mm thick cooler contains voids inside. Castings with feeder and coolers 20mm and 400mm thick were flawless. Microstructure evaluation showed that castings with and without defects have different structure. Castings with defects were characterized by higher volume fraction of Mg17Al12 intermetallic phase. Flawless castings were characterized by fully divorced eutectic.

Fracture Surface Development Coefficient and Sialon Ceramics’ Bending Strength

Resistance to brittle cracking is one of the most important functional properties of sialon ceramics. Evaluation of the resistance requires an analysis of decohesion processes occuring in the material. Aiming at a comprehensive description of the morphology of typically brittle fractures, a quantitative characterization was made using different methods and techniques, regarding the surface of fractures formed in a three-point bending test. By using the parameter Sdr, determined via the surface stereometry method, the fracture surface development coefficient, RS, typical for fractography, was calculated. Analysis of the research results indicates a proportional relation between parameter RS and the sialon ceramics’ bending strength.

Quantitative Description of Overlaps on Sialon Ceramics Fractures by the Multifractal Method

A quantitative description of overlaps on fractures in sialon ceramics, is presented in the paper. A conventional analysis, aiming at the determination of the percentage share of overlaps on the basis of quantitative fractography, was preceded by stereometric/fractal analyses. They enabled the selection of representative sections of samples and then, the production of transverse microsections in those places for an analysis of the fractures’ profiles using the light microscopy method and fractographic image analysis. Based on the compared results from both methods, a successful verification was made of the research methodology developed earlier for sintered carbides and proven for a chromium-molybdenum steel.

Investment Casting Design and Processing for Drone’s Micro-Engine Turbine Rotor Manufacturing

The research presents methods for modern design and processing tools to be used in manufacturing process of castings in the aviation industry. In the study it is described how to use a computer simulation software and rapid prototyping / rapid tooling methods for manufacturing of drone’s micro-engine turbine rotor. The computer simulation of flow and solidification process and the investment casting technology were applied for manufactured elements.

Porosity of Solid and Cored Turbine Blades of Aircraft Engines

Paper presents results of quantitative evaluation of porosity conducted on big, thin walled airfoil turbine blades made from Inconel 713C alloy. To decrease mass, blades are design and manufacture like thin walled cored castings. Manufacturing of big thin walled casting airfoil blades is extremely difficult. During exploitation casting work undergo cycle fatigue. In that cause casting should be free of casting defects, including porosity. Conducted research focused on Inconel 713C superalloy pouring temperature effect on porosity level of cored casted turbine blade. Results were compared to porosity of solid casted turbine blade. It was found that porosity of cored blades is lower than solid blade porosity. In cored blades higher porosity is located on airfoil convex side. Airfoil concave side has lower porosity.

Porosity in Turbine Blades Cast into New Shell Moulds Made of SiC Based Ceramics

The subject matter of the paper is the quantitative evaluation of gaseous and shrinkage porosity in the turbine blades using quantitative metallography methods. The research material consisted of blades with a polycrystalline structure made of IN 713C superalloys. Three different shell mould systems were used during the investment casting: shell A - typical industrial shell mould system and used in this work as the reference; shell B – similar to version A, but SiC grit was applied as back-up stucco; shell C – entirely SiC shell mould system. The blades of superalloy IN-713C cast into the wholly SiC shell mould system have revealed much lower porosity as compared to the blades cast into the typical industrial shell mould system.

Quantitative Characterization of Shrinkage and Gas Pores in Turbine Blades Made of MAR M247 and IN 713C Superalloys

The subject matter of the paper is the quantitative evaluation of gaseous and shrinkage porosity in construction elements of a low-pressure aircraft engine turbine using quantitative metallography methods. The research material comprised blades and blade segments with a polycrystalline structure made of IN 713C and MAR M247 superalloys. One of the major problems that occur in the precision castings is their porosity: gaseous, which is the result of emission of dissolved gases from the superalloy during solidification, and shrinkage, being the result of shrinkage of the superalloy and of insufficient feeding of the interdendritic space. The developed practical procedure of selective measurement of gaseous and shrinkage porosity enabling the examination of precision castings made of high-temperature creep resisting nickel superalloys is presented.