Advanced Research Methods in Shape Casting Conference Programme

9:30 – 10:00

Coffee and arrival

10:00 – 10:30

Welcome and introduction to ARCANE

Parallel sessions

Session 1

Session 2

10:45 – 11:05

Casting Modelling at Rolls-Royce: A Worthwhile Investment (Paul Tennant – Rolls-Royce)

This presentation will provide an overview of casting modelling capabilities at Rolls-Royce, highlighting current predictive methods and the potential advancements offered by ARCANE. Additionally, it will explore the increasing integration of automation in modelling, enabling more analysis to be completed in less time with fewer resources.

Strain Rate and Temperature Dependent Deformation Mechanisms in the Single Crystal Superalloy CMSX-4 – Insights from Full-Field Surface Mapping (Melvin Miquel - University of Oxford)
Methods used to rapidly obtain vast amounts of surface strain data and how this transfers to microscopic deformation behaviour observed in the SEM.

11:05 – 11:25

Modelling solidification microstructure using High-Performance Computing (Professor Andrew Kao – University of Greenwich)

A presentation on the background of TESA, a parallel multi-physics microstructure solidification code. The talk will have an emphasis on High Performance Computing allowing the capture of microscopic features from a macroscopic perspective, and involves the simulation of multi-billion cell calculations across 100-1000s of CPU cores.

Implications of the Grain Boundary Orientation and Precipitate distribution in Creep Life above 1000^oC (Neil D’Souza – Rolls-Royce)

Miniature testing has been used to quantify the role of grain boundary orientation and the microstructure, which is principally gamma prime distribution at close to solvus temperatures. Comparison is made with the single crystal of similar axial orientation and also aspects pertaining to miniature testing are addressed.

11:25 – 11:45

Competitive grain growth – towards a physics based model (Peter Soar – University of Greenwich)

This presentation will show the development of TESA in the ARCANE project to simulate observed microstructural behaviours and features. This includes modelling bi-crystal dendrite competition with buoyancy driven fluid flow to understand what factors make a particular crystal orientation more competitive and modelling the formation of solute channels in a single crystal microstructure which can lead to the formation of freckle chains.

Grain boundary microstructures in bi-crystals (Paul Withey - University of Birmingham)

The grain boundary structures in single crystal alloys show unusual precipitate structures at high mismatch angles. This paper will investigate the development of the grain boundary microstructure with increasing mismatch angle.

11:45 – 12:05

Modelling of flow induced grain refinement (Ivars Krastins – University of Greenwich)

A presentation on particle tracking in fluid flow using the LBM solver. This work is primarily for the TEAM project to look at the particle segregation during additive manufacturing. But it can potentially be used to look at dendrite fragmentation and stringer transport during solidification.

High Temperature Multi-Axial testing of Nickel Superalloys: model and method development (Mike Goode - University of Oxford)

This presentation will focus on developing the methods and equipment necessary to test nickel superalloy samples, with part-representative surface finishes, under tension/torsion conditions at high temperatures. To better understand the results generated, Crystal Plasticity Finite Element (CPFE) Models are used to contextualise and predict experimental behaviour.

12:05 – 12:25

An approach to binary representation of complex alloys for solidification modelling (Joseph Moses, Nils Warnken - University of Birmingham)

Single crystal superalloys are chemically very complex, with at least nine different chemical elements which interact with each other. Many modelling approaches were however developed for binary alloys, owing to the binary nature of large parts of solidification theory. Different approaches for deriving binary representation of multicomponent alloys are available. These create weighted averages of the constituting binary phase diagrams. In this work we develop a fundamentally different approach. The binarised alloy must be able to reproduce the pattern formation seen during directional growth of dendrites. Phase field simulation of dendrite growth in multicomponent alloy provide the basis from which the binarisation of the alloy is then determined.

Crystal Plasticity model development and validation, using tensile, fatigue and TMF data for CMSX-4 (Christos Argyrakis – Rolls-Royce)

A parametric study with varying SX orientation angles has been carried out using a crystal plasticity user material model in Abaqus. The grain orientation Euler angles are defined by the casting process distribution and previous elasticity, plasticity and creep model outputs have been benchmarked against the new single crystal model to make sure that the output predictions are in-line with the current analysis standard.

12:25 – 12:55

Discussion

Discussion

12:55 – 13:40

Lunch

13:40 – 14:00

Machine Learning for improving knowledge on mechanistic model (Marco Canducci – University of Birmingham)

Exploration of different strategies for learning or improving the knowledge about mechanistic models via scientific Machine Learning approaches.

14:00 – 14:20

Modelling interaction and reaction between multi-component alloys and complex ceramics - Introducing a new methodology (Joseph Moses, Nils Warnken - University of Birmingham)

Complex single crystal superalloys interact with oxide particles, which are for example part of the mould used to cast the alloy. This is by nature a chemically complex system, with multiple oxide phases present. This can lead to nucleation of alloy crystal where is it unwanted. We use modelling to study and predict these chemical interactions, linking them to experiments

14:20 – 14:40

Modelling of oxide creation, entrainment and capture in casting process (Jean-Christophe Gebelin - Rolls Royce)

The work presented investigate methods to model oxide during mould filling, looking at modelling creation and transport of oxide in the flow as well as phenomena that can capture and eliminate oxides from the flow, with the aim to be able to predict oxide being created, possibly captured, and where they end up once the mould filling is completed.

14:40 – 15:00

A method to measure heterogeneous nucleation and grain refinement potential in engineering alloys (Richa Gupta - University of Birmingham)

A talk on an experimental approach to determine the nucleation potency of an inclusion/impurity phase/ inoculant during solidification.

15:00 – 15:30

Discussion

15:30 – 15:45

Thank you and close