Application of X-Ray Computed Tomography to Identify Defects in Lost Wax Ceramic Moulds for Precision Casting of Turbine Blades
Krzysztof Żaba,
Dawid Gracz,
Tomasz Trzepieciński,
Marzanna Książek,
Ryszard Sitek,
Adam Tchórz,
Maciej Balcerzak,
Daniel Wałach
Affiliations
Krzysztof Żaba
Department of Metal Working and Physical Metallurgy of Non-Ferrous Metals, Faculty of Non-Ferrous Metals, AGH University of Krakow, Al. Adama Mickiewicza 30, 30-059 Cracow, Poland
Department of Manufacturing Processes and Production Engineering, Rzeszów University of Technology, 8 Powstancow Warszawy Ave., 35-959 Rzeszow, Poland
Marzanna Książek
Department of Materials Science and Engineering of Non-Ferrous Metals, Faculty of Non-Ferrous Metals, AGH University of Krakow, Al. Adama Mickiewicza 30, 30-059 Cracow, Poland
Ryszard Sitek
Faculty of Materials Science and Engineering, Warsaw University of Technology, Woloska 141, 02-507 Warsaw, Poland
Adam Tchórz
Łukasiewicz Research Network—Krakow Institute of Technology, ul. Zakopiańska 73, 30-418 Cracow, Poland
Maciej Balcerzak
Department of Metal Working and Physical Metallurgy of Non-Ferrous Metals, Faculty of Non-Ferrous Metals, AGH University of Krakow, Al. Adama Mickiewicza 30, 30-059 Cracow, Poland
Daniel Wałach
Department of Geomechanics, Civil Engineering and Geotechnics, AGH University of Krakow, Al. Adama Mickiewicza 30, 30-059 Cracow, Poland
This article presents the results of testing the suitability of X-ray computed tomography for the quality control of the casting moulds used for producing turbine blades. The research was focused on the analysis of cross-sectional images, spatial models and the porosity of moulds using a Phoenix L 450 microtomograph. The research material consisted of samples from three mixtures of ceramic materials and binders intended for producing casting moulds using the lost wax method. Various configurations of filling materials (Molochite and quartz flours) and binder (Remasol, Ludox PX 30 and hydrolysed ethyl silicate) mixtures were considered. X-ray computed tomography enabled the detection of a number of defects in the ceramic mass related to the distribution of mass components, porosity concentration and defects resulting from the specificity of the mould production. It was found that casting mould quality control on cross-sectional tomographic images is faster and as accurate as the analysis of three-dimensional models and allows for the detection of a whole range of ceramic defects, but the usefulness of the images is greatest only when the cross-sections are taken at an appropriate angle relative to the object being examined.
