Overview
Reduction of the fuel consumption and emission of nitrous oxide by jet engines is a priority of the EU ACARE SRA 2020 objectives. The development of an environmentally friendly aircraft engine considers using lightweight and efficient turbine components. It will have great impact on reduction of pollution and fuel consumption.
The aim of the project was to establish and improve castability and weldability of HAYNES® 282 alloy which is enabler material for manufacturing a lightweight turbine exhaust case with higher work temperature in comparison with the actual fabrication based on IN718 alloy. Two approaches were considered to abate the castability and weldability problems of cast wrought nickel alloys – by modifying: a) chemistry of the alloy and b) casting and welding process parameters. In order to improve castability and weldability for HAYNES® 282 – an enabler for turbine exhaust case, the following objectives had been defined:
- Development of numerical simulator of casting process to support the experimental activities and support interpretation of the experimental results;
- Experimental studies of castability limit parameters for HAYNES® 282 alloy;
- Development of the casting process technology challenging the limitation of the minimum wall thickness of 2 mm;
- Optimising the casting process parameters and post casting heat treatment for improving the weldability of the cast parts;
- Demonstration of the capacity of the developed technology by casting a component.
The project consisted of a 24-month duration and is structured in 5 technical WPs and 1 addressing management and coordination activities, perfectly linked with the concept of project (modelling, fundamental research and industrial trials).
The consortium consists of engine manufacturer (WSKRZ) and 2 technical universities (WUT and RUT). Such a structured consortium provided complex expertise abilities of designing, modelling and experimental trial possibilities on the industrial scale.
Funding
Results
Executive Summary:
The aim of the HITECAST project was to establish castability and weldability limits of Alloy B which is an enabler material for manufacturing a lightweight turbine components with higher work temperature in comparison with the currently fabricated based on IN718 alloy. The 24-months project was structured in 5 technical work packages and one addressing management and coordination. The consortium consisted of jet engines manufacturer (WSKRZ) and two technical universities (WUT and RUT).
The main objectives of the HITECAST project were:
- Designing 3D geometrical models of samples, runners elements, dies and turbine component for computational simulation and for performing wax assembles elements dies for wax injection technique.
- Preparation of thermal properties data base for materials used in the numerical modeling of casting process (Alloy B, shell moulds and shell raping insulator material)
- Castability numerical modeling via ProCast software as function of: alloy capacity, alloy chemical composition, melting, casting and shell temperature, geometry of runners system, thickness of cast section, pouring profile, shell mould material, number of shell coats, filtering system
- Numerical modeling of EX structure in cast made in AlloyB
- Optimization of wax patterns and wax assembles geometry for demo parts castings
- Optimization of shell mould systems for investment process of manufacturing turbine demo parts castings
- Optimization of investment casting parameters for Alloy B in context of manufacturing demo parts castings
- Establishment and improvement of castability for Alloy B – defining critical wall thickness of casts
- Optimization of heat treatment conditions for as cast Alloy B
- Casting of ten demo parts per drawing with required quality
- High temperature characteristics of AlloyB by Gleeble metallurgical simulator
- Optimization of welding parameters like: preparation method, type of welding torch, type of torch nozzle, type of shielding method, welding current and filler material in context of repairing welding of turbine demo parts castings
- Casting of ten demo parts per drawing with required quality
In view of the obtained results, it can be concluded that Alloy B was a good candidate for casting and welding of large and thin-walled elements of aero engine components. All objectives, deliverables and milestones predicted in the Annex 1 of GA nr 296250 during HITECAST project duration had been fulfilled.