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High temperature Ni-based super alloy casting process advancement

Objective

"Reduction of the fuel consumption and emission of nitrous oxide by jet engines is a priority of the EU ACARE SRA 2020 objectives. The development of an environmentally friendly aircraft engine considers using lightweight and efficient turbine components. It will have great impact on reduction of pollution and fuel consumption.
The aim of the project is to establish and improve castability and weldability of HAYNES® 282 alloy which is enabler material for manufacturing a lightweight turbine exhaust case with higher work temperature in comparison with the actual fabrication based on IN718 alloy. Two approaches can be considered to abate the castability and weldability problems of cast wrought nickel alloys – by modifying: a) chemistry of the alloy and b) casting and welding process parameters. In order to improve castability and weldability for HAYNES® 282 – an enabler for turbine exhaust case, the following objectives have been defined:
1.Development of numerical simulator of casting process to support the experimental activities and support interpretation of the experimental results.
2.Experimental studies of castability limit parameters for HAYNES® 282 alloy
3.Development of the casting process technology challenging the limitation of the minimum wall thickness of 2 mm.
4.Optimizing the casting process parameters and post casting heat treatment for improving the weldability of the cast parts.
5.Demonstration of the capacity of the developed technology by casting a component
The project consists of 24-month duration and is structured in 5 technical WPs and 1 addressing management and coordination activities, perfectly linked with the concept of project (modeling, fundamental research and industrial trials).
The consortium consists of engine manufacturer (WSKRZ) and 2 technical universities (WUT and RUT). Such a structured consortium will provide complex expertise abilities of designing, modeling and experimental trial possibilities on the industrial scale."

Call for proposal

SP1-JTI-CS-2011-01
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Coordinator

POLITECHNIKA WARSZAWSKA
Address
Plac Politechniki 1
00 661 Warszawa
Poland
Activity type
Higher or Secondary Education Establishments
EU contribution
€ 112 500
Administrative Contact
Hubert Matysiak (Dr.)

Participants (2)

POLITECHNIKA RZESZOWSKA IM IGNACEGO LUKASIEWICZA PRZ
Poland
EU contribution
€ 112 500
Address
Al Powstancow Warszawy 12
35-959 Rzeszow
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Krzysztof Kubiak (Prof.)
PRATT & WHITNEY RZESZOW SPOLKA AKCYJNA
Poland
EU contribution
€ 100 000
Address
Ulica Hetmanska 120
35 078 Rzeszow
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Robert Haligowski (Mr.)