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Hot isostatic pressing (HIPping) technology is used for healing the casting defects for aerospace applications. Castings used for aerospace applications like turbo-pumps need to meet very stringent quality requirements. Complexity of the castings used in these applications, makes it difficult to meet the quality requirements in all the areas. Defects like gas holes, shrinkages, cavities etc. may occur in few locations and need to be repaired by welding or healed by HIPping. In the present study, we attempted to simulate the defect healing capability of HIP in a systematic manner. Artificial defects were created in Austenite-Martensite grade stainless steel cast rod. These rods were then subjected to HIP prcoss cycle at 1150 °C and at a pressure of 1620 bar. Healing of the defects was ensured through X-ray radiography. Detailed microstructural analysis using optical metallography and scanning electron microscopy (SEM) with EDX was carried out before and after HIPping, to understand the defect healing mechanisms. These results are discussed in detail here.

04X13H5M5К9Л is a stainless maraging steel with high strength and excellent toughness. This alloy has been selected for making Impeller casting which is subjected to localized stresses reaching as high as 700 MPa at the tip of its vanes. The impeller rotates at 19000 RPM for 253 seconds.This alloy comprises of austenitic – martensitic dual phase at room temperature, in which martensite exhibits Body Centered Cubic (BCC) structure with moderate hardness (HRC 30) and high toughness. The required strength is achieved by precipitation of second phase particles in soft martensite matrix at suitable aging temperature. There is always a chance of reversion of martensite to austenite on heating either for extended period or at higher temperature. Thus optimization of aging temperature and time becomes highly critical keeping in mind the functional stress requirements of the component. The optimization has been done using Differential Scanning Calorimetric (DSC) analysis, dilatometric studies and experimental iterations of heat treatment temperatures and aging time.Different combination of strength and ductility could be achieved by varying heat treatment parameters. Martensite start and finish temperatures and austenitic reversion temperatures were established through DSC and dilatometric studies. Effect of subzero temperature on properties and microstructure of this steel is also presented here. Scanning Electron Microscopy and Energy Dispersive Spectroscopy were also carried out to analyze phases in different heat treatment conditions.

Rheocasting refers to a process in which a liquid metal is vigorously agitated during initial stage of solidification to produce globular semisolid slurry which remains highly fluid. This slurry is directly fed into any shaping operation to obtain SSM parts. Rheocasting is an energy saving as well as cost saving, good surface finish and negligible porosity for a specialized casting, in which heating step of thixocasting is completely eliminated. Rheocasting also offers shot size flexibility and amenable for processing of wrought alloys and metal matrix composites, which are otherwise difficult to process by thixocasting route. A slurry with globular shape of the solid phase particles and hence injected directly into the die. In the present development, Al base thin wall components for electronic packaging applications were produced by rheocasting process. The paper presents the die designing aspects, optimization of rheocasting process parameters to achieve the sound casting and mechanical property. Thin walled Al-Alloy components lot was realized by the novel processing technology, meeting dimensional accuracy, desired microstructure, mechanical property, value for high integrity component needed for space applications.

Investment casting has emerged as the foremost casting process for manufacturing of intricate parts where better dimensional accuracy is required. Use of rapid prototyping polymer patterns is one of the major advancements in investment casting process. Elimination of die making step as required in the traditional wax process makes it quicker and a cost effective process. The direct conversion of 3D CAD data into rapid prototyping pattern decreases development time, chances of costly mistakes, minimizes sustaining engineering changes and extend product lifetime by adding necessary features and eliminating redundant features early in the design.