Because single-crystal components are Jmrd to cast, accurate models of the casting parameters can help to reduce the scrap rate and lower costs. A defect map, which plots the occurrence of defects based on the temperature gradient and the solidification rate, can be used as a performance criterion in process modeling. This article describes the use of defect maps in the investment casting of a single-crystal turbine blade.

Editor's Notes: The results presented here are based on research funded by the U.S. Advanced Research Projects Agency (ARPA) through the Investment Casting Cooperative Arrangement (ICCAl. The ICCA is a consortium of five companies: General Electric Aircraft Engines, Pratt & Whitney, Howmet Corporation, PeC, and UES. In addition to these five member companiesl a number of research institutes are participating members of the program. For more information on the ICCA, refer to Reference 5. A richly linked World Wide Web version of this article with color versions of the figures has been prepared for 1MS OnLine. To access this version of the document contact http: //www. tms.org/pubs/journals/JOM/9510/Tu-9510.html.A major roadblock preventing the widespread use of casting simulation technology is the intensive effort required by a highly skilled professional to construct a finite-element model. To address this situation, this article proposes an integrated-model construction procedure that reduces model construction time for a typical aeropropulsion component from two weeks to two days. It also describes another step toward the accurate and practical prediction of the coating process through coupled heat transfer, fluid flow, and stress calculation.