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1

An Attempt to Use Various Metallurgical Slags in the Modification Processes of Casting Alloys

Sitko Jacek

Archives of Metallurgy and Materials

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2021

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Vol. 66, iss. 4

1067--1074

EN

The paper presents preliminary results of research on the use of certain smelting slags in the process of modification of casting alloys, leading to a change in the structure of these alloys and improvement of their mechanical and operational properties. The positive effect of ground copper slag with a fraction below 0.1 mm on the effect of modifying the hypoeutectic silumin AlSi7Mg towards changing the morphology of coarse-grained eutectic to fine-dispersive was demonstrated. The modifying effect also applies to the pre-eutectic α phase and results in the formation of additional crystallization sites (nucleation process), which was demonstrated by the thermal ATD solidification analysis, showing an increase in the temperature Tliq and TE max. The positive and noticeable influence of the mixture of copper and steel slag on the surface modifying effect of fragmentation of the structure was demonstrated in casting nickel superalloy IN-713C. Based on the results of research conducted so far on the modifying effect of cobalt aluminate, a hypothetical model of the impact of reduced metallic components of the applied metallurgical slags on the nucleation process and shaping of the microstructure of nickel alloys was developed.

2

Influence of Modification and Casting Technology on Structure of IN-713C Superalloy Castings

Binczyk F., Cwajna J., Gradoń P., Mańka M.

Archives of Foundry Engineering

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2016

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Vol. 16, iss. 3

11--14

EN

The paper presents the results concerning impact of modification (volume and surface techniques), pouring temperature and mould temperature on stereological parameters of macrostructure in IN713C castings made using post-production scrap. The ability to adjust the grain size is one of the main issues in the manufacturing of different nickel superalloy castings used in aircraft engines. By increasing the grain size one can increase the mechanical properties, like diffusion creep resistance, in higher temperatures. The fine grained castings. on the other hand, have higher mechanical properties in lower temperatures and higher resistance to thermal fatigue. The test moulds used in this study, supplied by Pratt and Whitney Rzeszow, are ordinarily used to cast the samples for tensile stress testing. Volume modification was carried out using the patented filter containing cobalt aluminate. The macrostructure was described using the number of grains per mm2, mean grain surface area and shape index. Obtained results show strong relationship between the modification technique, pouring temperature and grain size. There was no significant impact of mould temperature on macrostructure.

3

The Effect of Temperature on the Result of Complex Modification of IN-713C Superalloy Castings

Binczyk F., Gradoń P., Mańka M., Findziński R.

Archives of Foundry Engineering

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2015

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Vol. 15, iss. 4

13--16

EN

The paper presents the results of research on the determination of the effect of pouring temperature on the macrostructure of the castings subjected to complex (surface and volume) modification and double filtration. Tested castings were made of post-production scrap (gating system parts) of IN-713C superalloy. Tests included the evaluation of the number of grains per 1 mm2, mean grain surface area, shape factor and tensile strength. Casting temperature below 1470 °C positively influenced the modification effect. The grains were finer and the mechanical properties increased, especially for castings with thicker walls. On the other hand, manufacture of thin walled castings of high quality require pouring temperature above 1480 °C.

4

Surface Modification of Cored, Thin Walled Castings of Nickel Superalloy IN-713C

Binczyk F., Cwajna J., Gradoń P., Mańka M., Findziński R.

Archives of Foundry Engineering

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2015

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Vol. 15, iss. 3

17--20

EN

In current casting technology of cored, thin walled castings, the modifying coating is applied on the surface of wax pattern and, after the removal of the wax, is transferred to inner mould surface. This way the modification leading to grain refinement occur on the surface of the casting. In thin walled castings the modification effect can also be seen on the other (external) side of the casting. Proper reproduction of details in thin walled castings require high pouring temperature which intensify the chemical reactions on the mould – molten metal interface. This may lead to degradation of the surface of the castings. The core modification process is thought to circumvent this problem. The modifying coating is applied to the surface of the core. The degradation of internal surface of the casting is less relevant. The most important factor in this technology is “trough” modification – obtaining fine grained structure on the surface opposite to the surface reproduced by the core.

5

Surface modification and its influence on the microstructure and creep resistance of nickel based superalloy René 77

Zielińska M., Sieniawski J.

Archives of Metallurgy and Materials

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2013

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Vol. 58, iss. 1

95-98

EN

Superalloy René 77 is very wide used for turbine blades, turbine disks of aircraft engines which work up to 1050°C. These elements are generally produced by the investment casting method. Turbine blades produced by conventional precision casting methods have coarse and inhomogeneous grain structure. Such a material often does not fulfil basic requirements, which concern mechanical properties for the stuff used in aeronautical engineering. The incorporation of controlled grain size improved mechanical properties. This control of grain size in the casting operation was accomplished by the control of processing parameters such as casting temperature, mould preheating temperature, and the use of grain nucleates in the face of the mould. For nickel and cobalt based superalloys, it was found that cobalt aluminate (CoAl2O4) has the best nucleating effect. The objective of this work was to determine the influence of the inoculant’s content (cobalt aluminate) in the surface layer of the ceramic mould on the microstructure and mechanical properties at high temperature of nickel based superalloy René 77. For this purpose, the ceramic moulds were made with different concentration of cobalt aluminate in the primary slurry was from 0 to 10% mass. in zirconium flour. Stepped and cylindrical samples were casted for microstructure and mechanical examinations. The average grain size of the matrix ( phase), was determined on the stepped samples. The influence of surface modification on the grain size of up to section thickness was considered. The microstructure investigations with the use of light microscopy and scanning electron microscopy (SEM) enable to examine the influence of the surface modification on the morphology of ’ phase and carbides precipitations. Verification of the influence of CoAl2O4 on the mechanical properties of castings were investigated on the basis of results obtained form creep tests.

PL

Odlewy wykonane z nadstopu Rene 77 przeznaczone są na elementy części gorącej silników lotniczych (łopatki, tarcze wirnika turbiny). Odlewy tych elementów wytwarzane są najczęściej metodą wytapianych modeli. Łopatki turbin wytwarzane metodami konwencjonalnego odlewania precyzyjnego charakteryzują się gruboziarnistą i niejednorodną mikrostrukturą. Często więc materiał odlewu nie spełnia podstawowych wymagań dotyczących właściwosśi mechanicznych materiałów stosowanych w technice lotniczej. Poprawe jakości łopatek nadstopów niklu uzyskano poprzez kształtowanie rozmiarów ziarna podczas odlewania. Kontrole rozmiaru ziarn osiągnięto w wyniku zastosowania odpowiedniej temperatury zalewania, temperatury formy oraz modyfikacji składu chemicznego warstwy wierzchniej formy ceramicznej. Dla nadstopów na osnowie niklu najlepsze efekty rozdrobnienia ziarna uzyskano stosując glinian kobaltu (CoAl2O4). Celem pracy było okreslenie wpływu zawartoąci modyfikatora (glinianu kobaltu) w warstwie wierzchniej formy ceramicznej na mikrostrukturę i właściwości wytrzymałościowe w podwyższonej temperaturze odlewów wykonanych z nadstopu niklu Rene 77. W tym celu wykonano formy ceramiczne różniące się zawartością glinianu kobaltu w warstwie wierzchniej formy ceramicznej, która wynosiła 0, 5 i 10%mas. Odlano próbki schodkowe do oceny oddziaływania modyfikatora na mikrostrukture oraz stożkowe do badan wytrzymałościowych. Wyznaczono średnie pole powierzchni płaskiego przekroju ziarna (faza ) na przekrojach poszczególnych schodków. Uwzględniono również wpływ oddziaływania modyfikatora na rozmiar ziarn w zależności od grubości odlewu (wysokosc schodka). Badania mikrostruktury przy użyciu mikroskopu swietlnego i elektronowego skaningowego (SEM) umozliwiły okreslenie wpływu modyfikacji powierzchniowej na morfologie fazy ' i węglików. Ocenę wpływu modyfikacji powierzchniowej na właściwości wytrzymałościowe w warstwie wierzchniej odlewu w podwyższonej temperaturze wyznaczono w próbie przyspieszonego pełzania.

6

Surface modification, microstructure and mechanical properties of investment cast superalloy

Zielińska M., Kubiak K., Sieniawski J.

Journal of Achievements in Materials and Manufacturing Engineering

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2009

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Vol. 35, nr 1

55-62

EN

Purpose: The aim of this work is to determine physical and chemical properties of cobalt aluminate (CoAl2O4) modifiers produced by different companies and the influence of different types of modifiers on the grain size, the microstructure and mechanical properties of high temperature creep resisting superalloy René 77. Design/methodology/approach: The first stage of the research work took over the investigations of physical and chemical properties of cobalt aluminate manufactured by three different companies: Remet, Mason Color and Permedia Lublin. There were determined the grain size distribution of cobalt aluminate powder, the average diameter of the powder particles, phase composition, cobalt contamination. In the next step, the ceramic moulds were made with different kind of cobalt aluminate (Mason Color, Remet, Permedia Lublin) and its concentration (0.5%) in the primary slurry. The samples of stepped and cylindrical shape were poured in the ceramic moulds prepared earlier. The average grain size of the . phase, was determined on the stepped samples. The microstructure investigations let to examine the influence of the surface modification on the morphology of . ‘ - phase and carbides precipitations. Samples were turned from cylindrical castings for mechanical properties investigations: creep tests. Findings: Modification of the face coat of ceramic mould results in the reduction of the grains size of . matrix and disintegration of carbide precipitates. It results in the improvement of mechanical properties of the alloy. On the grounds of the obtained results, it was found that the type of used modifier influenced the grain size of the alloy and its mechanical properties. Research limitations/implications: The established physical and chemical properties of modifier let to get better control of grain size of the castings and their quality what will result in decrease of defective products. Originality/value: It was proved that the effectiveness of cobalt aluminate modifier as an inoculant depends not only on its concentration in ceramic slurry but on its chemical composition. The researches allowed to find the optimal concentration of Co in CoAl2O4 to produce casting elements made from superalloy René 77.

7

Criterion for selection the optimal physical and chemical properties of cobalt aluminate powder used in investment casting process

Zielińska M., Sieniawski J., Gajecka B.

Archives of Foundry Engineering

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2009

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Vol. 9, iss. 3

221-226

EN

The aim of this work was to determine physical and chemical properties of cobalt aluminate (CoAl2O4) modifiers produced by different companies and the influence of different types of modifiers on the grain size of high temperature creep resisting superalloys: Inconel 713C, René 77 and MAR-M 509. The first stage of the research work took over the investigations of physical and chemical properties of cobalt aluminate manufactured by three different companies: Remet, Mason Color and Permedia Lublin. There were determined the grain size distribution of cobalt aluminate powder, the average diameter and morphology of powder particles, phase composition, as well as sodium and cobalt content, pH value of water suspension and the bulk density. In the next step, the ceramic moulds were made with different kind of cobalt aluminate (Mason Color, Remet, Permedia Lublin) and its concentration (0, 5%) in the primary slurry. The samples of stepped shape were poured in the ceramic moulds prepared earlier. The average grain size of the \gamma phase was determined on the stepped samples. It was established that physical and chemical properties of cobalt aluminate modifier are different up to the manufacturer. For example the modifiers manufactured by Permedia; Mason Color and Remet companies have different the average diameter of particles- [...], and also cobalt content [...] mass, respectively. The grain size of \gamma matrix of superalloys depends on the kind of used inoculant. The best grain refinement of the matrix of superalloys: Inconel 713C, René 77 and MAR-M 509 was observed in the castings modified with the use of Mason Color modifier. On the grounds of literature data and obtained results it was established that the cobalt content of cobalt aluminate influences the intensity of nucleation process during the crystallization of superalloys: Inconel 713C, René 77 i MAR-M 509.