FE prediction of residual stresses of investment casting in a Bottom Core Vane under equiaxed cooling

This paper presents an investment casting simulation of the Bottom Core Vane (BCV) component of an aero-engine subjected to equiaxed cooling. The simulation is carried out using the Finite Element Method (FEM). Two FE codes (ABAQUS and ProCAST) are used for performing the simulation and the results from both codes are compared and reviewed. The main goal is to predict the residual stresses in the BCV in a casting simulation. Inconel 718 material is used for the ingot (BCV) and a ceramic material is used for the mould. The gap formation and the gap conductance models, between the ingot and the mould, are implemented into the Finite Element Analyses (FEA). Sensitivity studies of the mechanical calculations in ABAQUS and ProCAST, mould filling, mould materials, convection and friction coefficients are conducted to investigate their influences on the predicted residual stresses.