Stellite 6B Lost Wax Casting Gas Turbine Vane Components Foundry
Introduction
Stellite 6B is a cobalt-based alloy renowned for its excellent wear resistance, high-temperature strength, and superior corrosion and oxidation resistance—making it ideal for gas turbine vane components. At our specialized foundry, we manufacture lost wax cast Stellite 6B vanes with precision tolerances of ±0.05 mm, consistent microstructures, and porosity levels below 1%.
Engineered for extended service life in thermally aggressive turbine environments, our Stellite 6B components support reliable operation in both aerospace and power generation turbines.
Core Technology: Lost Wax Casting of Stellite 6B
Our Stellite 6B turbine vanes are produced via lost wax (investment) casting with multi-layer ceramic shell molds (8–10 coats), vacuum melting at ~1440°C, and mold preheating at 1050°C. Controlled solidification (cooling rates: 40–100°C/min) results in refined equiaxed grains (0.5–2 mm) and excellent dimensional stability. The process achieves tolerances of ±0.05 mm and porosity consistently under 1%.
Material Characteristics of Stellite 6B Alloy
Stellite 6B provides superior metallurgical stability, galling resistance, and mechanical strength in turbine conditions. It is widely used for vanes exposed to extreme temperatures, erosion, and high-speed gas flow. Key properties include:
Property | Value |
|---|---|
Melting Range | 1350–1440°C |
Density | 8.4 g/cm³ |
Tensile Strength (Room Temp.) | 965 MPa |
Yield Strength | 720 MPa |
Hardness | 35–42 HRC |
Thermal Stability | Up to 1050°C |
Corrosion/Oxidation Resistance | Excellent |
Stellite 6B maintains strength and dimensional integrity under continuous service at high temperatures, resisting oxidation, hot corrosion, and mechanical wear.
Case Study: Stellite 6B Gas Turbine Vane Components
Project Background
A gas turbine OEM required high-durability first-stage nozzle guide vanes for turbines operating at 980–1050°C. Our foundry delivered Stellite 6B components with strict adherence to ASTM F90 and ISO 9001 quality standards. Parts were cast to aerodynamic profiles with critical wall thicknesses controlled to within ±0.05 mm.
Typical Gas Turbine Vane Models and Applications
First-Stage Nozzle Guide Vanes: High-temperature vanes directing hot combustion gases, requiring oxidation resistance and thermal stability at >1000°C.
Second-Stage Transition Vanes: Exposed to high-cycle fatigue and intermediate temperatures, requiring excellent galling and thermal shock resistance.
Combustion Zone Vane Segments: Subject to turbulent flow, erosion, and chemical corrosion from exhaust gases.
Stationary Shroud Blades: Require high dimensional accuracy and consistent mechanical performance under cyclic thermal conditions.
These vane models are critical to maintaining turbine performance, airflow control, and thermal efficiency.
Turbine Vane Manufacturing Solutions
Casting Process Wax patterns are injection molded, assembled into ceramic clusters, and processed through vacuum-assisted lost wax casting. Pouring at ~1440°C and mold preheating at 1050°C ensure metallurgical purity, controlled grain size, and low shrinkage for profile consistency.
Post-processing Components undergo Hot Isostatic Pressing (HIP) at ~1180°C and 100 MPa to reduce porosity and enhance creep resistance. Finishing includes CNC machining for critical fit surfaces and edge profiles.
Surface Treatment Turbine vanes are optionally coated with Thermal Barrier Coatings (TBC), such as yttria-stabilized zirconia, applied via APS (Air Plasma Spray). These coatings extend thermal fatigue life and reduce operating metal temperature by ~150–200°C.
Testing and Inspection All parts undergo rigorous quality control, including X-ray inspection, CMM dimensional verification, metallographic microscopy, and tensile testing at elevated temperatures.
Core Manufacturing Challenges of Turbine Vane Components
Maintaining ±0.05 mm dimensional accuracy on complex aerodynamic contours.
Controlling porosity and grain structure to ensure high-cycle fatigue resistance.
Ensuring metallurgical cleanliness and coating adhesion in high-temperature service zones.
Results and Verification
Delivered Stellite 6B turbine vane components demonstrated:
Dimensional accuracy verified through 3D CMM scanning (±0.05 mm).
Porosity reduced below 1% through HIP and confirmed via X-ray.
Tensile strength ≥960 MPa and consistent hardness in the 35–42 HRC range.
Surface oxidation resistance validated through 1000-hour cyclic thermal exposure tests at 1050°C.
FAQs
Why is Stellite 6B ideal for casting turbine vane components?
What benefits does lost wax casting offer for precision gas turbine parts?
How do you verify vane dimensional accuracy and structural integrity?
What thermal barrier coatings are used to enhance vane longevity?
Can vane designs be customized for different turbine models and stages?
