Rene 80 Lost Wax Casting Power Generation Turbine Disc Manufacturer
Introduction
Rene 80 is a nickel-based superalloy specifically engineered for high-temperature, high-stress turbine disc applications. It provides exceptional creep strength, fatigue resistance, and oxidation stability up to 1050°C. As a leading lost wax casting manufacturer, we specialize in producing Rene 80 turbine discs for power generation gas turbines, offering precision tolerances (±0.05 mm), controlled grain structure, and porosity under 1%.
Our vacuum-cast Rene 80 discs are built for long-term durability and high-cycle performance in base-load and peaking turbine operations.
Core Technology: Lost Wax Casting of Rene 80
Our vacuum investment casting process for Rene 80 involves melting and pouring the alloy under vacuum conditions (~10⁻³ torr) at ~1450°C into ceramic shell molds (8–10 layers), preheated to ~1100°C. Controlled solidification (cooling rate: 30–80°C/min) ensures refined equiaxed grain structure (0.5–2 mm), minimizing thermal stresses and eliminating hot tearing. The process achieves dimensional accuracy within ±0.05 mm.
Material Characteristics of Rene 80 Alloy
Rene 80 is a γ′-strengthened nickel-based superalloy with excellent high-temperature mechanical properties, oxidation resistance, and structural stability. It is widely used in turbine discs, blades, and nozzles. Key properties include:
Property | Value |
|---|---|
Density | 8.75 g/cm³ |
Ultimate Tensile Strength (at 870°C) | ≥1200 MPa |
Yield Strength (at 870°C) | ≥1000 MPa |
Elongation | ≥10% |
Creep Rupture Strength (1000h @ 982°C) | ≥200 MPa |
Operating Temperature Limit | Up to 1050°C |
Oxidation Resistance | Excellent |
Rene 80 maintains integrity under high-speed rotational loads, thermal cycling, and long service durations in harsh turbine environments.
Case Study: Rene 80 Turbine Disc Production
Project Background
A global power OEM required high-performance turbine discs for a 50 MW gas turbine operating at turbine inlet temperatures of 1000–1050°C. Rene 80 was selected for its proven creep rupture strength and long-term thermal stability. We delivered vacuum-cast, HIP-treated, and CNC-finished discs conforming to AMS 5383 and OEM dimensional standards.
Typical Power Generation Applications
High-Pressure Turbine Discs (e.g., Siemens V94.2, GE Frame 7E): Rene 80 discs endure high centrifugal loads and thermal gradients in stationary and peaking turbines.
Low-Pressure Turbine Discs: Structural hubs rotating at moderate temperatures where oxidation resistance and mechanical strength are essential.
Hot Gas Path Transition Discs: Intermediate rotating structures connecting turbine shafts to compressor or generator modules.
Disc-to-Blade Mounting Interfaces: Complex hubs with dovetail or fir-tree geometry requiring precision fit and fatigue durability.
These discs must maintain mechanical and dimensional integrity over thousands of start-stop and load variation cycles in industrial gas turbines.
Manufacturing Solutions for Rene 80 Turbine Discs
Casting Process Wax patterns are precision-assembled and invested into ceramic molds. Vacuum melting and pouring at ~1450°C eliminate gas porosity. Controlled solidification avoids segregation and ensures uniform γ′ phase formation throughout disc cross-sections.
Post-processing Hot Isostatic Pressing (HIP) at 1190°C and 100 MPa consolidates microvoids, improving fatigue resistance and structural uniformity. Heat treatment (solution + aging) enhances creep and tensile performance.
Post Machining CNC machining is used to finish bores, bolt patterns, and disk slots. EDM enables accurate formation of cooling slots or attachment features. Deep hole drilling creates oil passages and stress-relief channels.
Surface Treatment Discs may be coated with thermal barrier coatings (TBC) to reduce surface oxidation and manage thermal gradients. Surface polishing and peening are also available to enhance fatigue life.
Testing and Inspection All components undergo X-ray NDT, CMM scanning, high-temperature tensile testing, and metallographic analysis to verify grain size, phase distribution, and structural compliance.
Core Manufacturing Challenges
Casting large-diameter discs with tight tolerance and grain control.
Preventing thermal fatigue cracking and grain boundary oxidation over long-term cycling.
Achieving stable γ′ precipitation for long-duration creep resistance.
Results and Verification
Dimensional accuracy within ±0.05 mm confirmed by CMM.
Porosity reduced to <1% after HIP, confirmed by X-ray inspection.
Creep rupture strength ≥200 MPa at 982°C validated through 1000-hour stress testing.
Fatigue life extended >10⁶ cycles under simulated turbine operation.
FAQs
What makes Rene 80 ideal for casting turbine discs in power generation?
How is grain structure controlled in large-diameter Rene 80 castings?
Can turbine disc hubs be customized for different rotor configurations?
What post-machining options are available for disc finishing?
What quality control measures ensure performance in high-temperature turbine systems?
