Introduction to Investment casting and Turbine Blade.pptx

**Introduction to Investment Casting:**

Investment casting, also known as lost-wax casting, is a precision manufacturing process used to create intricate metal components. It involves creating a wax pattern, coating it in ceramic, melting the wax to form a mold, and then pouring molten metal to produce the final part.

**Turbine Blade:**

Turbine blades are vital components in gas turbines, jet engines, and steam turbines. They efficiently extract energy from moving fluids, converting it into mechanical power. Designed to withstand high temperatures and forces, turbine blades are essential for aviation propulsion and power generation in gas and steam plants.

1. Department : Metallurgy Engineering Subject : Metallurgical Operations Seminar TITLE: ( 1) INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE Name : Aditya Shende (220133121023) Yash Shinde (220133121025) GOVERNMENT ENGINEERING COLLEGE Sector-28, GANDHINAGAR GUIDED BY : DR. I B DAVE PROF. D.V. MAHANT

2. Contents Introduction to Casting History Casting Introduction to Investment casting Applications Introduction to Turbine blade Turbine blade filling simulation Turbine blade and Terminology Performance Requirement of Turbine blade Structure of Turbine blade Advantages of investment casting Reasons of not using shell moulding and die casting for making turbine blades Summary Reference 11-09-2023 INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE 2

3. Introduction to casting CASTING[ 1 ] is the process in which molten metal flows by gravity or other force into a patterned mold and solidifies in the shape of the mold cavity. The part produced is called as casting. There are five steps in casting process : Pattern making. Molding. Melting and pouring. Fettling or shakeout. Heat treatment (if needed), finishing and inspection (testing). 11-09-2023 3 INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE

4. History of casting Fig 1 : History Of casting 11-09-2023 4 INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE It was in the eighth century B.C. fist cast iron was first made by the Chinese, but it was not until the invention of the blast furnace by the Europeans in the 14th century, however, that large quantities of cast iron were produced. Interestingly enough, according to the 39th census of world casting production 2004, China was the leader in casting produc - tion worldwide

5. Investment casting Fig 2 : Investment casting Fig 3 : Investment casting process Investment casting [ 2 ] is a manufacturing process in which a wax pattern is coated with a refractory ceramic material. Once the ceramic coating material is dry and hardened, the wax is melted out and leaves an internal cavity the shape of the final product's geometry. [ 3 ] 11-09-2023 5 INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE

6. Applications Energy:  The energy sector has a very specific use for this manufacturing technique. Wind turbine blades are huge, weigh tons, and require superior strength and surface finish. This combination of qualities is an advantage of this method.[ 1 ] Marine:  Investment casting of metal parts is common in the marine industry. Strong, corrosion-resistant metallic panels for ships and submarines are manufactured with special alloys. Since this method is compatible with numerous metal alloys, it is well suitable for this application. Aerospace:  This technique can manufacture  c rucial parts in aircraft engines and bodies owing to the requirements of complex geometries and strength.[ 4 ] Medical:  The ability to cast small parts with a superior surface finish puts this method at an advantage in the medical industry. Prosthetics, implants, and surgical equipment are some standard applications. Automotive : In the automotive industry, high-performance parts like drive train components, rocker arms, and power train elements are made. 11-09-2023 6 INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE

7. Introduction to Turbine blade A turbine blade is a specialized component used in turbines, such as steam turbines, gas turbines, or wind turbines, designed to capture the energy of a flowing fluid (such as steam, gas, or wind) and convert it into rotational mechanical energy.[ 5 ] These blades are typically aerodynamically shaped and made from materials capable of withstanding high temperatures and mechanical stress, enabling them to efficiently extract energy from the fluid and drive the turbine's rotation. Fig 4: Turbine Blade 11-09-2023 7 INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE

8. Turbine blade filling simulation 11-09-2023 INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE 8

9. Turbine blade and Terminology 11-09-2023 INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE 9

10. Performance Requirement of turbine blade Complex cooling structure : Cooling structure, aiming at reducing the operating temperature of components, is one of the most crucial measures to improve the reliability of turbine components working at high temperature. Advanced Grain structure: Thermal stress and strain caused by the uneven internal temperature or constrained expansion of the components under high temperature will have an adverse effect on the operation of the aero-engine. A rapid increase of thermal stress in a short time can lead the components to crack, and repeated impact of thermal stress and deformation can result in the destruction of components. A typical cyclic loading process is the process of the engine’s starting, accelerating, decelerating, and stopping.[ 6 ] Superalloys : The material of turbine blade should maintain reliable working under high temperature, which requires enough high temperature strength, good thermal stability, and corrosion resistance of the material. Materials commonly used is cobalt-based alloy, iron-based alloy. When the temperature is below 700- 800 °C, nickel-based super alloy. [ 6 ] 11-09-2023 10 INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE

11. Structure of Turbine blade Generally, the external part of blade in high-performance turbine consists of platform, blade body, and fir tree root.[ 6 ] The internal structure consists of pin fin, longitudinal rib, transverse rib, film hole, etc., to enhance the heat transfer and improve the heat-resisting performance of the combustion. The structures of turbine blades are shown in Fig Fig 5 : Illustration of turbine blade 11-09-2023 11 INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE

12. Investment casting Advantages [ 7 ] Flexible Design Superior Surface Finish  Less Casting Defects, Improve quality Tighter Tolerances, Closer Net Shapes Customizable size and No Quantity Limitation Disadvantages Longer Casting Cycles Quite Expensive Labour Intensive Difficult to Cast Cores 11-09-2023 12 INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE

13. Shell Moulding Shell molding is a variation of sand casting that uses a resin-coated sand mixture to create molds. It can be used for turbine blade production but is less common compared to investment casting. Disadvantages : - May not be as precise as investment casting for highly complex blade designs. Limited to certain materials. Reasons of not using shell moulding and die casting for making turbine blades [ 8 ] Die Casting Die casting is commonly used for high-volume production of parts with simpler geometries. It involves injecting molten metal into a mold cavity under high pressure. While die casting can produce parts quickly and economically, it is generally not the preferred method for turbine blades due to the complexity of blade shapes and the need for high-temperature materials. Disadvantages: - Limited to simpler part geometries. Not suitable for high-temperature alloys often used in turbine blades. Potential for porosity in the casting. 11-09-2023 13 INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE

14. Summary Turbine blades are commonly manufactured through investment casting, which offers precision and complexity for high-performance designs, including single-crystal blades. Shell molding is avoided due to limitations in achieving intricate geometries, while die casting is unsuitable because of its inability to create the necessary cooling passages and precise airfoil profiles, along with concerns about rapid cooling affecting material properties. Investment casting remains the preferred choice for its ability to produce intricate, high-quality turbine blades tailored for demanding applications. 11-09-2023 14 INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE

15. Reference O.P. Khanna , "A Text Book of Foundry Technology", Dhanpat Rai & Sons, 15th Edition, 2011. Peter Beeley “Foundry Technology” A division of Reed Educational and Professional Publishing Ltd 2nd Edition https://www.google.com/url?sa=i&url=https%3A%2F%2Fmakeagif.com%2 Fgif%2Finves tmentcastinganimation43TiKM&psig=AOvVaw34ATeiGKYDrYxuSQLPzNC&ust=1693226282097000&source=images&cd=vfe&opi=89978449&ved=0CBAQjRxqFwoTCNjhpMvt_IADFQAAAAAdAAAAABAD (Access on 27 August 2023 18:15 PM ) P.N. Rao , "Manufacturing Technology", TMH, 5th Edition,2013. Liu DX, Chen G et al (2003) Aero-engine: the heart of airplane. Aviation Industry Press,Beijing  (in Chinese) Turbine blade investment casting die technology by Dinghua Zhang, Yunyong cheng , Ruisong jiang , Neng wan published by national defence industry press. https://www.sunrise-metal.com/advantages-and-disadvantages-of-investment-casting/ (Access on 27 August 2023 18:37 PM ) CHAT GPT (Access on 27 August 2023 19:03 PM ) 11-09-2023 15 INTRODUCTION OF INVESTMENT CASTING AND TURBINE BLADE