Superalloy Parts Manufacturing Technology

Turbine Blade and Disk Manufacturing Technology

Neway's advanced manufacturing technology includes precision turbine blade casting using single-crystal and directional solidification techniques. We produce powder metallurgy turbine discs through HIP and advanced forging methods. Our dual-performance turbine disc technology integrates powder alloys and HIP diffusion bonding, achieving superior durability and high-temperature resistance for next-generation aerospace applications.

Single Crystal Dendrite Microstructure Refinement Technique

Primary dendrite spacing λ is the essential characteristic scale of single crystal structure and a critical indicator of quality inspection. The smaller the λ value, the finer the dendrite structure and the better the mechanical properties of the casting. At present, the HRS process is widely used both domestically and internationally to produce high-temperature alloy single-crystal castings. Due to the low tenure gradient G in the HRS process, the SC castings dendrite structure with high valuModifed techniques, such as the liquid metal cooling (LMC) and gas cooling casting (GCC), were developed to meet them and for highly efficient DS/SC casting.

Technology	Advantages	Link
Fine-Crystal Technology	Under the conditions of radiative heat transfer, the temperature gradient is multiplied by improving the heat insulation between the hot and cold regions, and the dendrite spacing is significantly reduced. The new technology has the advantages of low cost and remarkable effect. It has been widely used in the production of single-crystal blades.	Learn >>
Ultrafine Crystal Technology	Ultrafine crystal technology is being developed based on fine crystal technology, which significantly improves the heat transfer efficiency of the whole surface of the mold shell. The temperature gradient G is further increased, the dendrite spacing is reduced, and remarkable results have been achieved.	Learn >>

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Single Crystal Guide Vane Preparation and Multi Integrated Casting Technology

Compared with the narrow moving blades, the guide blades are difficult to be made into single crystal castings due to their wide structure. For the guide blades, whether they are arranged in a vertical or horizontal arrangement, it is difficult for the single crystal to grow from the small crystal selector to the wide edge plate, so it is very easy to produce mixed crystal defects.

Technology	Description	Link
Single blade casting method	For double and multiple guide blades, the edge plate area increases exponentially, making it more difficult to make single crystals. Usually, a single piece is cast and then welded together. Not only is the process complicated, but the weld leakage problem often causes scrapping, which has become a major problem in aircraft engine manufacturing.	Learn >>
New guide vane preparation process	The blade tilting die assembly can realize the gradual transition from the crystal selector to the edge plate, realize the sequential solidification of the blade body and the edge plate in the oblique upward direction, effectively avoid the generation of mixed crystal defects, and significantly reduce the loose defects on the upper surface of the casting.	Learn >>

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Preparation of Single Crystal Guide Blades and Multiple Integrated Casting Technology

The single crystal guide blade casting process utilizes the crystal selection or seed crystal method for precise control of grain orientation, reducing defects like cracks and impurities. By optimizing crystal growth direction ([001]), this technology enhances the performance of high-temperature components, such as turbine blades, improving their mechanical strength and thermal resistance in aerospace and energy industries.

Technology	Description	Link
Crystal Selection Technique	This technology involves selecting specific crystals that meet desired orientation criteria during the casting process. It ensures that the single-crystal growth is controlled to achieve the required properties in turbine blades.	Learn >>
Seed Crystal Method	The Seed Crystal Method is a more complex technology where a pre-prepared seed crystal is used to control the orientation of the growing crystal structure. This method offers better control over both the primary and secondary crystal directions, especially for controlling grain orientation.	Learn >>
General Problems with Seed Crystal Method	Issues such as incomplete melting, the formation of cracks, impurities, and oxidation during the casting process when using the seed crystal technique. These problems affect the quality and structural integrity of the cast single-crystal parts.	Learn >>
Improved Results	The improved casting process using the Seed Crystal Method, combined with advancements in heat treatment and melting processes, has resulted in fewer defects (e.g., fewer cracks and impurities) and better control of the crystal orientation.	Learn >>
Crystal Direction Control	This is a critical technology for casting single-crystal turbine blades, where the grain orientation, specifically direction, is carefully controlled. Ensuring that the crystals grow in the correct direction is essential for optimizing the mechanical properties, such as strength and resistance to thermal stresses.	Learn >>

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Comprehensive Control Technology of Crystal Defects in Single Crystal Castings

We focuses on controlling crystal defects in single crystal castings, such as stray grains, freckles, slivers, recrystallization, and low-angle boundaries. By optimizing solidification processes, heat treatment, and mold design, defects are minimized. This technology is crucial for producing high-performance turbine blades and aerospace components

Defects	Description	Link
Stray Grain	Formation: Results from improper cooling, leading to unaligned grain growth. Prevention: Improve control of temperature gradients and ensure proper directional solidification.	Learn >>
Freckle	Formation: Caused by convection currents carrying impurities to certain areas during solidification. Prevention: Modify the thermal gradient in the mold and reduce the convection effect through optimized casting conditions.	Learn >>
Sliver	Formation: Arises from irregularities in the mushy zone during solidification. Prevention: Ensure stable solidification parameters and avoid disturbances in the solidification front.	Learn >>
Recrystallization	Formation: Occurs during heat treatment when temperature differentials lead to grain growth and misalignment. Prevention: Ensure consistent temperature control during post-casting treatments to avoid recrystallization.	Learn >>
Low-Angle Boundary	Formation: Results from slight misalignments in grain orientation during cooling. Prevention: Optimize cooling rates and ensure uniform solidification to prevent misalignment between adjacent grains.	Learn >>

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Inclusion Detection Technology

Inclusion detection technology identifies and analyzes impurities in metal powders and turbine components using stereo microscopes, scanning electron microscopes (SEM), and ultrasonic inspection. By detecting inclusions as small as 0.4mm, this technology ensures material purity and structural integrity, critical for high-performance industries like aerospace and power generation, where even minor defects can compromise safety and efficiency.

Technology	Description	Link
Inclusion Detection Device	This custom-built detection device uses a combination of tools to identify and measure inclusions in both powder and solid materials. It ensures high-precision screening and purity control for superalloys and other high-performance materials.	Learn >>
Microscopic and SEM Analysis	These microscopic tools are used to detect inclusions on both macro and micro scales, providing detailed images of defects and allowing for accurate composition analysis.	Learn >>
Ultrasonic Detection	Ultrasonic inspection is a key technology for detecting internal defects in components without damaging them. It is critical for ensuring the structural integrity of high-pressure turbine discs, which are used in aerospace and energy sectors.	Learn >>
Inclusion Morphology Analysis	By examining the size, shape, and composition of inclusions, manufacturers can improve their processes to prevent such defects. This analysis helps in refining powder metallurgy techniques and casting processes to ensure high material quality.	Learn >>
Low-Angle Boundary	Formation: Results from slight misalignments in grain orientation during cooling. Prevention: Optimize cooling rates and ensure uniform solidification to prevent misalignment between adjacent grains.	Learn >>

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Single Crystal Blade Life Prediction

The life prediction technology for single-crystal turbine blades evaluates creep, low-cycle fatigue, and thermal mechanical fatigue using tests and simulations. It considers crystal orientation and grain boundaries to predict blade lifespan under extreme conditions. Applied in aerospace and power generation, this technology ensures reliable performance, optimizes maintenance, and prevents failures in high-stress turbine environments.

Technology	Description	Link
Creep and Fatigue Testing	Experimental tests that subject materials to long-term stress (creep tests) and cyclic loading (fatigue tests) to simulate real-world operating conditions for turbine blades.	Learn >>
Simulation Models	These models predict material behavior under stress, factoring in the effects of crystal orientation, grain structure, and thermal cycling. The models are validated through comparison with experimental results to ensure their accuracy.	Learn >>
Thermal Mechanical Fatigue	This technology tests how materials behave under combined thermal and mechanical stresses, which is particularly important for components exposed to extreme temperatures and mechanical loads, like turbine blades in aircraft engines.	Learn >>
Anisotropic Material Modeling	The models used here take into account the anisotropic (direction-dependent) properties of single-crystal superalloys, providing more precise predictions for how the material will perform under different types of stresses.	Learn >>

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Component Life Extension

The process involves analyzing the causes of component failure and implementing improvement measures. These include finite element numerical simulation, precise composition control, optimization of the manufacturing process, and heat treatment regulation to extend the lifespan of the component.

Technology	Description	Link
Finite Element Numerical Simulation (FEM)	To predict stress, strain, and potential failure regions in components before they are manufactured or during their service life. This simulation helps identify weak spots or areas prone to failure under certain loads or conditions.	Learn >>
Precise Composition Control	Ensures that the material composition is optimized for performance. By controlling alloy composition with precision, engineers can enhance mechanical properties such as strength, fatigue resistance, and thermal stability, which directly impact component life.	Learn >>
Optimization of Manufacturing Process	Refining manufacturing techniques to produce components with fewer defects, better grain structure, and enhanced overall quality. This includes improvements in casting, forging, and machining processes that result in higher component durability.	Learn >>
Regulation of Heat Treatment	Heat treatment processes are regulated to refine the microstructure of the material. By adjusting the temperature, time, and cooling rates during heat treatment, the grain structure can be optimized, improving creep resistance and overall fatigue life.	Learn >>