Precision Forming Technology of Large Superalloy Castings for Aircraft Engines

This book describes systematically the theory and technology of the precision forming of large, complex and thin-walled superalloy castings for aircraft engines, covering all the important basic aspects of the manufacturing process, including process design, wax pattern, ceramic molds, casting and solidification, heat treatment, repair casting and dimension precision control. The correlation of casting defects, structural characteristics and performance of castings is revealed through a range of tests. It also discusses the latest technologies and advances in this field – such as imaging the solidification process by means of synchrotron radiography, 3D computerized tomography and reconstruction of microporosity defects, analysis and diagnosis of error sources for dimension over-tolerance and adjusted pressure casting technology – which are of particular interest. Providing essential insights, the book offers a valuable guide to the design and manufacture of superalloy casting parts for aircraft engines. From the Back Cover This book describes systematically the theory and technology of the precision forming of large, complex and thin-walled superalloy castings for aircraft engines, covering all the important basic aspects of the manufacturing process, including process design, wax pattern, ceramic molds, casting and solidification, heat treatment, repair casting and dimension precision control. The correlation of casting defects, structural characteristics and performance of castings is revealed through a range of tests. It also discusses the latest technologies and advances in this field – such as imaging the solidification process by means of synchrotron radiography, 3D computerized tomography and reconstruction of microporosity defects, analysis and diagnosis of error sources for dimension over-tolerance and adjusted pressure casting technology – which are of particular interest. Providing essential insights, the book offers a valuable guide to the design and manufacture of superalloy casting parts for aircraft engines. About the Author Baode Sun is Chair Professor of Materials Science and Engineering at Shanghai Jiao Tong University (SJTU). He received his Ph.D. degree from Northwestern Polytechnic University, China, in 1993. He became “Yangtze River Scholar” Distinguished Professor in 2007 and Dean of School of Materials Science and Engineering in 2013. His research is focused on the fundamental and applied aspects of liquid metal processing and investment casting of large-size thin-wall structural components. He has published more than 200 technical papers, and he holds more than 100 Chinese patents. He won numerous prestigious research awards, such as the second prize of the National Technology Invention Award of China and the first prize of the Shanghai Science and Technology Invention Award.Jun Wang is Professor of Materials Processing at SJTU. He received his B.Sc. (1991), M.Sc. (1994) and Ph.D. (1997) at Southeast University. He was Research Fellow in the Venture Business Lab in Saga University and Senior Researcher in the Department of Materials Engineering at the University of Tokyo in Japan. His research focuses on investment casting process. He has published more than 200 peer-reviewed articles, and he holds 95 China patents and one US patent. He received a number of awards, including the 2nd prize of the National Technology Invention Award, the New Century Talents of Ministry of Education, China, and Shanghai Excellent Scientific Leader.  Da Shu is Professor of Materials Processing at SJTU. He received his B.Sc. (1994) at Nanjing University of Aeronautics and Astronautics and his M.Sc. (1997) and Ph.D. (2001) at SJTU. He was Academic Visitor at the Department of Materials, Oxford University, in 2009–2010. His research focuses on processing of advanced metallic materials and control of solidified structure. He has published more than 100 peer-review