PRECISION CASTING CONTROL of INTERNAL PROPERTIES

Purpose and goal

The purpose was to develop a simulation driven model where the properties regarding microstructure and distortions can be predicted and controlled to enable lighter components for a shorter development time. The simulation model was demonstrated with good results. The project showed that the use of the simulation model provides all the prerequisites for being able to manufacture 15% lighter precision cast components at a 25% shorter development time by being able to predict the component´s properties in advance.

Expected results and effects

The project has strengthened the possibility of establishing a Swedish value chain for the manufacture of aircraft engine components. Several parts of the value chain have been working close together with the development of advanced simulation models for predicting microstructure and shape compensation of distortions. In the short term, the results mean increased competitiveness and a stronger offer for both system suppliers (GKN), manufacturers (TPC) and software suppliers (NovaCast), while the longer-term effects are mainly by reduced CO2 emissions in the aero industry.

Planned approach and implementation

The simulation model developed in the project was based on collected data in a real production environment. The method allowed validation of temperature in both shells and in metal during vacuum casting. The experimental results for a simple geometry were used to develop boundary conditions for the thermal model, which then formed the basis for microstructure simulation, shape compensation and the development of all controlling parameters. These were then used on a demonstrator with good results. The implementation of the project is considered satisfactory.