Multiscale Modeling and Simulation of Directional Solidification Process of Ni-Based Superalloy Turbine Blade Casting
Abstract
:1. Introduction
2. Methods
2.1. Heat Transfer Model
2.2. Grain and Dendrite Growth Model
2.3. Multiscale Coupling Model
3. Results and Discussion
3.1. Simulation Parameters
3.2. Temperature and Mushy Zone Evolution
3.3. Grain Structure Evolution
3.4. Dendrite Growth
3.4.1. Two-Dimensional Dendrite Growth
3.4.2. Three-Dimensional Dendrite Growth
4. Conclusions
- (1)
- The developed multiscale model, which combined the 3D CA-FD method and phase-field method, can be used to calculate complex heat transfer processes, grain growth, and dendrite growth in superalloy directional solidification.
- (2)
- There is a larger temperature gradient and narrower mushy zone in the LMC process compared with the HRS process, while there is capacity for a larger withdrawal velocity in the LMC process. By applying varying withdrawal velocity, it is possible to obtain a flat mushy zone shape, which is favored for the growth of well-aligned grains.
- (3)
- The simulated structure of grains in HRS and LMC processes is in agreement with experimental results. The columnar grains in the starter block part in the HRS process are denser than those in the LMC process due to the better cooling effect of the water cooling copper plate.
- (4)
- Phase-field simulations have been performed to investigate the effect of solidification conditions on dendrite morphology and dendritic spacing. The simulation results were in agreement with experimental results as they both found that the dendrite morphology is coarser and the primary dendritic spacing is larger in the HRS process compared with those in the LMC process.
Author Contributions
Funding
Conflicts of Interest
References
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Parameters and Symbols | Unit | Values |
---|---|---|
Liquidus temperature, TL | K | 1672 |
Solidus temperature, TS | K | 1615 |
Thermal conductivity, λ | W·m−1·K−1 | 33.2 |
Density, ρ | kg·m−3 | 8780 |
Specific heat, cp | J·kg−1·K−1 | 773 |
Latent heat, ΔH | J·kg−1 | 9.9 × 104 |
Interface energy, σ | J·m−2 | 0.161 |
Initial concentration of X, c∞ | wt % | 39.006 |
Partition coefficient, k | – | 0.788 |
Liquidus slope, ml | K·wt %−1 | −3.95 |
Gibbs–Thomson coefficient, Γ | K·m | 3.65 × 10−7 |
Anisotropy strength, ε | – | 0.02 |
Liquid solute diffusivity, Dl | m2·s−1 | 3.6 × 10−9 |
Parameters | Unit | Values (HRS/LMC) |
---|---|---|
Temperature of the heating zone | K | 1773 |
Temperature of the cooling zone/tin bath | K | 298/523 |
Temperature of the chill | K | 298/523 |
Heat transfer coefficient between mold and tin | W·m−2·K−1 | –/4500 [11] |
Heat transfer coefficient between metal and chill | W·m−2·K−1 | 10,000 [28] |
Heat transfer coefficient between metal and mold | W·m−2·K−1 | 600 [29] |
Thermal conductivity of chill | W·m−1·K−1 | 401/14 [10] |
Thermal conductivity of mold | W·m−1·K−1 | 2.5 [11] |
Thermal conductivity of liquid tin | W·m−1·K−1 | –/34 |
Emissivity of the metal and furnace | – | 0.8 [28] |
Emissivity of the mold | – | 0.6 |
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Xu, Q.; Yang, C.; Zhang, H.; Yan, X.; Tang, N.; Liu, B. Multiscale Modeling and Simulation of Directional Solidification Process of Ni-Based Superalloy Turbine Blade Casting. Metals 2018, 8, 632. https://doi.org/10.3390/met8080632
Xu Q, Yang C, Zhang H, Yan X, Tang N, Liu B. Multiscale Modeling and Simulation of Directional Solidification Process of Ni-Based Superalloy Turbine Blade Casting. Metals. 2018; 8(8):632. https://doi.org/10.3390/met8080632
Chicago/Turabian StyleXu, Qingyan, Cong Yang, Hang Zhang, Xuewei Yan, Ning Tang, and Baicheng Liu. 2018. "Multiscale Modeling and Simulation of Directional Solidification Process of Ni-Based Superalloy Turbine Blade Casting" Metals 8, no. 8: 632. https://doi.org/10.3390/met8080632