Heat-Resistant Casting Dendrite Orientation for Turbocharger Caulking
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Solution Overview
Problem
Existing heat resistant castings for turbochargers face challenges with poor plastic deformation characteristics, leading to undesired deformation or cracking during caulking processes, which require large plastic deformation.
Innovation Solution
A heat resistant casting with an axial portion containing dendrites structured to have an average angle between the direction perpendicular to the central axis and the main axes of the dendrites within a range of 20 degrees, enhancing the plastic deformation characteristic and enabling improved joining strength through caulking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat resistant casting is installed by plastic processing such as caulking, then the body characteristic is less affected, but the heat resistant casting has poor plastic deformation characteristic and does not deform uniformly, causing undesired deformation or a crack
Solution Approach 1:
The invention applies local quality by creating a specific dendrite structure configuration in the axial portion of the heat resistant casting. The dendrites are oriented at a controlled angle (10-30 degrees) relative to the axial direction, creating a localized structural characteristic in the axial portion that differs from the rest of the casting. This local structural modification enables uniform plastic deformation during caulking while maintaining the overall heat resistant properties of the casting.
2Strength
If heat resistant casting is incorporated into the body by welding, then the joining is achieved, but the body may cause distortion due to local heating or cooling, or the heat resistant casting or the body may be affected by heat
Solution Approach 1:
The invention replaces the thermal joining method (welding) with a mechanical joining method (plastic deformation through caulking). By controlling the dendrite structure in the axial portion, the material becomes suitable for plastic deformation, allowing the axial portion to be joined to the body through caulking instead of welding. This substitution eliminates the harmful thermal effects of welding while achieving strong mechanical joining.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The heat resistant casting effectively prevents undesired deformation or cracking during caulking, achieving uniform deformation and increased joining strength, making it suitable for high-temperature applications like turbocharger nozzle vanes.
Implementation Method 1
dendrites in a structure of a region of an axial portion that is subjected to plastic processing, the dendrites having an average angle between a direction perpendicular to a central axis of the axial portion and main axes of the dendrites in a range of 20 degrees
Implementation Method 2
the heat resistant casting of the embodiment has a larger deformation in the region having an excellent plastic processing characteristic, compared to a conventional heat resistant casting, when processing such as caulking that accompanies a large plastic deformation
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A heat resistant casting having an axial portion includes dendrites in a structure of a region of the axial portion subjected to plastic processing. The dendrites have an average angle between a direction perpendicular to a central axis of the axial portion and main axes of the dendrites in a range of 20 degrees.