Rene 104 Equiaxed Crystal Casting Turbine Blade Components Supplier
Introduction
Rene 104 is a high-strength nickel-based superalloy engineered for advanced turbine blade applications, offering superior creep resistance, oxidation stability, and fatigue performance at temperatures exceeding 1100°C. As a professional equiaxed crystal casting supplier, we manufacture precision Rene 104 turbine blade components with tight tolerances (±0.05 mm), equiaxed grain control, and porosity under 1%.
Our cast blades are ideal for aerospace and power generation gas turbines, delivering long service life under extreme mechanical and thermal conditions.
Core Technology: Equiaxed Crystal Casting of Rene 104
Our equiaxed crystal casting process for Rene 104 involves vacuum melting and precision solidification control to produce uniform grain sizes (0.5–2 mm). The alloy is melted and poured at ~1450°C into ceramic molds preheated to 1100°C. Cooling rates of 30–80°C/min are maintained to ensure directional solidification without columnar grain formation. Final parts achieve dimensional tolerances of ±0.05 mm and porosity <1%.
Material Characteristics of Rene 104 Alloy
Rene 104 is a precipitation-strengthened nickel-based superalloy containing aluminum, titanium, and refractory elements for enhanced thermal performance. It is optimized for rotating and static components in high-pressure turbine stages. Key properties include:
Property | Value |
|---|---|
Density | 8.6 g/cm³ |
Tensile Strength (at 815°C) | ≥1300 MPa |
Yield Strength (at 815°C) | ≥1100 MPa |
Elongation | ≥12% |
Creep Rupture Strength (1000h @ 982°C) | ≥200 MPa |
Operating Temperature Limit | Up to 1150°C |
Oxidation Resistance | Excellent |
Rene 104 maintains mechanical integrity under high thermal gradients and aggressive hot gas flows.
Case Study: Rene 104 Turbine Blade Component Production
Project Background
A commercial aerospace engine manufacturer required equiaxed-cast high-pressure turbine blades for a next-generation jet engine platform. Rene 104 was chosen for its balance of strength, durability, and castability. We delivered blades compliant with AMS 5951 standards, fully machined and post-HIP treated for dimensional accuracy and fatigue resistance.
Typical Turbine Blade Applications
High-Pressure Turbine (HPT) Rotor Blades (e.g., GEnx, LEAP): Equiaxed Rene 104 blades capable of resisting creep and oxidation in the core hot section of large turbofans.
Industrial Gas Turbine Stator Vanes: Blades exposed to high heat and pressure in power generation turbines operating at continuous base-load service.
Jet Engine Transition Section Blades: Load-bearing blades bridging combustor to turbine, where thermal fatigue and surface oxidation are critical design factors.
APU Turbine Blades: Small-scale blades for auxiliary power units, where Rene 104’s fatigue strength is crucial for high-cycle reliability.
These components operate in environments exceeding 1100°C and must retain dimensional and mechanical integrity over thousands of cycles.
Manufacturing Solutions for Rene 104 Blades
Casting Process High-purity wax patterns are invested into ceramic shells and vacuum cast at ~1450°C. Equiaxed solidification is controlled by mold cooling and thermal profile management to produce consistent grain orientation and eliminate hot tearing.
Post-processing Hot Isostatic Pressing (HIP) at 1190°C and 100 MPa reduces porosity to <1%. Solution and aging treatments optimize γ' phase precipitation for mechanical stability and creep resistance.
Post Machining Final part features are completed using CNC machining. EDM is used for trailing edges and thin sections, and deep hole drilling is applied for blade cooling holes and internal flow channels.
Surface Treatment Thermal barrier coatings (TBC) are applied via plasma spray to insulate against thermal fatigue. Surface polishing and oxidation-resistant aluminide coatings are available for surface stability at extreme temperatures.
Testing and Inspection Every blade undergoes X-ray inspection, CMM dimensional verification, high-temperature tensile testing, and metallographic analysis to confirm grain control and phase stability.
Core Manufacturing Challenges
Achieving equiaxed grain uniformity in thin-airfoil and complex blade geometries.
Preventing hot tearing and distortion in high-content γ' alloys during solidification.
Maintaining fatigue and creep resistance after long-term exposure at >1100°C.
Results and Verification
Dimensional tolerance within ±0.05 mm confirmed via 3D CMM scanning.
Porosity <1% post-HIP verified via radiographic inspection.
Creep rupture strength ≥200 MPa at 982°C confirmed in 1000-hour stress tests.
No grain boundary cracking or γ' degradation after 1000 thermal cycles at 1150°C.
FAQs
Why is Rene 104 suitable for equiaxed turbine blade casting?
What are the benefits of equiaxed casting versus directional solidification for blades?
Can Rene 104 be used for both rotating and static turbine parts?
What coatings enhance Rene 104’s oxidation performance in gas turbine environments?
How do you ensure dimensional and metallurgical consistency in turbine blade casting?
