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Materials 2014, 7(3), 1625-1639; doi:10.3390/ma7031625
Article

Numerical Simulation and Optimization of Directional Solidification Process of Single Crystal Superalloy Casting

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Received: 17 December 2013; in revised form: 19 February 2014 / Accepted: 21 February 2014 / Published: 28 February 2014
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Abstract: The rapid development of numerical modeling techniques has led to more accurate results in modeling metal solidification processes. In this study, the cellular automaton-finite difference (CA-FD) method was used to simulate the directional solidification (DS) process of single crystal (SX) superalloy blade samples. Experiments were carried out to validate the simulation results. Meanwhile, an intelligent model based on fuzzy control theory was built to optimize the complicate DS process. Several key parameters, such as mushy zone width and temperature difference at the cast-mold interface, were recognized as the input variables. The input variables were functioned with the multivariable fuzzy rule to get the output adjustment of withdrawal rate (v) (a key technological parameter). The multivariable fuzzy rule was built, based on the structure feature of casting, such as the relationship between section area, and the delay time of the temperature change response by changing v, and the professional experience of the operator as well. Then, the fuzzy controlling model coupled with CA-FD method could be used to optimize v in real-time during the manufacturing process. The optimized process was proven to be more flexible and adaptive for a steady and stray-grain free DS process.
Keywords: numerical simulation; directional solidification; single crystal superalloy; fuzzy controlling strategy numerical simulation; directional solidification; single crystal superalloy; fuzzy controlling strategy
This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

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MDPI and ACS Style

Zhang, H.; Xu, Q.; Liu, B. Numerical Simulation and Optimization of Directional Solidification Process of Single Crystal Superalloy Casting. Materials 2014, 7, 1625-1639.

AMA Style

Zhang H, Xu Q, Liu B. Numerical Simulation and Optimization of Directional Solidification Process of Single Crystal Superalloy Casting. Materials. 2014; 7(3):1625-1639.

Chicago/Turabian Style

Zhang, Hang; Xu, Qingyan; Liu, Baicheng. 2014. "Numerical Simulation and Optimization of Directional Solidification Process of Single Crystal Superalloy Casting." Materials 7, no. 3: 1625-1639.


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