Defect Prediction and Multi-objective Process Optimization in Investment Casting of K4169 Superalloy Thin-walled Complex Volute Structures

ZHANG Hengrui; DONG Yiwei; WANG Haidong; YANG Leilei; LIAO Yuting

doi:10.3969/j.issn.1674-6457.2025.11.004

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (11) : 47-57. DOI: 10.3969/j.issn.1674-6457.2025.11.004

Intelligent Processing of Advanced Materials

Defect Prediction and Multi-objective Process Optimization in Investment Casting of K4169 Superalloy Thin-walled Complex Volute Structures

ZHANG Hengrui¹, DONG Yiwei^1,*, WANG Haidong², YANG Leilei², LIAO Yuting¹

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Abstract

The work aims to address issues such as difficult control of shrinkage porosity defects and redundant volume of the gating system in the investment casting of thin-walled complex volute components made of K4169 superalloy, and to provide an optimized scheme for the high-quality and low-cost manufacturing of the castings. A full-process numerical simulation was conducted based on the ProCAST finite element platform. Multi-point S-type double platinum-rhodium thermocouples were used to measure temperature data during the casting process, and the interfacial heat transfer coefficient between the casting and the mold shell was inversely calculated to improve simulation accuracy. A regression model was established, and the Pareto frontier solution set was generated according to the NSGA-II algorithm and the TOPSIS method to determine the optimal process parameters. The structure of the gating system was optimized, the placement posture of the casting was adjusted, and tests were carried out to verify the optimization effect. Data on defect location, volume, and mechanical properties of the casting from simulation and actual measurement were compared. The average absolute error between simulated and measured temperatures was controlled within ±2 ℃, with a root mean square error of 2.1 ℃. The optimal process parameters were determined as a pouring temperature of 1 450 ℃ and a preheating temperature of 1 050 ℃. After structural optimization, verification showed that the total volume of shrinkage porosity decreased by 63%, and the volume of the gating system reduced by 29%. For the castings produced in actual production, the room-temperature tensile strength reached 890 MPa, and the yield strength reached 680 MPa, all meeting the design requirements. The production qualification rate was increased to 80%. In conclusion, the interfacial heat transfer coefficient model effectively improves simulation accuracy. The coordinated optimization of the gating system and process parameters achieves both defect control and improvement of material utilization, and it has both practicality and efficiency in casting engineering. KEY WORDS: superalloy; aviation volute structure; investment casting; numerical simulation; multi-objective process optimization; shrinkage defects

Key words

superalloy / aviation volute structure / investment casting / numerical simulation / multi-objective process optimization / shrinkage defects

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ZHANG Hengrui, DONG Yiwei, WANG Haidong, YANG Leilei, LIAO Yuting. Defect Prediction and Multi-objective Process Optimization in Investment Casting of K4169 Superalloy Thin-walled Complex Volute Structures[J]. Journal of Netshape Forming Engineering. 2025, 17(11): 47-57 https://doi.org/10.3969/j.issn.1674-6457.2025.11.004

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Funding

National Natural Science Foundation of China (52475491, 51705440); Aeronautical Science Foundation of China (20170368001, 20230003068002, 20240003068001); Foundation of State Key Laboratory of Intelligent Manufacturing Equipment and Technology (IMETKF2024013); Sichuan Science and Technology Program (2025YFHZ0039)