Gas Turbine Parts Lost Wax Casting Manufacturer
Introduction
Lost wax casting provides unmatched precision (tolerances ±0.05 mm) and superior surface quality (Ra ≤3.2 µm) required for manufacturing complex gas turbine components. At Neway AeroTech, we specialize in producing high-performance gas turbine parts using advanced investment casting techniques. Our capabilities ensure optimal functionality in critical industries, including aerospace, power generation, and oil and gas.
Our turbine components exhibit robust mechanical properties (tensile strength 900–1450 MPa), exceptional corrosion and oxidation resistance, and reliable performance in temperatures up to 1100°C.
Core Technology of Lost Wax Casting
Wax Pattern Injection: Highly accurate wax patterns are created with dimensional precision of ±0.03 mm, replicating complex turbine geometries with consistency.
Ceramic Mold Development: Ceramic shells (10–15 mm thickness) formed by repeated slurry dips provide structural integrity during casting.
Controlled Dewaxing: Ceramic molds heated to approximately 250°C, removing wax effectively without distortion, ensuring exact shape replication.
Vacuum-Assisted Casting: Casting performed at temperatures up to 1650°C under vacuum (<0.01 MPa oxygen) ensuring minimal porosity (<0.1%) and oxidation-free parts.
Shell Removal & Finishing: Ceramic shells are mechanically removed; parts are precisely cleaned and finished to achieve surface roughness Ra ≤3.2 µm.
Advanced Heat Treatment: Components undergo specialized heat treatments, including solutionizing and aging (around 1050°C), enhancing tensile strength and fatigue life.
Material Characteristics for Gas Turbine Components
Property | Specification |
|---|---|
Typical Materials | Nickel-based alloys (Inconel 718, Inconel 738), CMSX-4, Titanium alloys (Ti-6Al-4V) |
Tensile Strength | 900–1450 MPa |
Yield Strength | ≥850 MPa |
Temperature Resistance | Up to 1100°C |
Dimensional Accuracy | ±0.05 mm |
Surface Finish | Ra ≤3.2 µm |
Corrosion/Oxidation | Exceptional at high temperatures |
Pressure Capacity | Up to 80 MPa |
Case Study: Gas Turbine Parts Lost Wax Casting
Project Background
A major global power generation provider required precision-engineered turbine components capable of sustained high-temperature (up to 1100°C), high-pressure operation (80 MPa). Key performance criteria included precise dimensional accuracy, robust mechanical properties, and high oxidation resistance.
Common Gas Turbine Components and Applications
Turbine Blades: Cast from single-crystal alloys (e.g., CMSX-4) to ensure maximum creep resistance at temperatures up to 1100°C.
Nozzle Guide Vanes: Optimized for directing high-temperature gases (≥1000°C), utilizing alloys like Inconel 738 for superior thermal fatigue resistance.
Combustor Liners: Engineered for exceptional oxidation resistance, durability, and stability in continuous high-temperature (up to 1050°C) operation.
Turbine Discs: Manufactured with nickel-based superalloys, offering exceptional fatigue strength and reliability in rotational applications at elevated temperatures.
Selection and Structural Features
Materials like CMSX-4 and Inconel 718 selected for high-temperature strength (>900 MPa tensile strength), oxidation resistance, and creep resistance. Structural optimizations include aerodynamic shapes, cooling passages, and reinforced stress points.
Gas Turbine Components Manufacturing Solution
Precision Wax Injection: Wax patterns accurately formed (±0.03 mm tolerances), enabling consistent reproduction of intricate cooling channels and blade shapes.
Ceramic Shell Construction: Repeated slurry coatings achieve shell thicknesses of 10–15 mm, essential for dimensional integrity and mold durability.
Vacuum Casting: Alloy casting at ~1600°C under vacuum (<0.01 MPa oxygen), ensuring porosity <0.1% and defect-free microstructures.
Heat Treatment: Customized solution and aging treatments at ~1050°C significantly enhance mechanical strength (up to 1450 MPa tensile strength).
Precision CNC Machining: Advanced superalloy CNC machining guarantees dimensional accuracy (±0.05 mm) and intricate surface detailing.
Thermal Barrier Coatings (TBC): Application of specialized Thermal Barrier Coatings increases thermal protection and prolongs component life.
Non-Destructive Testing (NDT): Rigorous radiographic (X-ray inspection) and ultrasonic evaluation confirm internal structural integrity.
Operational Performance Testing: High-fidelity tests replicate turbine conditions, verifying component reliability and performance under real-world conditions.
Core Manufacturing Challenges
Maintaining stringent dimensional tolerances (±0.05 mm).
Minimizing casting porosity levels (<0.1%).
Ensuring consistent mechanical and thermal properties across complex geometries.
Extensive testing protocols to validate fatigue and corrosion resistance at extreme temperatures.
Results and Verification
Dimensional Accuracy Verification: Advanced Coordinate Measuring Machines (CMM) validated precision within ±0.05 mm tolerance requirements.
Mechanical Testing Validation: Tensile strengths consistently reached 900–1450 MPa, exceeding design criteria and industry benchmarks.
Oxidation Resistance Confirmation: ASTM-standard cyclic oxidation tests demonstrated outstanding resistance at temperatures exceeding 1000°C.
NDT and Quality Assurance: Radiographic and ultrasonic inspections confirmed zero internal defects, meeting rigorous aerospace and industrial standards.
Surface Finish Verification: Surface roughness consistently below Ra 3.2 µm, significantly reducing aerodynamic drag and improving turbine efficiency.
FAQs
What materials does Neway AeroTech typically use for gas turbine components?
What level of dimensional accuracy can be achieved through lost wax casting?
How does Neway AeroTech ensure defect-free castings for turbine components?
Can custom designs and specifications be accommodated for specialized turbine parts?
What types of testing and quality assurance processes are used for turbine castings?
