Directional solidification of large superalloy castings with radiation and liquid-metal cooling: A comparative assessment

A columnar-grain variant of single-crystal RENÉ N4 has been directionally solidified (DS) over a range of conditions in order to assess the possible benefits of the use of liquid metal-enhanced cooling for large cross-sectional castings. Castings were solidified at a rate of 2.5 mm/min using conventional radiation cooling and at rates between 2.5 and 8.5 mm/min using liquid-metal cooling (LMC) with tin as a cooling medium. Thermocouples inserted in the casting directly measured thermal gradients during solidification. The LMC process exhibited higher gradients at all withdrawal rates. The higher thermal gradients resulted in a refined structure measurable by the finer dendrite-arm spacing. Additionally, the conventionally cast material exhibited several freckle-type defects, while none were observed in the liquid-metal-cooled castings.

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