Combustion Swirler
Overview
Focus:
Casting SimulationIndustry:
IndustrialDimensions (mm):
104.75 X 50.8Weight (g):
439Complex Part
USA Made
Efficient Delivery
Rapid Prototyping
Soluble Cores
Thickness Variations
The swirler is a thin-walled part used for an industrial gas turbine combustion system. It is made at our facility in Warsaw, USA using nickel alloy.
Concept Development
A key challenge with this part was the thin wall, thick-to-thin sections and complex geometry. Tight dimensional requirements as a result of this complex internal geometry make this a complex part to inject and shell.
We worked with the customer to develop the concept and feedback on designs using our expert knowledge of the castability of materials and geometries.
Prototyping & Simulation
Simulations and rapid 3D-printed prototypes were used to overcome any challenges presented to us by the complexity of the design. These processes allowed us to understand solidification rates, and led to us identifying an issue with the gating that we could then correct to ensure proper solidification.
We were able to use non-destructive testing methods on the prototypes to further test the results and identify any risks posed before entering into the full series production run.
Manufacturing Processes
Special tooling utilising soluble cores was leveraged to allow for the complex geometry to be injected. Trials to optimise mould manufacture on our fully automated lines were also used to ensure a good coverage during the mould build to reduce scrap and rework to the process to acceptable levels. We were able to leverage decades of process experience and specially developed systems to achieve the best results for our customer.
Quality Control & Testing
Results were verified with internal NDT in our world-class testing lab. This process presented us with an additional challenge due to the tight limits from the NDT specifications. The processes we used included x-ray testing and liquid penetrant testing. We also carried out in-the-field testing to ensure the component was reliably fit for purpose.
In overcoming the solidification challenges with careful testing, and using our expertise to identify the possibility of employing soluble cores to cast the complex geometries we were able to cast a top-class component that met the customer’s needs.
Impact
By ensuring through simulation and prototyping, along with our expertise in complex casting procedures, that the components were viable before we started casting, we were able to reduce scrap and costly rejections when testing in the field. By supplying quality, repeatable castings we are also making sure the customer benefits from best total cost of ownership.
Get In Touch
We take pride in building successful, long-term relationships with our clients, because their reputation is our priority.
If that sounds like an investment castings partner you’d like to work with, you can book an introduction call with our friendly and knowledgeable New Relations Team — in a language and time zone to suit you.