Spiral grain selectors are used to grow single-crystal (SX) turbine blades during investment casting. Competitive growth in the spiral selectors leads to the selection of a single grain that subsequently grows to form the blade. In this study, the effect of spiral design on grain selection during investment casting was investigated through a series of experiments. It is found that the spiral design can effectively reduce the grain number but is not able to optimize axial grain orientations during solidification, the effectiveness of grain selection is strongly dependent on the spiral “take-off” angle, and spirals with smaller take-off angles are most potent. It is proposed that grain selection in the spiral is controlled by the geometry of the spiral via a “geometrical blocking” mechanism.

Grain Selection in Spiral Selectors During Investment Casting of Single-Crystal Turbine Blades: Part I. Experimental Investigation

Simulation of grain selection during single crystal casting of a Ni-base superalloy

Branching-induced grain boundary evolution during directional solidification of columnar dendritic grains

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

A columnar-to-equiaxed transition (CET) was induced by controlling the cooling rate in the directional solidification of an Al-15 wt.% Cu alloy. The morphological evolution of the mush–liquid interface in CET was tracked and recorded by X-ray imaging. The dendrite growth and detachment, solute distribution at the growth front and excessive solute enrichment in the liquid pockets were clearly observed. Based on the observations, it was found that there is an obvious increase in melt density in the liquid pocket due to the excessive solute enrichment. The density difference between the melt and the solid is an important reason for dendrite detachment and fragment movement, which is considered as the key to the inducement of CET. Finally, the CET process and the growth of equiaxed dendrites at the mush–liquid interface were described from the viewpoint of dendrite detachment.

In situ observation of columnar-to-equiaxed transition in directional solidification using synchrotron X-radiation imaging technique

Under the condition of unidirectional solidification of alloy, an engineering model for grain selection has been developed. This is a 2D, deterministic model, depending upon the theory of columnar dendrite growth. This engineering model is applied to single crystal casting process. The ratio between number of well oriented products and total number of trails is defined to be a yield rate. Here, if the direction of [0 0 1] of a selected single crystal is within 10° from the long side of the product, is judged to be well oriented. The parameters for calculation are the angle, width and length of pigtail. The effect of these parameters on the yield rate has been investigated. In the range of this study, the yield rate does not exceed 90%. The yield rate decreases if the angle of pigtail increases or decreases. There are also the most suitable value of the diameter and length of pigtail in order to get high yield rate of single crystal casting.

Analysis of single crystal casting process taking into account the shape of pigtail

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Analysis of single crystal casting process taking into account the shape of pigtail