CN102416463A - Electroslag fusion casting manufacturing method for annular plate of hydraulic generator - Google Patents

Electroslag fusion casting manufacturing method for annular plate of hydraulic generator Download PDF

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Publication number
CN102416463A
CN102416463A CN2011104049600A CN201110404960A CN102416463A CN 102416463 A CN102416463 A CN 102416463A CN 2011104049600 A CN2011104049600 A CN 2011104049600A CN 201110404960 A CN201110404960 A CN 201110404960A CN 102416463 A CN102416463 A CN 102416463A
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crystallizer
casting
founding
annular plate
slag
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CN102416463B (en
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徐超
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SHENYANG SHENGHUA SPECIAL CASTING CO Ltd
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SHENYANG SHENGHUA SPECIAL CASTING CO Ltd
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Abstract

The invention discloses an electroslag fusion casting manufacturing method for an annular plate of a hydraulic generator. The method is characterized by comprising the following steps of: 1) controlling slag systems and slag amount; 2) igniting; 3) selecting a crystallizer; 4) rotating the crystallizer by using a control system; 5) selecting power supply parameters; 6) controlling casting alloy components after fusion casting; and 7) selecting a casting thermal processing process. A near-net-shape forming annular plate manufacturing technology is provided for producing annular anti-tear steel plates for hydraulic generator seat rings, top covers and bottom rings at present; a rotatable crystallizer is used for electroslag fusion casting formation, so that technical requirements on production of the annular plate are met; and the produced annular plate has high laminated tearing resistance, higher fatigue resistance and higher crack generation and expansion resistance, and the quality and the performance of the annular plate are not lower than those of a specially-forged product which is made of the same material as that of the annular plate.

Description

A kind of hydrogenerator is with the electroslag smelting casting manufacturing approach of ring flat-plate
Technical field
The present invention relates to a kind of technology of producing extraordinary anti-lamellar tearing steel plate, particularly relate to a kind of electroslag smelting casting technology-specific of utilizing in producing the electroslag smelting casting manufacturing approach of hydrogenerator with ring flat-plate.
Background technology
Along with country to the adjustment of power construction structure and the attention of environmental protection, the develop actively water power has become the guilding principle that China power industry is built.Water power belongs to reproducible clean energy resource, helps environmental protection, and Hydropower Development improves design, manufacturing and the production capacity of large-scale high head hydraulic turbine group, be promote national economic development with the demand that promotes development of machinery industry.
In the hydraulic turbine, spiral case seat ring, top cover and base ring are important components, and structure will have enough strength and stiffness.In use owing to the trapezoidal welding of employing, thereby to the anti-lamellar tearing performance of material higher requirement is arranged, particularly, its tear resistance is had strict requirement as important component part---the ring flat-plate of seat ring, top cover and base ring.
At present; Domestic steel plate thickness is that the extraordinary anti tear steel plate of 80~250mm mainly relies on import; Its production technology mainly adopts the extraordinary rolling mill practice that forges; Promptly in forging process, not only require steel plate to have good comprehensive mechanical properties, and will guarantee that rolled plate Z is to having good anti-lamellar tearing performance.The control of its anti-lamellar tearing alloying component impurity component and processing technology be the domestic similar steel plate of big yield strength of still can't producing at present; Particularly big thickness steel plate; Exactly because this technical bottleneck makes domestic use to this special steel plate receive very big restriction.Because this special rolling steel plate is square slab, in use be cut into the ring covering of the fan simultaneously, so also cause more a large amount of steel wastes, further increase use cost based on the demand size.
Summary of the invention
The objective of the invention is to solve the technical bottleneck of this series products of domestic production, and developed a kind of new method of utilizing electroslag casting process to be exclusively used in to produce the ring flat-plate that hydraulic generator field ring, top cover and base ring use.The present invention adopts the electroslag smelting casting technology; Produce hydrogenerator and use ring flat-plate, the ring flat-plate internal soundness of production is not less than with material forging quality standard, can reach the performance requirement of Z to anti-lamellar tearing steel plate of yield strength 550MPa rank and Z35 plate; Can satisfy the design and the serviceability requirement of hydrogenerator ring flat-plate parts; And on the electroslag casting process basis, through adopting the one-sided arc cooling surface founding mode of closure step by step, reasonable crystallization control device and electrode relative position reach nearly clean type mode and produce foundry goods; Reduce ring flat-plate ring covering of the fan cutting quantity, increase stock utilization.
The present invention is the production with ring flat-plate anti tear steel plate of present hydraulic generator field ring, top cover and base ring; A kind of ring flat-plate manufacturing technology of clean nearly moulding is provided; And through adopting rotatable crystallizer electroslag smelting casting moulding; Reach the specification requirement of producing ring flat-plate, the ring flat-plate of being produced has good anti-lamellar tearing performance, higher fatigue resistance ability, the generation of higher crack and scalability, and its quality and performance are not less than with the extraordinary forging product of material.
Technical solution of the present invention is: this hydrogenerator comprises design and makes the crystallizer that encircles fan-shaped inner chamber with the electroslag smelting casting manufacturing approach of ring flat-plate, prepares consutrode with refinery practice, adopts the electroslag casting process moulding.Be characterized in: the electroslag smelting casting operating process: be used to accomplish the task such as double refining purification, foundry goods near-net-shape of refining consutrode material, have following steps.
1. the slag system and quantity of slag control: slag system adopts with CaF 255~85%, Al 2O 315~45% is main, and can require to add a small amount of MgO, the CaO slag system that comes from different backgrounds and possess different abilities according to actual alloy refining, and it adds weight and is not higher than 30%, and the quantity of slag is generally 1%~10% of foundry goods.
2. the mode of igniting: consutrode adopts solid-state in crystallizer or liquid slag is ignited, and its chemical composition is TiO with the percentage by weight 2: 35~65%, CaF 2: 35~65%.
3. crystallizer is selected: the material of crystallizer is full copper or all steel or copper steel combination mould; Adopt vertically ring covering of the fan casting; With ring covering of the fan round dot is pivot; Guarantee that consutrode is vertical with founding face; While is along with the crystallizer that is rotated of founding; And the fan-shaped outer camber line one side crystallizer cooling surface of closed hoop progressively, reach the purpose of the nearly clean type ring flat-plate of founding.
Fan-shaped outer camber line one side of the ring of crystallizer adopts the movable crystallizer cooling surface (as shown in Figure 1) that is flexible coupling.
4. crystallizer Rotable Control System: encircle fan-shaped crystallizer through clamps on a disk rotatable platform, survey liquation face position through inductive probe, through the crystallization control device speed of rotation, make the founding liquid level position all the time perpendicular to consutrode.
5. power supply parameter is selected: according to the geometric parameter of casting dimension, electrode and crystallizer and cooperate rotation parameter and founding is confirmed each respective electrical parameters such as founding power, voltage, electric current, note stablizing of maintenance voltage and current in the fusion-casting process.Wherein Control of Voltage in 50~115V, Current Control at 5000~20000A.
6. foundry goods alloying component (by weight percentage, content is this element maximum level in the table) after the founding.
7. heat treating castings technology: be the potential of eliminating foundry goods internal stress, the performance mechanical property of materials, adopt quenchings+tempering process, and adopt other heat treatments with optimization foundry goods combination property according to actual performance and technological requirement.
Anti-hot tearing and elimination internal stress heat treatment temperature are 300~900 ℃, and the quenching technical temperature is 600~1100 ℃, and the tempering process temperature is 450~750 ℃, and can require to adopt double tempering according to actual process.
Mechanical performance after the heat treating castings.
Figure BDA0000117344280000032
Compared with prior art, the invention has the beneficial effects as follows.
1. electroslag smelting casting is the refining consutrode to be carried out double refining purify, and purifies the lamellar tearing harmful element, and the foundry goods matrix is pure.And, reach the purpose of founding near-net-shape through the rotated mold filing design.
2. foundry goods solidifies in water mold, and cooling velocity is fast, solid-liquid forward position crystallization temperature gradient is big, since the foundry goods rapid solidification, foundry goods dense structure.The metal crystallizer dimensional accuracy is high, distortion is little, thereby cast(ing) surface is bright and clean, allowance is little.Owing to adopt vertically ring covering of the fan casting, be pivot with ring covering of the fan round dot, encircle fan-shaped outer camber line one side and adopt the movable crystallizer cooling surface that is flexible coupling; When guaranteeing that consutrode is vertical with founding face; Along with the carrying out of founding crystallizer rotation, the fan-shaped outer camber line one side crystallizer cooling surface of closed hoop progressively, rationally crystallization control device and electrode relative position reach closely only the type mode and produce the foundry goods purpose; Reduce ring flat-plate ring covering of the fan cutting quantity, increase stock utilization.
3. the refining foundry goods can reach the mechanical performance and flaw detection requirement with the material forging; Defectives such as chemical composition is even, dense structure, dendrite refinement, little, no loose, the no slag inclusion shrinkage cavity of microscopic segregation; Field trash is disperse and distributes; Be superior to the external refining steel fatigue life, the not available isotropic advantage of forge piece is arranged again, have higher fatigue resistance ability and higher crack simultaneously and generate and scalability.
4. because metal crystallizer can repeat repeatedly to use, especially at production wide-angle ring flat-plate, reduce welding capacity in the ring flat-plate use, also need not the large-sized forging production equipment, production procedure is short, the ring flat-plate excellent performance of producing.
Description of drawings
Fig. 1 is a crystallizer and can progressively closed cooling surface sketch map.
Mark among the figure: 1. electrode, 2. crystallizer, 3. progressively closure is flexible coupling.
The specific embodiment
Embodiment 1:
1. the slag system batching adopts: CaF 270%, Al 2O 330%.The quantity of slag is 3% of a casting weight.
2. the mode of igniting: consutrode adopts solid slag to ignite TiO in crystallizer 2: 50%, CaF 2: 50%.
3. the selection of crystallizer: adopt the copper steel combination mould, its structure adopts outer camber line one side to be closed cooling surface (Fig. 1) progressively.
4. power consumption parameter: confirm that according to casting dimension, electrode and crystallizer physical dimension founding voltage is 55V, electric current 6500A.
Through electroslag casting process, by the crystallizer moulding ring flat-plate of setting shape.Its chemical composition does.
The foundry goods mechanical performance does after the heat treatment.
Embodiment 2:
1. the slag system batching adopts: CaF 270%, Al 2O 330%.The quantity of slag is 3.4% of a casting weight.
2. the mode of igniting: consutrode adopts solid slag to ignite TiO in crystallizer 2: 50%, CaF 2: 50%.
3. the selection of crystallizer: adopt full Cu crystallizer, its structure adopts outer camber line one side of piecemeal combined type to be closed cooling surface progressively.
4. power consumption parameter: confirm that according to casting dimension, electrode and crystallizer physical dimension founding voltage is 75V, electric current 12000A.
Through electroslag casting process, by the crystallizer moulding of setting shape.Its chemical composition does.
The foundry goods mechanical performance does after the heat treatment.
Figure BDA0000117344280000054
Embodiment 3:
1. the slag system batching adopts: CaF 270%, Al 2O 330%.The quantity of slag is 2.5% of a casting weight.
2. the mode of igniting: consutrode adopts solid slag to ignite TiO in crystallizer 2: 45%, CaF 2: 55%.
3. the selection of crystallizer: adopt all steel crystallizer, its structure adopts outer camber line one side to be closed cooling surface progressively.
4. power consumption parameter: confirm that according to casting dimension, electrode and crystallizer physical dimension founding voltage is 50V, electric current 7500A.
Through electroslag casting process, by the crystallizer moulding ring flat-plate of setting shape.Its chemical composition does.
Figure BDA0000117344280000061
The foundry goods mechanical performance does after the heat treatment.
Embodiment 4:
1. the slag system batching adopts: CaF 270%, Al 2O 330%.The quantity of slag is 2.5% of a casting weight.
2. the mode of igniting: consutrode adopts solid slag to ignite TiO in crystallizer 2: 45%, CaF 2: 55%.
3. the selection of crystallizer: adopt all steel crystallizer, its structure adopts outer camber line one side to be closed cooling surface progressively.
4. power consumption parameter: confirm that according to casting dimension, electrode and crystallizer physical dimension founding voltage is 55V, electric current 7500A.
Through electroslag casting process, by the crystallizer moulding ring flat-plate of setting shape.Its chemical composition does.
The foundry goods mechanical performance does after the heat treatment.
Embodiment 5:
1. the slag system batching adopts: CaF 270%, Al 2O 330%.The quantity of slag is 3.5% of a casting weight.
2. the mode of igniting: consutrode adopts solid slag to ignite TiO in crystallizer 2: 45%, CaF 2: 55%.
3. the selection of crystallizer: adopt the copper steel combination mould, its structure adopts outer camber line one side to be closed cooling surface progressively.
4. power consumption parameter: confirm that according to casting dimension, electrode and crystallizer physical dimension founding voltage is 55V, electric current 6500A.
Through electroslag casting process, by the crystallizer moulding ring flat-plate of setting shape.Its chemical composition does.
The foundry goods mechanical performance is after the heat treatment:
Embodiment 6:
1. the slag system batching adopts: CaF 270%, Al 2O 330%.The quantity of slag is 4.5% of a casting weight.
2. the mode of igniting: consutrode adopts solid slag to ignite TiO in crystallizer 2: 45%, CaF 2: 55%.
3. the selection of crystallizer: adopt all steel crystallizer, its structure adopts outer camber line one side to be closed cooling surface progressively.
4. power consumption parameter: confirm that according to casting dimension, electrode and crystallizer physical dimension founding voltage is 85V, electric current 8700A.
Through electroslag casting process, by the crystallizer moulding ring flat-plate of setting shape.Its chemical composition does.
The foundry goods mechanical performance does after the heat treatment.

Claims (4)

1. a hydrogenerator is with the electroslag smelting casting manufacturing approach of ring flat-plate, comprises design and makes the crystallizer of the fan-shaped inner chamber of ring, prepares consutrode with refinery practice, adopts the electroslag casting process moulding.It is characterized in that the electroslag smelting casting operating process: be used to accomplish the task such as double refining purification, foundry goods near-net-shape of refining consutrode material, include following steps:
1) slag system and quantity of slag control
Slag system adopts with CaF 255~85%, Al 2O 315~45% is main, and requires to add MgO, the CaO slag system that comes from different backgrounds and possess different abilities according to actual alloy refining, and it adds weight and is not higher than 30%, and the quantity of slag is generally 1%~10% of foundry goods;
2) mode of igniting
Consutrode adopts solid-state in crystallizer or liquid slag is ignited, and its chemical composition is TiO with the percentage by weight 2: 35~65%, CaF 2: 35~65%;
3) crystallizer is selected
The material of crystallizer is full copper or all steel or copper steel combination mould; Adopt vertically ring covering of the fan casting; With ring covering of the fan round dot is pivot; Guarantee that consutrode is vertical with founding face; While is along with the crystallizer that is rotated of founding; And the fan-shaped outer camber line one side crystallizer cooling surface of closed hoop progressively, reach the purpose of the nearly clean type ring flat-plate of founding;
4) crystallizer Rotable Control System
Encircle fan-shaped crystallizer and pass through clamps on a disk rotatable platform, survey liquation face position,, make the founding liquid level position all the time perpendicular to consutrode through the crystallization control device speed of rotation through inductive probe;
5) power supply parameter is selected
According to the geometric parameter of casting dimension, electrode and crystallizer and cooperate rotation parameter and founding is confirmed each respective electrical parameters such as founding power, voltage, electric current, note keeping the stable of voltage and current in the fusion-casting process.Wherein Control of Voltage in 50~115V, Current Control at 5000~20000A;
6) foundry goods alloying component (by weight percentage, content is this element maximum level in the table) after the founding
7) heat treating castings technology
For eliminating the potential of foundry goods internal stress, the performance mechanical property of materials, adopt quenching+tempering process and heat treatment method, to optimize the foundry goods combination property.
2. hydrogenerator according to claim 1 is characterized in that with the electroslag smelting casting manufacturing approach of ring flat-plate fan-shaped outer camber line one side of ring of crystallizer adopts the movable crystallizer cooling surface that is flexible coupling.
3. hydrogenerator according to claim 1 is with the electroslag smelting casting manufacturing approach of ring flat-plate; It is characterized in that the anti-hot tearing in the step 7) heat treating castings technology and eliminating the internal stress heat treatment temperature is 300~900 ℃; The quenching technical temperature is 600~1100 ℃, and the tempering process temperature is 450~750 ℃.
4. hydrogenerator according to claim 1 is characterized in that with the electroslag smelting casting manufacturing approach of ring flat-plate the mechanical performance after the heat treating castings is:
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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102756111A (en) * 2012-07-13 2012-10-31 沈阳市盛华特种铸造有限公司 Electroslag fusion casting manufacture method of rotating wheel blanks of impact type hydraulic generator
CN103184391A (en) * 2013-03-22 2013-07-03 北京科技大学 Annular plate steel used for top cover of million-kilowatt-level large-scale hydraulic turbine and manufacturing method thereof
CN104174834A (en) * 2014-08-08 2014-12-03 沈阳铸造研究所 Electroslag casting production method for waterwheel blade green compact
CN107790684A (en) * 2016-08-31 2018-03-13 沈阳铸造研究所 A kind of electroslag smelting casting method of fixation and traveling electrode manufacture without public die cavity casting
CN109894603A (en) * 2018-12-19 2019-06-18 鞍钢铸钢有限公司 A kind of special thick electroslag slab production method
CN112285140A (en) * 2020-10-20 2021-01-29 北京航空航天大学 Quantitative characterization method for early-stage propagation rate of internal crack of single crystal ultrahigh cycle fatigue
CN113798474A (en) * 2020-06-12 2021-12-17 沈阳航空航天大学 Electroslag additive manufacturing method

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CN101480715A (en) * 2009-01-21 2009-07-15 东北大学 Electroslag smelting casting device with additional electromagnetic stirring and method
CN101607306A (en) * 2009-07-02 2009-12-23 沈阳铸造研究所 Electroslag smelting casting method of fixed blades of water turbine
CN102069174A (en) * 2009-11-24 2011-05-25 铜陵市大明玛钢有限责任公司 Method for producing centrifugal electroslag smelting and casting double-base composite roller

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JPS5913564A (en) * 1982-07-15 1984-01-24 Hitachi Ltd Electroslag casting method
CN1297107A (en) * 1999-11-18 2001-05-30 机械工业部沈阳铸造研究所 Method for making lower ring of large or middle water turbine
CN1288793A (en) * 2000-09-29 2001-03-28 徐登红 Successive electroslay smelting casting process of crank shaft blank
CN101480715A (en) * 2009-01-21 2009-07-15 东北大学 Electroslag smelting casting device with additional electromagnetic stirring and method
CN101607306A (en) * 2009-07-02 2009-12-23 沈阳铸造研究所 Electroslag smelting casting method of fixed blades of water turbine
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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102756111A (en) * 2012-07-13 2012-10-31 沈阳市盛华特种铸造有限公司 Electroslag fusion casting manufacture method of rotating wheel blanks of impact type hydraulic generator
CN103184391A (en) * 2013-03-22 2013-07-03 北京科技大学 Annular plate steel used for top cover of million-kilowatt-level large-scale hydraulic turbine and manufacturing method thereof
CN104174834A (en) * 2014-08-08 2014-12-03 沈阳铸造研究所 Electroslag casting production method for waterwheel blade green compact
CN107790684A (en) * 2016-08-31 2018-03-13 沈阳铸造研究所 A kind of electroslag smelting casting method of fixation and traveling electrode manufacture without public die cavity casting
CN107790684B (en) * 2016-08-31 2019-11-15 沈阳铸造研究所 A kind of fixation and traveling electrode manufacture the electroslag casting method without public chamber casting
CN109894603A (en) * 2018-12-19 2019-06-18 鞍钢铸钢有限公司 A kind of special thick electroslag slab production method
CN113798474A (en) * 2020-06-12 2021-12-17 沈阳航空航天大学 Electroslag additive manufacturing method
CN113798474B (en) * 2020-06-12 2022-06-17 沈阳航空航天大学 Electroslag additive manufacturing method
CN112285140A (en) * 2020-10-20 2021-01-29 北京航空航天大学 Quantitative characterization method for early-stage propagation rate of internal crack of single crystal ultrahigh cycle fatigue

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