Elimination of misrun and gas hole defects of investment casting TiAl alloy turbocharger based on numerical simulation and experimental study

Casting technology of thin-wall TiAl alloy turbochargers was studied by investment casting and numerical simulation. Misruns and gas holes were the main defects observed in preliminary work due to the poor fluidity of alloy, and to gas entrapment. In order to eliminate these defects, cast parameters, such as centrifugal rotation rate and mould preheating temperature, were optimized by numerical simulation, meanwhile, the structure of the shell mould was optimized to improve the filling capacity of TiAl alloy. Pouring experiments were carried out by vacuum induction melting furnace equipped with a water-cooled copper crucible based on the above optimization. The quality of the TiAl alloy casting was analyzed by fluorescent penetrant inspection and X-ray detection. The results show that a centrifugal rotation rate of 200 rpm, mould preheating temperature of 600 °C, shell preparation through organic fiber addition can dramatically improve the mould filling capacity, and integrated turbochargers were finally prepared.