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Aspects of a novel casting process for the production of nickel-based superalloy high pressure turbine blades

Newell, Matthew David (2009)
Eng.D. thesis, University of Birmingham.

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A novel process in which individual turbine blades are produced by the high rate solidification method has been developed. The technology, with an optimised radiation baffle, gave a thermal gradient of 11.64 x 10\(^3\) K.m\(^{-1}\), whilst maintaining a flat solidification front, calculated using a specially created and validated process model. The corresponding primary dendrite arm spacing was reduced to 165 x 10\(^{-6}\) m and the calculated freckle potential was below the critical threshold limit identified by Beckermann et al. (2000), even in highly freckle prone alloys. Low angle grain boundaries formed when misorientation accumulates in growing dendrite envelopes which subsequently converge were studied experimentally. While extensive dendrite branching or steady state growth was found to lead to an average primary dendrite misorientation of 2.3 ° that was random in nature, enhanced growth kinetics accompanying non steady state growth, found in platforms, produced a monotonic increase in accumulated misorientation of up to 10°. It was concluded that the latter is due to mechanical moments arising from extensive growth of unsupported tertiary dendrite branches growing laterally across the platform normal to the direction of gravity. The degree of misorientation is therefore dependent on local geometry and mushy zone shape.

Type of Work:Eng.D. thesis.
Supervisor(s):Green, Nick and Harding, Richard
School/Faculty:Colleges (2008 onwards) > College of Engineering & Physical Sciences
Department:Department of Metallurgy and Materials
Additional Information:

Some information from the thesis is published in:
N. D'Souza, M. Newell, K. Devendra, P.A. Jennings, M.G. Ardakani, B.A. Shollock, Formation of low angle boundaries in Ni-based superalloys, Materials Science and Engineering: A, Volumes 413-414, International Conference on Advances in Solidification Processes, 15 December 2005, Pages 567-570, ISSN 0921-5093, DOI:

M. Newell, K. Devendra, P.A. Jennings, N. D'Souza, Role of dendrite branching and growth kinetics in the formation of low angle boundaries in Ni-base superalloys, Materials Science and Engineering: A, Volume 412, Issues 1-2, International Conference on Recent Advances in Composite Materials, 5 December 2005, Pages 307-315, ISSN 0921-5093, DOI:

Subjects:TN Mining engineering. Metallurgy
Institution:University of Birmingham
ID Code:525
This unpublished thesis/dissertation is copyright of the author and/or third parties. The intellectual property rights of the author or third parties in respect of this work are as defined by The Copyright Designs and Patents Act 1988 or as modified by any successor legislation. Any use made of information contained in this thesis/dissertation must be in accordance with that legislation and must be properly acknowledged. Further distribution or reproduction in any format is prohibited without the permission of the copyright holder.
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