Effect of Assembly Modes on the Directional Solidification Process of Single-crystal Guide Vanes

YANG Zhenyu; CHEN Hao; HU Songsong; ZHENG Sujie; LUO Kailun; LUO Yushi; DAI Shenglong

doi:10.3969/j.issn.1674-6457.2026.04.018

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (4) : 178-185. DOI: 10.3969/j.issn.1674-6457.2026.04.018

Superalloy Forming

Effect of Assembly Modes on the Directional Solidification Process of Single-crystal Guide Vanes

YANG Zhenyu¹, CHEN Hao², HU Songsong³, ZHENG Sujie¹, LUO Kailun¹, LUO Yushi¹, DAI Shenglong¹

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Abstract

The work aims to investigate the effect of two assembly modes (vertical vane body and inclined vane body) on the directional solidification process of single-crystal guide vanes, thereby providing technical and theoretical support for optimizing the directional solidification process and industrial production of single-crystal guide vanes. ProCAST + CAFE numerical simulation was employed to simulate the evolution of temperature field, undercooling, and grain structure during directional solidification for vertical vane body and inclined vane body at 40°. The inclined-assembly guide vanes were fabricated with the seed crystal embedding method and then subject to microstructural observation and crystal orientation determination via Electron Backscatter Diffraction (EBSD). Under the vertical assembly mode, the solid-liquid interface evolved from an initial near-planar shape to a concave shape in the upper-middle part of the vane body as the solidification progressed, accompanied by an increase in the width of the mushy zone. A high undercooling zone formed at the edge of the lower platform, leading to the generation of stray grains. Severe shrinkage porosity was also observed in the upper edge of the platform and the middle part of the vane body. In contrast, for the 40° inclined assembly mode, the solid-liquid interface maintained a wavy near-planar shape throughout the solidification process, with a narrow and stable mushy zone. The overall undercooling of the vane was reduced, and no stray grains were formed. Combined with the seed crystal embedding method, single crystals with <001> orientation were successfully obtained. Only a small amount of shrinkage porosity was detected in the platform, while the vane body exhibited minimal shrinkage porosity. Compared with the vertical vane assembly mode, the 40° inclined vane assembly mode effectively suppresses the formation of stray grains and shrinkage porosity. It is therefore recommended as the preferred assembly scheme for improving the manufacturing quality of single-crystal guide vanes.

Key words

guide vanes / assembly mode / stray grains / shrinkage porosity / temperature field

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YANG Zhenyu, CHEN Hao, HU Songsong, ZHENG Sujie, LUO Kailun, LUO Yushi, DAI Shenglong. Effect of Assembly Modes on the Directional Solidification Process of Single-crystal Guide Vanes[J]. Journal of Netshape Forming Engineering. 2026, 18(4): 178-185 https://doi.org/10.3969/j.issn.1674-6457.2026.04.018

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