A novel configuration for single-crystal superalloy hollow blade manufacturing based on shell/core integral mold
Shell/core integral mold fabricated by additive manufacturing possess high shell/core bonding strength, which is promising to improve the dimensional accuracy and integrity of single-crystal (SX) hollow blade while improving the manufacturing efficiency. In this study, a novel inverted configuration...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-03-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425001309 |
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| author | Binqiang Wang Zhexu Li Kun Bu Zhongliang Lu Jiawei Zhang Sheng Mou Shengjie Ren Haoyu Zhao |
| author_facet | Binqiang Wang Zhexu Li Kun Bu Zhongliang Lu Jiawei Zhang Sheng Mou Shengjie Ren Haoyu Zhao |
| author_sort | Binqiang Wang |
| collection | DOAJ |
| description | Shell/core integral mold fabricated by additive manufacturing possess high shell/core bonding strength, which is promising to improve the dimensional accuracy and integrity of single-crystal (SX) hollow blade while improving the manufacturing efficiency. In this study, a novel inverted configuration of SX hollow blade was proposed based on shell/core integral mold, resulting in a 55 mm reduction of platform height compared to the upright configuration. Temperature field, microstructure, stress and displacement field were simulated using finite element method, showcasing the superiority of the inverted blade. Compared to the upright blade, the inverted blade exhibited nearly flat liquidus isotherm, of which undercooling was decreased while thermal gradient of platform was increased, leading to the successful attainment of a SX. Stress and displacement distribution for two configurations of SX hollow blade were extremely similar under constraints removal condition, therefore, blade configuration doesn't greatly affect stress and displacement field of SX hollow blade. The formability and integrity of SX hollow blade, [001] orientation controlled by substrate stimulating technique were verified by directional solidification experiment. This work provides a new strategy for SX hollow blade manufacturing. |
| format | Article |
| id | doaj-art-c67aef3fd31041a99429bd1b3b9aab92 |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-03-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-c67aef3fd31041a99429bd1b3b9aab922025-01-24T04:45:18ZengElsevierJournal of Materials Research and Technology2238-78542025-03-013516291640A novel configuration for single-crystal superalloy hollow blade manufacturing based on shell/core integral moldBinqiang Wang0Zhexu Li1Kun Bu2Zhongliang Lu3Jiawei Zhang4Sheng Mou5Shengjie Ren6Haoyu Zhao7Key Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an, 710072, China; Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, Northwestern Polytechnical University, Xi'an, 710072, ChinaKey Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an, 710072, China; Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, Northwestern Polytechnical University, Xi'an, 710072, ChinaKey Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an, 710072, China; Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, Northwestern Polytechnical University, Xi'an, 710072, China; Corresponding author. Key Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an, 710072, China.State Key Laboratory for Manufacturing Systems Engineering, School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an, 710049, ChinaState Key Laboratory for Manufacturing Systems Engineering, School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an, 710049, ChinaKey Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an, 710072, China; Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, Northwestern Polytechnical University, Xi'an, 710072, ChinaKey Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an, 710072, China; Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, Northwestern Polytechnical University, Xi'an, 710072, ChinaKey Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an, 710072, China; Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, Northwestern Polytechnical University, Xi'an, 710072, ChinaShell/core integral mold fabricated by additive manufacturing possess high shell/core bonding strength, which is promising to improve the dimensional accuracy and integrity of single-crystal (SX) hollow blade while improving the manufacturing efficiency. In this study, a novel inverted configuration of SX hollow blade was proposed based on shell/core integral mold, resulting in a 55 mm reduction of platform height compared to the upright configuration. Temperature field, microstructure, stress and displacement field were simulated using finite element method, showcasing the superiority of the inverted blade. Compared to the upright blade, the inverted blade exhibited nearly flat liquidus isotherm, of which undercooling was decreased while thermal gradient of platform was increased, leading to the successful attainment of a SX. Stress and displacement distribution for two configurations of SX hollow blade were extremely similar under constraints removal condition, therefore, blade configuration doesn't greatly affect stress and displacement field of SX hollow blade. The formability and integrity of SX hollow blade, [001] orientation controlled by substrate stimulating technique were verified by directional solidification experiment. This work provides a new strategy for SX hollow blade manufacturing.http://www.sciencedirect.com/science/article/pii/S2238785425001309Single-crystal hollow bladeDimensional accuracyStray grainFinite element methodDirectional solidification |
| spellingShingle | Binqiang Wang Zhexu Li Kun Bu Zhongliang Lu Jiawei Zhang Sheng Mou Shengjie Ren Haoyu Zhao A novel configuration for single-crystal superalloy hollow blade manufacturing based on shell/core integral mold Journal of Materials Research and Technology Single-crystal hollow blade Dimensional accuracy Stray grain Finite element method Directional solidification |
| title | A novel configuration for single-crystal superalloy hollow blade manufacturing based on shell/core integral mold |
| title_full | A novel configuration for single-crystal superalloy hollow blade manufacturing based on shell/core integral mold |
| title_fullStr | A novel configuration for single-crystal superalloy hollow blade manufacturing based on shell/core integral mold |
| title_full_unstemmed | A novel configuration for single-crystal superalloy hollow blade manufacturing based on shell/core integral mold |
| title_short | A novel configuration for single-crystal superalloy hollow blade manufacturing based on shell/core integral mold |
| title_sort | novel configuration for single crystal superalloy hollow blade manufacturing based on shell core integral mold |
| topic | Single-crystal hollow blade Dimensional accuracy Stray grain Finite element method Directional solidification |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425001309 |
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