Heating Block for Casting Continuator Under-Cooling
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Solution Overview
Problem
In crystallographically oriented casting for gas turbine blades, the continuator often experiences under-cooling, leading to the restriction of single crystal growth and the formation of high angle boundaries, which reduces the strength of the blade at high temperatures.
Innovation Solution
A system and method that includes a heating block to absorb heat from a furnace and apply localized heating to the continuator, ensuring it cools at the same rate as the mould and preventing under-cooling, thereby promoting single crystal growth at the same angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a continuator is used to communicate the tip shroud region to the root region by bypassing the aerofoil region, then the single crystal grain angle is maintained throughout the component, but the continuator experiences under-cooling that freezes off the alloy and restricts single crystal growth
Solution Approach 1:
A heating block is positioned adjacent to the continuator to provide localized heating specifically to the continuator region. This creates a non-uniform temperature distribution where the continuator is heated differently from the rest of the mould, preventing under-cooling and alloy freeze-off while maintaining the desired single crystal grain angle consistency throughout the component.
2Strength
If the continuator cools at a faster rate than the mould, then solidification occurs, but high angle boundaries form where the continuator joins the mould, reducing blade strength
Solution Approach 1:
The heating block provides localized thermal treatment specifically to the continuator and its junction regions with the mould. This controlled local heating prevents the formation of high angle boundaries by maintaining appropriate cooling rates at the continuator-mould interfaces, thereby preserving blade strength while still achieving solidification.
Solution Approach 2:
The heating block is positioned in advance adjacent to the continuator before casting begins. This preliminary arrangement ensures that when molten alloy is introduced, the continuator is already in the correct thermal state to prevent under-cooling and high angle boundary formation, proactively avoiding strength reduction issues.
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 solution enhances the growth of single crystals at the same angle, preventing the formation of high angle boundaries and increasing the strength of the component, especially at high temperatures, making it more resistant to creep or distortion.
Implementation Method 1
a heating block disposed adjacent to the seed holder and extending towards the continuator. The heating block is configured to heat the continuator by absorbing heat from the furnace
Implementation Method 2
a furnace configured to heat the mould
Implementation Method 3
The cavity is configured to receive a molten castable material therein
Data Source
AI summary
A system for casting a component. The system includes a base, a seed holder extending from the base and configured to receive a seed crystal therein. The system further includes a mould for casting the component. The mould includes a first end region, a second end region, and a principle portion extending between the first end region and the second end region. The system further includes a continuator fluidly communicating the first end region with the second end region by bypassing the principle portion. The system further includes a furnace configured to heat the mould. The system further includes a heating block disposed adjacent to the seed holder and extending towards the continuator.