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Assessment of a controlled solidification aluminium investment casting technique for use in helicopter gearboxes

机译:评估用于直升机变速箱的可控凝固铝熔模铸造技术

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摘要

By using a combination of cast plates and a helicopter gearbox casting, the superiority of a controlled solidification investment casting process in terms of strength, ductility and fatigue resistance was observed, when compared to three sand casting processes (conventional, low pressure and low pressure with chills) and a conventional investment casting process was observed. The most important factors responsible for the high levels of tensile strength and ductility and fatigue life were a refined grain size, a fine distribution of particles, a low level of porosity and a reduction in the level of bifilm formation. When porosity levels were low, i.e. less than 0.6%, a refined grain size and microstructure have been shown to be the most important factors influencing strength and ductility. Further improvements in the fatigue life within the 'as-cast' controlled solidification investment process can be achieved by the use of hot isostatic pressing (HIPping). No statistically significant difference in the fatigue life between the 'as-cast' and machined surfaces was observed. A higher degree of mechanical property scatter, as measured by Weibull Modulus and the Coefficient of Variance (CV), was observed between the TGB casting and the cast plates inferring the design of the filling system used by the foundry had not been optimised resulting in higher metal flow and surface turbulence and a greater likelihood of bifilms occurring within the casting.
机译:与三个砂型铸造工艺(常规,低压和低压砂型铸造)相比,通过结合使用铸造板和直升机齿轮箱铸造,可以观察到受控凝固熔模铸造工艺在强度,延展性和抗疲劳性方面的优势。寒冷),并观察到传统的熔模铸造工艺。导致高水平拉伸强度,延展性和疲劳寿命的最重要因素是细化的晶粒尺寸,颗粒的精细分布,低孔隙率和双膜形成水平的降低。当孔隙率水平低,即小于0.6%时,已表明细化的晶粒尺寸和微观结构是影响强度和延展性的最重要因素。通过使用热等静压(HIPping),可以在“铸态”受控凝固投资过程中进一步改善疲劳寿命。在“铸态”和机加工表面之间的疲劳寿命方面,没有观察到统计学上的显着差异。在Weibull模量和变异系数(CV)的测量下,在TGB铸件和铸板之间观察到更高程度的机械性能散布,这表明铸造厂所使用的填充系统的设计没有得到优化,从而导致更高的机械性能。金属流动和表面湍流,以及铸件内发生双膜的可能性更大。

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