本論文研究引擎渦輪段渦輪葉片及噴嘴等之精密鑄造與鋁化鍍層技術的製程/微組織模擬，內容包括(1).使用實驗計畫法改善製程，(2).鎳基超合金之熱性質研究，(3).使用電腦模擬系統之製程改善，(4).等軸晶渦輪噴嘴鑄造製程之顯微組織及空心複雜單方向凝固製程渦輪葉片之顯微組織等模擬及實驗驗證，與(5).高溫鋁化鍍層製程改善等五個部份。
　　本研究首先使用實驗計畫法，改善傳統精密鑄造法製作超合金等軸晶渦輪噴嘴鑄造製程方案，以高效率選擇參數之方法，獲得巨觀包括表面晶粒，目視、螢光、X光、尺碼等非破壞檢驗及微觀包括微縮孔含量及分佈、夾渣、陶模/金屬間反應，合金缺乏，與顯微結構等金相破壞觀察、檢驗等等合乎規格要求之鑄件後，再以熱差分析 (DTA)，示差掃描熱量計分析 (DSC) 及電腦輔助冷卻曲線分析 (CA-CCA) 等裝備及方法，獲取材料之熱性質，包括γ′相之固溶溫度，固相線溫度，液相線溫度，潛熱及固相率與溫度間之關係等，接著使用3-D CAD軟體繪製不同鑄造方案之渦輪噴嘴及空心葉片模型，採用有限元素法，經網格化後，由模擬軟體之前處理器將材料之性質指派，並將金屬-陶模界面，成核條件，輻射因子，起始、邊界條件及方程式與缺陷形成指標等設定後，以模擬器進行充填及凝固分析，藉由模擬分析找出最適製程改善方案，將分析所得之溫度場，然後應用推測學之晶胞自生(Cellular Automaton, CA)模式，配合成核、成長、方位等指標，再以模擬器進行分析及計算，來進行等軸晶及方向晶晶粒組織型態（包括形狀、大小及方向）的模擬預測，所得之結果於後處理器中顯示，再與實際精密鑄造程序所得之鑄件晶粒比較，確定晶粒大小、形狀、粒度均勻度及角度。最後以氣體滲透法鋁化法改善製程以提昇基材之表面抗高溫氧化能力，同時探討鑄件本身之表面粗糙度及鑄件擺放方式對鍍層厚度及鍍層內鋁含量之影響與鑄件表面缺陷，如夾渣物，凸出物，凹陷，孔洞等，對鍍層形態及高溫抗氧化性之影響。
　　本研究各部份所獲得的成果如下：
　　實驗計畫法方面，成功的由64個製程參數獲得原1,008個製程參數之結果，並以低成本、高效率實驗計畫，製作出合乎巨觀 (包括目視、螢檢及X-光) 及微觀檢驗規格要求之複雜6片一組噴嘴鑄件。微縮孔含量經實際切割3個成品 (每個噴嘴21塊，共63塊)，在50倍顯微鏡(實際面積為2.26到 2.58 mm2之範圍)下觀察，最多只有4.0%，合於規格要求。
　　探討René77合金熱性研究方面，本研究所量測及分析結果為：γ′相固溶溫度為1135℃，固相線溫度為1264℃、液相線溫度為1357℃。由示差掃描熱量計分析所得之潛熱值為140.4 kJ/kg。利用電腦輔助冷卻曲線分析可得到精確的René77合金之固相率對溫度的分佈函數，提供合金凝固熱傳模擬之重要依據。
　　電腦模擬系統之製程改善方面，藉由模擬結果得知，最好之方案優於實驗計畫法，不僅可完全消除巨觀縮孔且微縮孔含量最差部份只有1.0 %。經與相同方案設計下實驗所得之鑄件結果比較，非常的吻合。
　　等軸晶渦輪噴嘴鑄造件及空心複雜單方向凝固製程渦輪葉片等之表面晶粒形態進行模擬預測製程之顯微組織及實驗驗證方面，本研究以推測學模型之晶胞自生模式及有限元素熱傳模式，配合熱性研究及成核、成長、方位，等軸晶-柱狀晶轉變等預測指標，成功的模擬出多元素超合金之表面3D晶粒形態。等軸晶晶粒形態並經由平均粒度及粒度均勻度分佈參數之定量分析，與實際相同條件實驗所得之鑄件比較，不僅晶粒形態分佈吻合，晶粒大小之定量上也很接近。而柱狀晶晶粒形態經由晶粒形態、大小與晶粒數目、晶粒方位偏離﹝001﹞角度及晶粒寬度等之定量分析，與實際相同條件實驗所得之鑄件比較，不僅晶粒形態分佈吻合，晶粒大小、方位之定量結果上也很接近。研究結果顯示所採用之電腦模擬系統是相當準確而可靠的，經由本系統的輔助，工程師可以數值實驗的方式有效取得適當的方案設計。
　　高溫氣體滲透法鋁化鍍層製程改善方面，所得之實驗結論為，鑄件之擺放方式將影響鍍層厚度之均勻性，但對鍍層最外層鋁含量之影響則無規則性。鑄件表面粗糙度Ra高於1.89 µm時，表面粗糙度對鍍層厚度及品質有相當大影響，而Ra低於1.40 µm時，表面粗糙度對鍍層厚度及品質則沒有明顯的影響。鑄件表面有凸出物或凹陷等缺陷將容易附著氧化物並造成鍍層形態之改變，而夾渣物及孔洞則會阻擋擴散之進行，造成鍍層出現缺口，這些鍍層型態皆會影響高溫抗氧化性質。

Turbine blade and vane are jet engine key components. The purpose of this dissertation is to improve process technology and process /microstructure simulation of casting and surface coating for two complex turbine section parts. The cast parts under investigation are a René 77 equiaxed 6-vane turbine multi-nozzle of dimensions 230mmL*180mmH*51mmW and a Mar-M-247LC complex hollow directionally solidified blade of dimensions 53mmL*50mmH*15mmW.

This dissertation is divided into five sections. It begins by describing how a good quality multi-vane segment may be produced utilizing Design of Experiment (DOE) methods. This is then followed by René 77 thermal measurements including γ′solvus, solidus and liquidus temperatures, latent heat and solid fraction versus temperature relations utilizing Differential Thermal Analyzer (DTA), Differential Scanning Calorimeter (DSC) and Computer Aided-Cooling Curve Analysis (CA-CCA). Thermal data are then applied to the casting simulation model to obtain optimal process parameters and to predict cast multi-vane segment porosity defects which are then compared with actual casting experiment results. Next a stochastic model which couples a Cellular Automaton technique with finite element solidification heat transfer scheme is applied to the casting simulation model with grain nucleation/ growth model and other criteria to simulate grain morphology on a casting surface for equiaxed and columnar grain solidification which are then compared with actual casting experiment results. Lastly, improvement of the cast surface via vapor phase aluminized coating process is assessed.

The results are summarized as follows:
1. The DOE method not only succeeds in selecting 64 critical process parameters from the original 1,008 parameters, but also chooses an optimal gating system to meet low cost and high efficiency requirements. Final castings obtained are free from macroporosity, and the worst microporosity occurs on the inner and outer shrouds of third blade tip-section in the range of 4% under 50X magnification.

2. Regarding measurement of the René 77 thermal data - DTA shows theγ′solvus temperature is 1135℃, and solidus and liquidus temperatures are 1264℃ and 1357℃ respectively. The DSC illustrates that latent heat is 140.4 kJ/kg. The CA-CCA method aptly displays the solid fraction versus temperature relation.

3. Casting simulation models are used to obtain optimal process design and predict porosity defects. The simulated result for macroporosity formation of the René 77 complex nozzle segment investment casting alloy agrees very well with the experimental measurements obtained from the actual casting. Simulated results for microporosity formation for the nozzle segment investment casting also agree very well with the experimental porosity map. Such agreement is not only qualitative in nature but also even accurate regarding absolute quantity. The simulated results show that macroporosity from the optimal gating design is completely eliminated and the microporosity is lower than the DOE’s design. It also shows that the worst microporosity formation is around 1.5% for this optimal casting design.

4. Regarding grain morphology simulation modeling, a computer simulation system which adopts finite element method to model the mold filling and solidification behavior via stochastic Cellular Automaton methods together with nucleation and grain growth behavior models are used to predict grain morphology of equiaxed and directionally solidified castings. Simulated grain morphology results of the complex nozzle segment casting and in the complex blade casting agree quite well with experimental observations obtained from the actual casting. The quantitative values of the average grain size, grain uniformity index, grain number, grain width and grain orientation are furthermore compared between simulated results and actual experimental measurements and also show good consistency.

5. Casting surface improvement by application of vapor phase aluminized coating: An out of pack/above pack process is employed to investigate the effects on surface roughness and part orientation on the quality of the vapor phase aluminized coating for a René 77 nozzle segment casting. The following conclusions are reached based on the experimental results. (1) Casting orientation can significantly affect the coating thickness uniformity, however orientation has small effect on coating aluminum content. Casting orientation #3, of which placement in the chamber is inner shroud pointing inward, trailing edge leftward and concave side upward, result not only in aluminum content and thickness specifications being met but also in a far more uniform coating. (2) Casting surface roughness has an evident effect on the occurrence of coating thickness irregularities when coating is thicker than 1.87µm, yet effects on coating roughness become insignificant when the surface roughness of the casting is below 1.43µm. (3) Surface defects of negative surface intrusions and positive matter extrusions cause grit particles and oxides to embed in the casting and subsequently change coating morphology. Inclusions and open voids, however, impede the diffusion process and cause discontinuity in the coat film. These irregular coatings deteriorate high temperature resistance properties of the coated casting.

Based upon the above, it may be concluded that the utilization of the employed computer simulation system is reasonably accurate in predicting defects arising from mold filling, solidification or grain morphology for complex investment turbine component castings, and thus such system may be considered as a valuable tool by engineers in efficiently obtaining optimal design of casting parameters.

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