大型复杂薄壁 TiAl 合金扩压机匣精密铸造数值模拟与工艺优化

Numerical simulation and process optimization of precision casting for large complex thin-walled TiAl alloy compressor casing

摘要

基于 ProCAST 数值模拟软件，对比分析离心铸造与重力铸造对 Ti-48Al-2Nb-2Cr 合金扩压机匣成形的影响。结果表明：离心浇注（转速 400 r/min）通过增强熔体充型定向性与凝固过程强制对流，与重力浇注相比，显著缩短凝固时间，缩松缺陷体积减少 21.8%；针对厚壁区热节问题，创新设计弯冒口浇注系统，将内环法兰边缺陷转移至冒口，与直冒口相比，缩松缺陷体积降低 47.1%。实验验证表明，经工艺优化制备的铸件 X 射线检测无内部缺陷，显微观察未见缩松，薄壁支板区因快速冷却形成细晶组织（片层团 400 μm），与厚壁法兰边相比，其室温和 750 ℃抗拉强度分别提高 4.9% 和 10%。研究结果为大型复杂薄壁 TiAl 构件的高质量成形提供可靠工艺方案。

Abstract

Based on ProCAST numerical simulation software, the effects of centrifugal casting and gravity casting on the forming of Ti-48Al-2Nb-2Cr alloy diffuser casing are analysed comparatively. The results show that centrifugal pouring at rotational speed of 400 r/min enhances the directional mold filling of molten metal and forced convection during solidification. Compared with gravity pouring, it greatly shortens solidification time and reduces shrinkage porosity volume by 21.8%. A curved riser gating system is innovatively designed to address hot spots in thick-wall regions, transferring defects on the inner ring flange to the risers. This design cuts shrinkage porosity volume by 47.1% relative to the straight risers. Experimental verification confirms that castings fabricated with optimized processes have no internal defects detected by X-ray inspection and no shrinkage porosity observed under microstructure examination. Fine-grained structures with lamellar colonies of 400 μm form in thin-wall support plates due to rapid cooling. Its tensile strength at room temperature and 750 ℃ rises by 4.9% and 10%, respectively, comparing with thick-wall flanges. These findings provide a reliable process scheme for high-quality forming of large-scale complex thin-wall TiAl components.

关键词

TiAl 合金 / 数值模拟 / 浇注工艺 / 离心铸造

Key words

TiAl alloy / numerical simulation / pouring process / centrifugal casting

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