Casting technology for lightweight components for environmentally friendly aero engines&gasturbines

Purpose and goal

The aim of this work was to develop a casting process for industrialization of thin walled turbine components. Thais is a strategic technology required for manufacture lighter weight jet engines that are more environmentally friendly. Through the technical results of this work TPC has succeded in tailoring a casting process to enable manufactrue of thinner walled airfoil components for turbines. These results are directly applicable to manufacture of parts for jet engines.

Results and expected effects

This work has equipped TPC with the capability to cast complex thin walled structures. Deliverable results include development of a simulation tool trimmed to predict solidification behavior in thin structures as well as a casting process tailored to produce thin structures. The results from the study were directly industrialized and used to produce thin walled components with complex geometries for industrial gas turbines.

Approach and implementation

The work included identify important material properties and process parameters crucial to produce thin, complex components and thus develop new process technology. Initially a literature survey was done to acquire relevant thermodynamic material properties to create a reliable simulation tool. Then a study was performed to identify parameters critical increasing fluidity and thereby castability of thin sections. A series of casting trials were performed to trim the simulation model. These results were then used to industrialize new thin-walled components for gas turbines.