SC Casting – Single Crystal Casting Process for Large Gas Turbine Blades

Directionally solidified (DS) and single crystal (SC) components have been used in aircraft turbines for many years. They are also used in smaller turbines for land-based power generation. However, the adoption of SC technology for large land-based gas turbines is limited by the formation of grain defects in large and complex turbine blades, which is an impediment to the production of energy and cost efficient land based gas turbines. A new casting technology, developed by the Foundry Institute at RWTH Aachen University, overcomes the problem and allows significant reduction of grain defect formation while improving the quality of single crystal components.

Commercial Opportunities: During the single crystal solidification of large gas turbine blades, grain defects are often formed as a consequence of heterogeneous nucleation related to geometrical features on the components. The innovative HC/SC casting technology allows to effectively control the thermal conditions in the casting process and the progression of the liquidus isotherm during solidification. The formation of stray grains can be suppressed, and a high quality single crystal turbine blade can be manufactured.

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