Continuous numerical simulation framework for casting and heat treatment of complex curved parts: material manufacturing and surface accuracy optimization

Deformation of turbine blades during casting and heat treatment affects engine efficiency and manufacturing precision. This study investigates the deformation behavior of single-crystal nickel-based superalloy blades using numerical simulations and experiments. The casting and heat treatment processes have typically been treated as isolated stages in previous studies, making it difficult to establish a coupled relationship between them. This work develops a numerical framework to transfer the residual stress and deformation predicted from the casting process into the heat treatment simulation. This framework systematically analyzes the temperature field, stress field, and deformation behavior of turbine blades throughout both processes. Experimental validation confirms its accuracy, providing valuable insights for optimizing blade precision and improving production quality.