A comprehensive understanding of grain selection in spiral grain selector during directional solidification

It is of great importance to further investigate grain selection mechanism for the production of single crystal(SX) turbine blade because a single crystal with optimized crystal orientation will enhance service performance of the blade severely.In this paper,single crystals with different deviation angles,i.e.6°,12° and 29°, were obtained using directional solidification under the same casting conditions.It has been found that the grain selection in spiral selector is a coupling process where high order dendrites branch in the front side and primary dendrites disappear in the back side based on the metallographic analysis and electron back scatter diffraction(EBSD).Considering the development of liquid/solid interface by numerical simulation,a combination effect with space expansion,geometrical restriction and grain competition was proposed for spiral grain selection.The space expansion mechanism dominates the process as it provides growth space and driving force for high order dendrites advancing.Thereby,the smaller the take-off angle(θ) is,the larger space and the stronger driving force high order dendrites will get,and the higher efficient the selector will be. The competitive growth between the secondary dendrites plays more contribution than that of primary dendrites,i.e.grain with preferred secondary dendrites instead of preferred primary dendrites could outcompete during grain selection,and this is the reason why spiral grain selector cannot optimize the orientation of the primary dendrites.These findings provide experimental evidence for spatial control of SX growth,and benefit the sophistic casting fields such as turbine blade casting for improved yield.

Influence of spiral crystal selector on crystal orientation of single crystal superalloy

To increase efficiency and improve performance, reducing cost and emissions, advanced single crystal Ni-based superalloys are required in aerospace propulsion and power generating gas turbines. With the development of alloy, significant improvements in casting techniques have been achieved by introducing the directionally solidified （DS） casting process followed by single crystal （SX） technique. The deviation of preferred orientation of single crystal superalloys is one of the most important defects in casting. In directional solidification equipment with high temperature gradient, single crystal specimens of DZ417G alloy were prepared successfully by the modified Bridgeman method with spiral grain selector. The orientation was investigated by means of X-ray diffraction （XRD） and electron backscattered diffraction （EBSD）.The results show that the crystal selector with a smaller angle can effectively reduce the deviation of preferred orientation.

Effects of directional solidification parameters and crystal selector on microstructure of single crystal of Ni-base superalloys

The single crystal of nickel-base super alloy is widely used for making turbine blades.The microstructure of the alloy,especially the deviation of preferred orientation of single crystal,possesses the most important effects on the mechanical properties of the blades.In this study,the single crystal ingot and blade of DZ417G alloy are prepared by means of the spiral crystal selector as well as the directional solidification method,and the effect of the parameters(i.e.,the shape of samples,the withdrawal rate)and the structure of the spiral crystal selector on the formation of single crystal and the crystal orientation are investigated.This method can prepare not only the single crystal ingot with simple shape but also the single crystal blades with the complex shape,the simple with rod-shape can form the single crystal easily with a relatively fast withdrawal rate,but the blade with complex shape requires much slower withdrawal rate to form single crystal.The length of the crystal selector almost has no effect on the crystal orientation.However,the angle of selector plays an obvious role on the orientation;the selector with a smaller angle can effectively reduce the deviation of preferred orientation;the appropriate angle of selector to obtain optimal orientation is found to be around30°and the deviation of preferred orientation is about30°for this selector.

Modes of Grain Selection in Spiral Selector during Directional Solidification of Nickel-base Superalloys

The modes of grain selection in spiral selector were investigated by both a ProCAST simulation and experimental confirmation.The results show that the efficiency of grain selection in starter block is associated with the geometry shape.At the early stage of grain selection,the optimization of grain orientation is dominated by competitive grain growth,but the optimization of grain orientation in starter block is gradually dominated by geometry shape at the later stage of grain selection.Besides,the spiral part could also optimize the orientation of the selected single crystal when the initial angle is large enough,and the single crystal selection in spiral parts with different pitch lengths and initial angles is dominated by different modes.The simulation results agree well with experimental ones.

螺旋选晶器温度场对选晶过程的影响

为了有效分析螺旋选晶器温度场梯度对其选晶效果的影响,应用ProCAST和CAFE对镍基高温单晶合金DD4在螺旋选晶器中的晶粒组织演化进行了仿真模拟。结果表明,在其选晶过程中,在激冷面产生大量晶粒生长方向随机分布的晶核,随着离激冷面距离的增加,选晶器内的晶粒组织由等轴晶转变柱状晶,最终选出一个与<001>方向一致的晶粒;从选晶器内组织演化和晶粒数量变化角度分析,中间温度梯度的选晶效果均优于其他两种温度梯度。

单晶高温合金定向凝固螺旋选晶器数值模拟与实验研究

通过Pro CAST模拟软件数值模拟了温度场对螺旋选晶器引晶段晶粒生长的影响。在模拟和实验的基础上,研究了引晶段晶粒取向、密度和尺寸的变化规律。结果表明,随着引晶段高度增加,晶粒的取向得到优化,晶粒密度减小,晶粒尺寸增大,为引晶段的高度设计提供了理论支持。从宏观和微观角度解释了螺旋选晶器螺旋段晶粒竞争生长的演化过程,为实际生产提供了理论依据。

Effect of competitive crystal growth on microstructural characteristics of directionally solidified nickel-based single crystal superalloy

Directionally solidified single crystal superalloy test bars were prepared by the spiral grain selection method.The microstructural evolution and orientation characteristics of the starter block and spiral part were studied,and the influence of the competitive growth of crystals on the microstructural characteristics was analyzed.The results show that the divergent grain groups,with small size and randomly oriented grains,appear at the bottom of the start block due to the chilling effect,which is an important area for competitive growth.As the height of the starter block increases,the primary dendrite spacing increases,and the grain density decreases;furthermore,the proportion of grains with an orientation deflection angle less than 10°gradually increases.The<001>texture gradually becomes stronger as the height of the starter block increases,which indicates that the competitive growth of crystals gradually weakens.At the initial stage of the crystal selection in the spiral part,the obstacle of adjacent grains and spiral passage is the main working mechanism.The grains located at the inner side of the front edge of the spiral passage have the growth advantage.The single crystal screening process is achieved at about two-thirds of the spiral height,and the single crystal with the orientation deviation angle of 6.7°from the casting axis is prepared.

采用快速凝固法和螺旋选晶法制备DZ417G高温合金单晶的拉伸性能研究

通过快速凝固法和螺旋选晶法制备得到DZ417G高温合金的单晶,研究了选晶器角度、单晶取向和拉伸性能之间的关系。实验结果表明:热处理之后,单晶DZ417G高温合金室温下最大拉伸强度达到1 215MPa;700℃时最大拉伸强度达到972MPa;在760℃/725MPa条件下,持久寿命达到119h。单晶的拉伸性能与其取向与(001)方向夹角的大小成反比;取向偏差越小,单晶的拉伸性能越好;当选晶器角度为30°时,获得最佳性能。

定向凝固大模组螺旋选晶器温度场演化和晶粒生长

针对高速凝固法(HRS法)定向凝固设备的现有问题,集成了中心加热系统和底部水冷散热系统,在原有HRS单晶炉基础上改进了加热冷却方式,设计了一种新型高效的大模组单晶叶片生长设备。通过商业建模软件UG和有限元模拟软件ProCAST,对新型单晶炉在定向凝固过程中,螺旋选晶器的温度场演化过程和晶粒生长行为进行了研究。结果表明,新设备显著提高了固液界面前沿的温度梯度及其稳定性,有效解决了单晶铸件生长过程中的阴影效应问题,减少了单晶叶片的铸造缺陷,提高了单晶品质和叶片合格率。

单晶高温合金螺旋选晶过程的数值模拟与实验研究 Ⅰ.引晶段

从实验及模拟角度对比研究了引晶段的晶粒密度和取向随晶粒生长高度(研究位置距试样底面的高度)的变化规律,并给出了引晶段参数的设计准则.采用EBSD晶体取向成像技术获得了引晶段截面的晶粒形貌和取向极图;采用CA-FD方法,针对单晶定向凝固过程进行数理建模与仿真,实现了凝固过程的三维宏观温度场与微观组织生长的模拟计算.从宏、微观角度解释了定向凝固过程的晶粒竞争演化行为,为引晶段设计提供理论支持.

镍基单晶高温合金螺旋选晶过程的数值模拟

采用ProCAST&CAFE模型,模拟了选晶法制备镍基单晶高温合金DD3过程中的晶粒组织演化。结果表明,选晶器引晶段的主要作用是优化晶粒取向,随着距引晶段底部距离的增加,<001>晶向与热流方向偏离角较大的晶粒逐渐被淘汰,到达距引晶段底部26 mm处时,<001>取向的晶粒与热流方向之间的夹角平均值小于10°。螺旋选晶段的主要作用是获得单一晶粒,其对晶粒的取向没有优化作用。螺旋选晶过程中,靠近螺旋通道外侧的晶粒因受到螺旋通道较强的几何阻碍逐渐失去生长空间,而靠近螺旋通道内侧的晶粒通常被选为最终的单晶。螺旋选晶段对晶粒的选择或淘汰与该晶粒在螺旋通道内所处的位置(螺旋通道的内侧或外侧)有密切关系,而与晶粒的晶体学取向没有必然联系。

镍基单晶高温合金DD3制备过程中晶粒演化和选晶行为的EBsD研究

采用选晶法在改进的Bridgman定向凝固炉上进行镍基单晶高温合金DD3定向凝固实验,研究了选晶法制备镍基单晶高温合金过程中晶粒组织演化和螺旋选晶行为,采用电子背散射衍射(EBSD)技术对晶粒的竞争过程进行分析.结果表明,选晶器引晶段的主要作用是优化晶粒取向.获得取向良好的<001>定向凝固组织.在距激冷板36.1 mm处,90%的<001>取向晶粒与轴向偏离小于10°,只有很少的晶粒取向与轴向偏离大于12°.螺旋选晶段的主要作用是确保只有一个晶粒进入型腔,在选晶段沿螺旋方向攀旋一周时就可获得单晶组织.选晶过程中,远离选晶器螺旋通道内侧的晶粒由于受到螺旋通道较强的几何约束,进而被靠近螺旋通道内侧的晶粒所淘汰.螺旋选晶器的狭窄通道对枝晶生长的阻碍作用是实现螺旋选晶的主要原因.

DD6合金选晶器定向凝固的数值模拟与实验

使用有限元数值模拟和实验方法对DD6合金选晶器定向凝固过程的温度影响、晶粒组织以及晶粒生长进行了研究。结果表明,温度场模拟与选晶器定向凝固过程的温度变化基本相符,晶粒组织生长的模拟能够反映晶粒竞争生长的实际情况,与实验试样基本一致。由于取向与温度梯度不一致晶粒的位置被取代,使得引晶段中的晶粒平均半径随着高度增加而增大,晶粒密度不断减小,两者有负指数关系。对比了螺旋段不同高度截面EBSD晶粒取向实验成像与晶粒模拟结果,组织模拟与实验结果较为吻合。通过分析螺旋通道中的晶粒竞争生长关系,位于螺旋通道内侧和上部的晶粒更具有位置优势,容易被选晶器选出。

单晶高温合金螺旋选晶器选晶行为的模拟和试验研究

通过试验和模拟的方法分析了选晶器引晶段的晶粒组织演化规律和不同情况下等温线的形态分布,以及倾斜等温线下晶粒竞争生长的过程,同时研究了螺旋段的选晶行为。结果表明,引晶段的不同高度具有不同的组织形态,引晶段主要靠晶粒间的竞争生长作用优化晶粒取向,不同形态的等温线下晶粒的优先生长方向不同。螺旋段主要靠螺旋通道对枝晶生长的几何约束选择晶粒,确保只有一个晶粒进入型腔生长成为单晶组织。

抽拉速率对螺旋选晶器选晶行为和晶体取向演变的影响

采用宏观-微观耦合的元胞自动机(CAFE)方法,研究了不同抽拉速率对螺旋选晶器的选晶行为和晶体取向演变的影响,并通过实验对仿真结果进行了验证。结果表明:在相同的抽拉速率下,随着与激冷面距离的增大,枝晶数目逐渐减少,一次枝晶臂间距逐渐增大。随着抽拉速度由2 mm/min增加到8 mm/min,一次枝晶臂间距逐渐减小,枝晶茎数增加,枝晶间距逐渐减小,枝晶组织逐渐细化。在模拟过程中,在螺旋选择器启动块的3种抽拉速率下,固态组织的数量、面积和颜色都是相似的;在螺旋部分,在5 mm/min提取速率下晶体的微结构数量比其他2个提取速率下的少,并且面积更大,颜色更浅。从选晶器的晶粒组织演变和金相组织分析结果可以得出,中等抽拉速率(5 mm/min)下选晶器的选晶效率优于其他2种抽拉速率。

定向凝固镍基单晶高温合金螺旋选晶过程显微组织与晶体的生长

采用选晶法制备DD4单晶高温合金试棒,研究引晶段和选晶段显微组织演变及晶体竞争生长过程。结果表明,随着引晶段高度增加,一次枝晶间距增加,晶粒密度显著降低,<001>织构增强。引晶段高度在20mm时,初始晶粒取向偏转角均小于10°,且最终约有35个明显尺寸且取向良好的晶粒进入螺旋段。位于螺旋通道内侧的晶粒,在螺旋选晶过程中最容易被选出。在约1/3螺旋高度处实现了单晶的筛选过程,制备出<001>生长方向与铸件轴向约8.9°偏差角的单晶体。