Papers by Satyanarayana A
Ceramic cores are used as sacrificial inserts to generate intricate and complex hollow shapes in ... more Ceramic cores are used as sacrificial inserts to generate intricate and complex hollow shapes in components made of advanced
materials for aero-engine and aerospace applications. Development of tooling to precisely and accurately shape the ceramic core using
Ceramic Injection Moulding (CIM) method is of primary concern. To meet stringent dimensional requirements, the tool geometry has to be
precisely compensated for shrinkage and distortion phenomenon observed in the entire process of the component development. In advanced
aero-engine applications, the hot end components of the turbine stage consisting of blade/vane castings have extremely complex internal
geometry generated using the ceramic cores. This application of investment casting technology has been well established in DMRL. In a
recent effort, tooling for ceramic cores have been successfully developed to produce complex shaped rotors for space application using
powder metallurgy techniques. Present paper attempts to highlight issues related to tooling for ceramic cores for development of a near-net
shaped, Ni-based Superalloy Dual Property HIP Rotors.
In the process of investment casting of precision
blade/vane components for aero-engine applicati... more In the process of investment casting of precision
blade/vane components for aero-engine applications,
generation of a precison wax pattern is the first critical step. A
significant part of the dimensional deviations observed in the
casting can be attributed to the wax pattern. During the
process of generation of wax pattern through injection
moulding, two types of dimensional deviations occur, namely
shrinkage and warpage. Shrinkage deviations are predictable
to a an extent as they are predominantly an outcome of the
injection temperature, which is controllable. Warpage on the
other hand is difficult to predict as it depends on many other
factors of injection molding process. However, control of
distortion is critical in order to conform to the strict
dimensional tolerances of aerospace standards imposed on the
turbine blade/cane castings. Simulation based studies are
emerging as the preferred route for prediction of extent and
location of warpage in precision wax patterns. In the present
study, Moldex3D based simulation package has been utilized
to anlyze the effect of injection temperature, packing pressure,
cooling time and flow rate on the distortion behavior of a
stepped pattern. Two types of waxes with different rheological
properties have also been included to gauge the effect of
change in wax on the warpage. A full factorial design of
experiments has been configured and results of the analysis of
variance is presented.
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Papers by Satyanarayana A
materials for aero-engine and aerospace applications. Development of tooling to precisely and accurately shape the ceramic core using
Ceramic Injection Moulding (CIM) method is of primary concern. To meet stringent dimensional requirements, the tool geometry has to be
precisely compensated for shrinkage and distortion phenomenon observed in the entire process of the component development. In advanced
aero-engine applications, the hot end components of the turbine stage consisting of blade/vane castings have extremely complex internal
geometry generated using the ceramic cores. This application of investment casting technology has been well established in DMRL. In a
recent effort, tooling for ceramic cores have been successfully developed to produce complex shaped rotors for space application using
powder metallurgy techniques. Present paper attempts to highlight issues related to tooling for ceramic cores for development of a near-net
shaped, Ni-based Superalloy Dual Property HIP Rotors.
blade/vane components for aero-engine applications,
generation of a precison wax pattern is the first critical step. A
significant part of the dimensional deviations observed in the
casting can be attributed to the wax pattern. During the
process of generation of wax pattern through injection
moulding, two types of dimensional deviations occur, namely
shrinkage and warpage. Shrinkage deviations are predictable
to a an extent as they are predominantly an outcome of the
injection temperature, which is controllable. Warpage on the
other hand is difficult to predict as it depends on many other
factors of injection molding process. However, control of
distortion is critical in order to conform to the strict
dimensional tolerances of aerospace standards imposed on the
turbine blade/cane castings. Simulation based studies are
emerging as the preferred route for prediction of extent and
location of warpage in precision wax patterns. In the present
study, Moldex3D based simulation package has been utilized
to anlyze the effect of injection temperature, packing pressure,
cooling time and flow rate on the distortion behavior of a
stepped pattern. Two types of waxes with different rheological
properties have also been included to gauge the effect of
change in wax on the warpage. A full factorial design of
experiments has been configured and results of the analysis of
variance is presented.
materials for aero-engine and aerospace applications. Development of tooling to precisely and accurately shape the ceramic core using
Ceramic Injection Moulding (CIM) method is of primary concern. To meet stringent dimensional requirements, the tool geometry has to be
precisely compensated for shrinkage and distortion phenomenon observed in the entire process of the component development. In advanced
aero-engine applications, the hot end components of the turbine stage consisting of blade/vane castings have extremely complex internal
geometry generated using the ceramic cores. This application of investment casting technology has been well established in DMRL. In a
recent effort, tooling for ceramic cores have been successfully developed to produce complex shaped rotors for space application using
powder metallurgy techniques. Present paper attempts to highlight issues related to tooling for ceramic cores for development of a near-net
shaped, Ni-based Superalloy Dual Property HIP Rotors.
blade/vane components for aero-engine applications,
generation of a precison wax pattern is the first critical step. A
significant part of the dimensional deviations observed in the
casting can be attributed to the wax pattern. During the
process of generation of wax pattern through injection
moulding, two types of dimensional deviations occur, namely
shrinkage and warpage. Shrinkage deviations are predictable
to a an extent as they are predominantly an outcome of the
injection temperature, which is controllable. Warpage on the
other hand is difficult to predict as it depends on many other
factors of injection molding process. However, control of
distortion is critical in order to conform to the strict
dimensional tolerances of aerospace standards imposed on the
turbine blade/cane castings. Simulation based studies are
emerging as the preferred route for prediction of extent and
location of warpage in precision wax patterns. In the present
study, Moldex3D based simulation package has been utilized
to anlyze the effect of injection temperature, packing pressure,
cooling time and flow rate on the distortion behavior of a
stepped pattern. Two types of waxes with different rheological
properties have also been included to gauge the effect of
change in wax on the warpage. A full factorial design of
experiments has been configured and results of the analysis of
variance is presented.