CN102619862B - MW grade wind-powered torsion shaft and preparation technology thereof - Google Patents
MW grade wind-powered torsion shaft and preparation technology thereof Download PDFInfo
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- CN102619862B CN102619862B CN201110028332.7A CN201110028332A CN102619862B CN 102619862 B CN102619862 B CN 102619862B CN 201110028332 A CN201110028332 A CN 201110028332A CN 102619862 B CN102619862 B CN 102619862B
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Abstract
The invention aims to provide a torsion shaft for an aerogenerator, and an electroslag refusion casting method thereof, and the torsion shaft combines technical advantages of arc metallurgy and technical advantages of electroslag refusion casting (ESRC). A casting produced by adopting the preparation technology of the MW grade wind-powered torsion shaft provided in the invention has the advantages of uniform and compact crystal tissue, high purity, less nonmetallic inclusions, possessing of excellent compactness and fatigue resistance, reaching of forging flaw detection quality standards, realization of near net-shape forming, and low cost. The internal quality of the produced torsion shaft is obviously better than that of torsion shafts produced through sand casting.
Description
Technical field
[0001] the present invention relates to torsional axis and preparation process thereof for MW class wind turbine.
Background technique
[0002] along with China's economic development and environmental protection need, the demand of clean energy resource further increases, and wind-power electricity generation becomes one of important energy.Along with the development & construction of wind-power electricity generation, wind-power electricity generation is to high efficiency, maximization future development, more and more high to the quality requirement of the important spare part of wind-power electricity generation.Meanwhile, wind-driven generator is on land, and the complex environments such as ocean (require operating ambient temperature: normal temperature type-15 are ℃ to+45 ℃; Low form-30 ℃ are to+45 ℃; Living environment temperature: normal temperature type-25 ℃ are to+45 ℃; Low form-45 ℃ are to+45 ℃) application very harsh to the quality requirement of wind power generating set parts, except thering is higher nondestructive inspection rank and mechanical property, also need to possess antifatigue and certain corrosion resisting property.
Table 1.MW class wind turbine torsional axis size table.
| Station location marker | Figure paper size (mm) | Station location marker | Figure paper size (mm) |
| A/B | 350-900/200-800 | E1/E2 | 50-350 |
| C1/C2 | 200-550 | F | 1500-8000 |
| D1/D3 | 150-450 | G | 400-4500 |
| D2 | 150-500 | ? | ? |
At present, MW torsional axis for class wind turbine (Fig. 1,2 and table 1) production method mainly contains sand casting process and forges two kinds.Sand casting process casting quality and steel quality and casting technique are closely related, although provide the molten steel of high-quality by furnace outer refining technology (AOD or VOD) for Foundry Production, but the casting defects such as sand casting process is inevitable produces loose, shrinkage cavity, burning into sand, be mingled with, make interiors of products quality unstable, be difficult to meet the requirement of high-performance, high flaw detection level index, not only cause foundry goods to scrap in a large number, directly affect Security and the life-span of wind-driven generator operation simultaneously.Forging method is produced wind-powered electricity generation torsional axis and is conventionally adopted refining steel ingot (comprising electroslag remelting steel ingot), by forging, obtain blank, quality increases compared with sand-cast, but because torsional axis shape is special, stock utilization is very low, complex process axis central part is of low quality, high expensive.
Summary of the invention
The object of the present invention is to provide a kind of wind-driven generator torsional axis and electroslag smelting casting method thereof, arc metallurgy and electroslag smelting casting (ESRC) technical advantage are rolled into one.Adopt the preparation process of MW level wind-powered electricity generation torsional axis provided by the invention, the foundry goods crystalline structure even compact of producing, purity is high, sonims is few, have good compactness and anti-fatigue performance, can reach the flaw detection quality standard of forging, can realize foundry goods near-net-shape again, and cost is lower.The torsional axis internal soundness of producing is obviously better than sand casting process.
The present invention specifically provides a kind of wind-driven generator torsional axis, it is characterized in that: the brilliant arm of long shoot of described its as cast condition blank macrostructure of MW level wind-powered electricity generation torsional axis becomes 25-65 ° of angle with axle center.The dendrite dendrite not obvious and sand casting process that is different from forging moves towards.(as shown in Fig. 3,4,5)
The present invention specifically provides a kind of wind-driven generator torsional axis, it is characterized in that: the microstructure after its heat treatment of described MW level wind-powered electricity generation torsional axis is tempered sorbite or the tempered sorbite with martensite position phase.
The present invention also provides the preparation process of this MW level wind-powered electricity generation torsional axis, it is characterized in that: by adopting consutrode GS-18NiMoCr3-6, GS-34CrNiMo6 or GS-42CrMo4 steel to carry out electroslag smelting casting method, prepare torsional axis, its process parameter is:
A, slag system and the quantity of slag are controlled:
Slag system ingredient is CaF
2and Al
2o
3, its weight ratio is: CaF
2: Al
2o
3=60～70:30～20, the quantity of slag is casting weight 1.5～5%;
B, the mode of igniting:
Adopt solid-state or liquid slag to ignite, its chemical composition is TiO by weight percentage
2: 40%～60%, CaF
2: 60%～40%;
The selection of c, power supply parameter:
Founding voltage and current is:
U=[(0.5～0.7) D
crystallizer+ (25～35)]
I=[(580～680)+(30～36) d
electrode]
D in above formula
crystallizer, d
electrodebe respectively the long-pending equivalent diameter of crystallizer and electrode sections, unit is mm, and the unit of U is V, and the unit of I is A; In fusion-casting process, note keeping the stability of electric current and voltage.
The consutrode wherein adopting is GS-18NiMoCr3-6 steel, GS-34CrNiMo6 steel or GS-42CrMo4 steel; Electrode size: diameter range Φ 140～Φ 350mm, length range 6000～20000mm.
Its composition proportion of GS-18NiMoCr3-6 steel is weight percentage: C0.17～0.22%, Si0.30～0.60%, Mn0.80～1.20%, S≤0.015%, P≤0.02%, Cr0.4～0.9%, Ni0.6～1.1%, Mo0.40～0.7%, Fe surplus;
Its composition proportion of GS-34CrNiMo6 steel is weight percentage: C0.30～0.37%, Si0.30～0.60%, Mn0.60～1.00%, S≤0.025%, P≤0.015%, Cr1.40～1.70%, Ni1.40～1.70%, Mo0.15～0.35%, Fe surplus; Electrode size: diameter range Φ 140～Φ 350mm, length range 6000～20000mm;
Its composition proportion of GS-42CrMo4 steel is weight percentage: C0.38～0.45%, Si0.30～0.60%, Mn0.60～1.00%, S≤0.025%, P≤0.025%, Cr0.80～1.20%, Mo0.20～0.30%, Fe surplus; Electrode size: diameter range Φ 140～Φ 350mm, length range 6000～20000mm.
The preparation process of MW level wind-powered electricity generation torsional axis of the present invention, is characterized in that: at CaF
2-Al
2o
3in slag system, add a small amount of MgO and CaO, it adds gross weight≤10%.
The preparation process of MW level wind-powered electricity generation torsional axis of the present invention, is characterized in that: after founding, adopt the pre-heat treatment technique, heat treatment temperature is 750～780 ℃, and foundry goods is cooling with stove; Adopt afterwards anti-deforming and Anti-cracking technique to carry out quenching with Subsequent tempering: quenching 840-980 ℃, tempering 520-640 ℃.
The electroslag smelting casting crystallizer that the present invention also provides the preparation process of described MW level wind-powered electricity generation torsional axis to adopt, it is characterized in that: the crystallizer of employing is divided into crank crystallizer and conventional axle crystallizer two-part, crank crystallizer part consists of joint I 21, joint II 22, joint III 23, joint IV 24, and conventional axle crystallizer is partly joint V 25;
Crystallizer is to consist of the inner chamber template 5 adapting with crank shape, water seam plate 11, water jacket plate 12 and the transition die cavity 15 set up in the thickest position of crank, water seam plate 11 is arranged on the outside of inner chamber template 5, the inner side of water jacket plate 12, between water seam plate 11 and water jacket plate 12, be water jacket 14, water jacket 14 bottoms are installed with a plurality of intake pipes 4, top is installed with a plurality of outlet pipes 3; Turnover water pipe respectively on pressing close to lower flange position and with 5 °-15 ° of flanged plate angulations; Inner chamber template 5, water seam plate 11, water jacket plate 12 and water jacket 14 are tightly connected by upper flange 1, lower flange 2 and legislation blue 13; On crank crystallizer, be increased in the transition die cavity 15 of the thickest position of crank and conventional axle position, transition die cavity 15 is highly 150-300mm, adopts round-corner transition.
MW level scale wind power torsion shaft electroslag casting crystallizer provided by the invention, it is characterized in that: described crystallizer has yielding supporting facility, be device for detecting temperature, described device for detecting temperature is comprised of the thermocouple 16 and the external connection data collector of thermocouple 16 that insert crystallizer internal cavity.The thermocouple groove of device for detecting temperature processes in advance on crystallizer, and thermocouple groove is squeezed into crystallizer copper depth of inner cavity 2-10mm, and thermocouple 16 can freely be torn group connection data collector open so that thermometric.
MW level scale wind power torsion shaft electroslag casting crystallizer provided by the invention, it is characterized in that: between inner chamber template 5 and water seam plate 11, template stiffening rib 10 is set, and be welded into a whole with inner chamber template 5 and water seam plate 11, inner chamber template 5 outsides are separated into four regions, each region forms independent water circulation, water seam width between inner chamber template 5 and water seam plate 11 is 15-45mm, even transition.
MW level scale wind power torsion shaft electroslag casting crystallizer provided by the invention, is characterized in that: on template stiffening rib 10, process the groove 8 of long 20-100mm, wide 15-45mm, make two regional connectivities that face mutually in four regions in inner chamber template 5 outsides.
MW level scale wind power torsion shaft electroslag casting crystallizer provided by the invention, is characterized in that: water jacket 14 is installed in the water seam outer 50-100mm of plate 11 place.
MW level scale wind power torsion shaft electroslag casting crystallizer provided by the invention, is characterized in that, adopts locating device for positioning pin: 2 employing locating studs of upper flange 1 and lower flange, 17 location (network for location as shown in figure 12).Locating stud 17 can require to arrange between each layer of crystallizer according to available accuracy (conventionally diagonal positions 1 and 4 angles are respectively set all arrange), and between locating stud 17 and pin control, gap can be according to required precision setting.By locating device for positioning pin, can realize after minute crystal crystallizer cooperation, die cavity gap is no more than 4mm, and axially concentricity is no more than 2mm.
MW level scale wind power torsion shaft electroslag casting crystallizer provided by the invention, it is characterized in that: described crank crystallizer is just like two kinds of yielding modes shown in Figure 16,18, yielding auxiliary device is set on crystallizer, this device is comprised of U-shaped groove a6, U-shaped groove b7, jack 9 and L plate 18, by jack 9, affects L plate 18 to slide along U-shaped groove.Realize the nervous position 40 be no more than ± 6mm of stove amount of deformation of surplus.Crystallizer is made a concession auxiliary device except L plate 18, and remaining part and crystallizer can freely be torn group open, are convenient to maintenance and use.
MW level scale wind power torsion shaft electroslag casting crystallizer provided by the invention, it is characterized in that: described torsional axis crystallizer is divided into the opposite opened Split assembled crystallizer of 10,5 joint by crank quantity, somatotype position 19 is divided into joint I 21, joint II 22, joint III 23, joint IV 24 and joint V 25 by this crystallizer.There are two kinds of somatotype schemes (seeing Figure 15,17).
MW level scale wind power torsion shaft electroslag casting crystallizer provided by the invention, is characterized in that: inner chamber template 5 is to adopt 3D solid die-forging forming with whole copper coin, and other position all adopts steel plate.Described copper coin is copper plate, and thickness is 10-25mm, and water seam plate 11 and water jacket plate 12 are made by 10mm steel plate, and upper flange 1, lower flange 2 and legislation blue 13 are made by 15-25mm Plate Steel.Template stiffening rib, lacing wire thickness are 15-25mm.
Crystallizer provided by the invention can be realized the foundry goods demoulding smoothly, has transition die cavity, and crank position can be monitored, and can realize axially and making a concession, and without large deformation, positioning precision is high.
In torsional axis fusion-casting process, adopt crystallizer water temperature control system, foundry goods different parts fusion-casting process is carried out to temperature control, adjusting process parameter, guarantees foundry goods inside and surface quality at any time.
The purity of metallic matrix and crystallization are two key issues of metallurgical quality of cast.By electroslag casting process, consutrode is carried out to refining and casting, can guarantee that the purity of foundry goods metallic matrix and the order of crystallization process carry out, thereby realize refining Foundry Production.This refining casting technique molten steel of can fully effectively purifying, is removed contained gas in steel, sonims in a large number.Foundry goods crystalline structure even compact, sulphur and phosphorus content is low, sonims is few, have higher intensity, toughness, anti-fatigue performance.
Refining foundry goods (ESRC) can reach the mechanical property of forging, chemical composition evenly, dense structure, dendrite refinement, microscopic segregation be little, without loose, without defects such as slag inclusion, shrinkage cavities, slag inclusion is disperse and distributes, higher than Clean Steel, have again the not available isotropy advantage of forging rolling part fatigue life.Compare with GB/T1591-94D low-alloy high-tensile structural steel standard, refining cast product performance increases substantially.Tensile strength increases more than 10%, and yield strength increases more than 10%, and normal temperature impact toughness increases by 200% left and right, and low-temperature impact toughness (40 ℃) increases by 100% left and right, and reduction of cross sectional area, specific elongation increase more than 10%.
Tool of the present invention has the following advantages:
1, wind-powered electricity generation torsional axis belongs to super large reducing (diameter of equivalent circle changes and to be not less than
times) and super overflow far away (overflow distance is for conventional overflow is apart from being not less than 2.5 times) foundry goods.
2, electroslag smelting casting foundry goods matrix is pure, can reach the mechanical property of forging, and chemical composition evenly, dense structure, dendrite refinement, microscopic segregation be little, without defects such as slag inclusion, scabs, is difficult for producing the casting defects such as common pore, shrinkage porosite simultaneously.Slag inclusion is disperse and distributes, and higher than Clean Steel, have again the not available isotropy advantage of forging rolling part fatigue life.
3, metal crystallizer dimensional accuracy high, be out of shape littlely, thereby casting surface is bright and clean, machining allowance is little.Meanwhile, owing to adopting consecutive solidification technique, foundry goods does not have pouring system and rising head, so using rate of metal is high, realizes foundry goods near-net-shape.
4, foundry goods solidifies in water-cooled copper-steel composite crystallizer, and rate of cooling is fast, solid-liquid forward position crystallization temperature gradient is large, due to foundry goods consecutive solidification, and foundry goods dense structure.
Accompanying drawing explanation
Fig. 1 MW class wind turbine torsional axis plan view;
Fig. 2 MW class wind turbine torsional axis side view;
Fig. 3 electroslag smelting casting (not heat treatment) MW level wind-powered electricity generation torsional axis blank low power metallographic microscope;
Fig. 4 metal mold is forged (not heat treatment) MW level wind-powered electricity generation torsional axis low power metallographic microscope;
Fig. 5 sand casting process (not heat treatment) MW level wind-powered electricity generation torsional axis low power metallographic microscope;
Fig. 6 MW level scale wind power torsion shaft electroslag casting mold structure schematic diagram;
Fig. 7 MW level scale wind power torsion shaft electroslag casting crystallizer sectional view;
Fig. 8 MW level scale wind power torsion shaft electroslag casting crystallizer sectional view;
Crystallizer overall structure schematic diagram for Fig. 9 MW level scale wind power torsion shaft electroslag casting;
Figure 10 crank and conventional axle transition die cavity schematic diagram;
Figure 11 device for detecting temperature---thermocouple 16 position views (thermocouple 16 connection data collectors);
Figure 12 locating stud 17 schematic diagram;
Figure 13 locating stud 17 positions arrange figure;
Crystallizer founding position distribution schematic diagram for Figure 14 MW level scale wind power torsion shaft electroslag casting;
Crystallizer internal cavity side view and somatotype scheme one schematic diagram for Figure 15 MW level scale wind power torsion shaft electroslag casting;
Figure 16 MW level scale wind power torsion shaft electroslag casting is made a concession auxiliary device one schematic diagram with crystallizer;
Crystallizer internal cavity plan view and somatotype scheme two schematic diagram for Figure 17 MW level scale wind power torsion shaft electroslag casting;
Figure 18 MW level scale wind power torsion shaft electroslag casting is made a concession auxiliary device two schematic diagram with crystallizer.
Embodiment
Embodiment 1
Its composition of consutrode adopting and weight percentage be in Table 2, electrode size: Φ 200 * 13000mm.
Table 2GS-18NiMoCr3-6 steel consutrode composition and weight percentage
| C％ | Si％ | Mn％ | S％ | P％ | Cr％ | Ni％ | Mo％ | Fe |
| 0.18 | 0.43 | 1.05 | 0.002 | 0.018 | 0.74 | 0.99 | 0.61 | Surplus |
Mold structure, as shown in Fig. 6～13, is tightly connected and is formed by upper flange 1, lower flange 2 and legislation blue 13 by inner chamber template 5, water seam plate 11 and water jacket plate 12.Torsional axis crystallizer is divided into the opposite opened Split assembled crystallizer of 10,5 joint by crank quantity, somatotype position 19 is divided into joint I 21, joint II 22, joint III 23, joint IV 24 and joint V 25 by this crystallizer.
Water seam plate 11, water jacket plate 12 and legislation blue 13 adopt common A3 steel plate materials to be integrally connected by structure welding mode.Inner chamber template 5 adopts the thick forging forming of copper plate of 15mm.Water seam plate 11 is arranged on the outside of inner chamber template 5, the inner side of water jacket plate 12, and template stiffening rib 10 is integrally welded with inner chamber template 5 and water seam plate 11, so just inner chamber template outside is divided into independent water circulation region.In template stiffening rib and lacing wire, add respectively section chief 25mm, wide 20mm sees through the thick groove 8 of steel plate, two regions of facing mutually is also all communicated with, to avoid causing this district's water-cooled variation or Non-water-cooled to cause the accident because certain subregion water circulation goes wrong again.
Upper flange 1, lower flange 2 and blue 13 steel plate thickness of making laws are 20mm; Template stiffening rib 10, lacing wire thickness are 25mm; Water seam plate 11 is 10mm with water jacket plate 12 thickness.Water-cooled width between inner chamber template 11 and water seam plate 12 is 25mm.This structure of crystallizer makes crystallizer when water flowing is cooling, both can realize the independent water circulation in each district also can realize the associating water circulation of facing mutually region, has improved resistance of deformation and the water-cooled ability of crystallizer.
Water jacket 14 is sleeved on the water seam outer 60mm of plate 11 place, its upper/lower terminal respectively with upper flange 1 and lower flange 2 welded seals.In the bottom of water jacket 14, be installed with 4 (every layer) intake pipes 4, on the top of water jacket 14, be installed with 4 (every layer) outlet pipes 3.Turnover water pipe respectively on pressing close to lower flange position and with 5 °-15 ° of flanged plate angulations.In four regions of water jacket 14 and lacing wire joint, also place respectively two outlet pipes 3.Intake pipe 4 and outlet pipe 3, be common steel tube, and all adopt welding manner to be connected with water jacket 14.
Inner chamber template 5 adopts 3D solid die-forging forming to make, and model three-dimensional entity model, then by model conversation mfg. moulding die, finally utilizes mould by monoblock copper coin die-forging forming crystallizer internal cavity template 5.
On crystallizer, arrange and make a concession auxiliary device (Figure 16), this device is comprised of U-shaped groove a6, U-shaped groove b7, jack 9 and L plate 18, by jack 9, affects L plate 18 to slide along U-shaped groove.Crystallizer is made a concession auxiliary device except L plate 18, and remaining part and crystallizer can freely be torn group open, are convenient to maintenance and use.
The thermocouple groove of device for detecting temperature processes in advance on crystallizer, and thermocouple groove is squeezed into crystallizer copper depth of inner cavity 5mm, and thermocouple 16 can freely be torn group connection data collector open so that thermometric.
Diagonal form setting is pressed in the position of locating stud 17.Adopt somatotype scheme shown in Figure 15.
Electroslag smelting casting:
1) electroslag casting process is to above-mentioned consutrode refining, and makes foundry goods.Slag system proportioning is weight percentage: CaF
2: 60%, Al
2o
3: 30%, MgO:5% and CaO:5%.The quantity of slag is 3% of casting weight.
2) mode of igniting
Consutrode adopts solid slag to ignite in crystallizer, and its Chemical composition is weight percentage: TiO
250%, CaF
250%.
3) power consumption parameter:
Different parts (Figure 14) power consumption parameter, in Table 3, notes keeping the stability of electric current and voltage in fusion-casting process.
Table 3 different parts power consumption parameter
4) in torsional axis fusion-casting process, adopt mould temperature control system, to positioning monitoring and temperature in foundry goods different parts fusion-casting process, control (Figure 11).After crank monitoring, there is the theoretical foundation that electric power is controlled, by foundry goods different parts is adopted to different electric power, foundry goods is inner and surface quality is good.
5) top of the slag is crossed the middle section 1 hour of founding position 24 (Figure 14), and crystallizer back-off state starts jack 9, makes to make a concession crystallizer and makes a concession (yielding mode is shown in Figure 16) along U-shaped groove.
Through above-mentioned manufacturing process, produce wind-driven generator torsional axis electroslag smelting casting part.The brilliant arm of long shoot of its as cast condition blank macrostructure becomes 25-65 ° of angle with axle center, as shown in Figure 3.After testing, torsional axis chemical composition is in Table 4:
Table 4 torsional axis chemical composition
| C％ | Si％ | Mn％ | S％ | P％ | Cr％ | Ni％ | Mo％ | Fe |
| 0.18 | 0.40 | 1.01 | 0.002 | 0.018 | 0.71 | 0.99 | 0.60 | Surplus |
After the founding of MW level wind-powered electricity generation torsional axis, adopt the pre-heat treatment technique, heat treatment temperature is 750 ℃, and foundry goods is cooling with stove.Adopt afterwards anti-deforming and Anti-cracking technique to carry out quenching with Subsequent tempering (quenching 960 ℃, 600 ℃ of tempering).
After torsional axis heat treatment, foundry goods mechanical property is in Table 5:
Foundry goods mechanical property after the heat treatment of table 5 torsional axis
Following standard test is pressed in nondestructive inspection:
UT:EN12680-1-1997 (2) inspection area: all
MT:EN1369-1997 (2) inspection area: all
MW class wind turbine uses torsional axis through chemical composition analysis, mechanical properties test, and nondestructiving inspecting test, indices is all qualified.
Embodiment 2
Its composition of consutrode adopting and weight percentage be in Table 6, electrode size: Φ 180 * 15000mm.
Table 6GS-34CrNiMo-6 steel consutrode composition and weight percentage
| C％ | Si％ | Mn％ | S％ | P％ | Cr％ | Ni％ | Mo％ | Fe |
| 0.34 | 0.41 | 0.69 | 0.018 | 0.014 | 1.58 | 1.55 | 0.33 | Surplus |
Mold structure is as shown in Fig. 6～13, and yielding device as shown in figure 18, adopts somatotype scheme shown in Figure 17, and other structure is with embodiment 1.
Electroslag smelting casting:
1) electroslag casting process is to above-mentioned consutrode refining, and makes foundry goods.Slag system proportioning is weight percentage: CaF
2: 70%, Al
2o
3: 30%, the quantity of slag is casting weight 3.2%.
2) mode of igniting
Consutrode adopts solid slag to ignite in crystallizer, and its Chemical composition is weight percentage: TiO
250%, CaF
250%.
3) power consumption parameter:
Different parts power consumption parameter, in Table 7, notes keeping the stability of electric current and voltage in fusion-casting process.
Table 7 different parts power consumption parameter
4) in torsional axis fusion-casting process, adopt the method for measuring " having solidified casting weight " to coordinate entity to calculate foundry goods fusion-casting process molten steel position, different parts adopts different electric power (Figure 14).Facts have proved, foundry goods is inner and surface quality is good.
5) top of the slag is crossed the middle section 1 hour of founding position 24 (Figure 14), and crystallizer back-off state starts jack 9, makes to make a concession crystallizer and makes a concession (yielding mode is shown in Figure 18) along U-shaped groove.
Through above-mentioned manufacturing process, produce wind-driven generator torsional axis.After testing, torsional axis chemical composition is in Table 8:
Table 8 torsional axis chemical composition
| C％ | Si％ | Mn％ | S％ | P％ | Cr％ | Ni％ | Mo％ | Fe |
| 0.32 | 0.35 | 0.67 | 0.016 | 0.014 | 1.55 | 1.54 | 0.33 | Surplus |
After the founding of MW level wind-powered electricity generation torsional axis, adopt the pre-heat treatment technique, heat treatment temperature is that 760 ℃ of foundry goods are cooling with stove.Adopt afterwards anti-deforming and Anti-cracking technique to carry out quenching with Subsequent tempering (quenching 900 ℃, 580 ℃ of tempering).
After torsional axis heat treatment, foundry goods mechanical property is in Table 9:
Foundry goods mechanical property after the heat treatment of table 9 torsional axis
Following standard test is pressed in nondestructive inspection:
MT:EN1369-1997 (2) inspection area: all
UT:EN12680-1-1997 (2) inspection area: all
MW class wind turbine uses torsional axis through chemical composition analysis, mechanical properties test, and nondestructiving inspecting test, indices is all qualified.
Embodiment 3
Its composition of consutrode adopting and weight percentage be in Table 10, electrode size: Φ 250 * 8000mm.
Table 10GS-42CrMo4 steel consutrode composition and weight percentage
| C％ | Si％ | Mn％ | S％ | P％ | Cr％ | Mo％ | Fe |
| 0.41 | 0.58 | 0.94 | 0.016 | 0.018 | 0.99 | 0.25 | Surplus |
Mold structure is with embodiment 1.
Electroslag smelting casting:
1) electroslag casting process is to above-mentioned consutrode refining, and makes foundry goods.Slag system proportioning is weight percentage: CaF
2: 70%, Al
2o
3: 20%, MgO:5% and CaO:5%.The quantity of slag is 3.5% of casting weight.
2) mode of igniting
Consutrode adopts solid slag to ignite in crystallizer, and its Chemical composition is weight percentage: TiO
250%, CaF
250%.
3) power consumption parameter:
Different parts power consumption parameter, in Table 11, notes keeping the stability of electric current and voltage in fusion-casting process.
Table 11 different parts power consumption parameter
4) in torsional axis fusion-casting process, adopt the method prediction foundry goods fusion-casting process molten steel position of " entity calculating ", different parts adopts different electric power.Facts have proved, foundry goods is inner and surface quality is good.
5) top of the slag is crossed the middle section 1 hour of founding position 24 (Figure 14), and crystallizer back-off state starts jack, makes to make a concession crystallizer and makes a concession (with embodiment 1) along U-shaped groove.
Through above-mentioned manufacturing process, produce wind-driven generator torsional axis.After testing, torsional axis chemical composition is in Table 12:
Table 12 torsional axis chemical composition
| C％ | Si％ | Mn％ | S％ | P％ | Cr％ | Mo％ | Fe |
| 0.40 | 0.50 | 0.91 | 0.015 | 0.018 | 0.99 | 0.25 | Surplus |
After the founding of MW level wind-powered electricity generation torsional axis, adopt the pre-heat treatment technique, heat treatment temperature is that 750 ℃ of foundry goods are cooling with stove.Adopt afterwards anti-deforming and Anti-cracking technique to carry out quenching with Subsequent tempering (quenching 860 ℃, 540 ℃ of tempering).
After torsional axis heat treatment, foundry goods mechanical property is in Table 13:
Foundry goods mechanical property after the heat treatment of table 13 torsional axis
Following standard test is pressed in nondestructive inspection:
UT:EN12680-1-1997 (2) inspection area: all
MT:EN1369-1997 (2) inspection area: all
MW class wind turbine uses torsional axis through chemical composition analysis, mechanical properties test, and nondestructiving inspecting test, indices is all qualified.
Claims (6)
1. a preparation process for MW level wind-powered electricity generation torsional axis, is characterized in that: by adopting consutrode to carry out electroslag smelting casting method, prepare torsional axis, its process parameter is:
A, slag system and the quantity of slag are controlled:
Slag system ingredient is CaF
2and Al
2o
3, its weight ratio is: CaF
2: Al
2o
3=60～70:30～20, the quantity of slag is casting weight 1.5～5%;
B, the mode of igniting:
Adopt solid-state or liquid slag to ignite, its chemical composition is TiO by weight percentage
2: 40%～60%, CaF
2: 60%～40%;
The selection of c, power supply parameter:
Founding voltage and current is:
U=[(0.5～0.7) D
crystallizer+ (25～35)]
I=[(580～680)+(30～36) d
electrode]
D in above formula
crystallizer, d
electrodebe respectively the long-pending equivalent diameter of crystallizer and electrode sections, unit is mm, and the unit of U is V, and the unit of I is A;
The consutrode wherein adopting is GS-18NiMoCr3-6 steel, GS-34CrNiMo6 steel or GS-42CrMo4 steel; Electrode size: diameter range Φ 140～Φ 350mm, length range 6000～20000mm;
The crystallizer adopting is divided into crank crystallizer and conventional axle crystallizer two-part, and crank crystallizer part consists of joint I (21), joint II (22), joint III (23), joint IV (24), and conventional axle crystallizer is partly joint V (25);
Crystallizer is to consist of the inner chamber template (5) adapting with crank shape, water seam plate (11), water jacket plate (12) and the transition die cavity (15) set up in the thickest position of crank, water seam plate (11) is arranged on the outside of inner chamber template (5), the inner side of water jacket plate (12), between water seam plate (11) and water jacket plate (12), be water jacket (14), water jacket (14) bottom is installed with a plurality of intake pipes (4), top is installed with a plurality of outlet pipes (3), turnover water pipe respectively on pressing close to lower flange position and with 5 °-15 ° of flanged plate angulations; Inner chamber template (5), water seam plate (11), water jacket plate (12) and water jacket (14) are tightly connected by upper flange (1), lower flange (2) and legislation blue (13); On crank crystallizer, be increased in the transition die cavity (15) of the thickest position of crank and conventional axle position, transition die cavity (15) is highly 150-300mm, adopts round-corner transition;
Described crystallizer has yielding supporting facility, i.e. device for detecting temperature, and described device for detecting temperature is comprised of the thermocouple (16) and the external connection data collector of thermocouple (16) that insert crystallizer internal cavity; Yielding auxiliary device is set on crystallizer, and this installs by U-shaped groove a(6), U-shaped groove b(7), jack (9) and L plate (18) form, and by jack (9), affects L plate (18) to slide along U-shaped groove.
2. according to the preparation process of MW level wind-powered electricity generation torsional axis described in claim 1, it is characterized in that: at CaF
2-Al
2o
3in slag system, add a small amount of MgO and CaO, it adds gross weight≤10%.
3. according to the preparation process of MW level wind-powered electricity generation torsional axis described in claim 1 or 2, it is characterized in that: after founding, adopt the pre-heat treatment technique, heat treatment temperature is 750～780 ℃, and foundry goods is cooling with stove; Adopt afterwards anti-deforming and Anti-cracking technique to carry out quenching with Subsequent tempering: quenching 840-980 ℃, tempering 520-640 ℃.
4. according to the preparation process of MW level wind-powered electricity generation torsional axis described in claim 1, it is characterized in that: between inner chamber template (5) and water seam plate (11), template stiffening rib (10) is set, and be welded into a whole with inner chamber template (5) and water seam plate (11), inner chamber template (5) outside is separated into four regions, each region forms independent water circulation, water seam width between inner chamber template (5) and water seam plate (11) is 15-45mm, even transition; Water jacket (14) is installed in the water seam outer 50-100mm of plate (11) place.
5. according to the preparation process of MW level wind-powered electricity generation torsional axis described in claim 4, it is characterized in that: on template stiffening rib (10), process the groove (8) of long 20-100mm, wide 15-45mm, make two regional connectivities that face mutually in four regions in inner chamber template (5) outside; Inner chamber template (5) is to adopt 3D solid die-forging forming with whole copper coin, and other position all adopts steel plate.
6. according to the preparation process of MW level wind-powered electricity generation torsional axis described in claim 1, it is characterized in that: described its composition proportion of GS-18NiMoCr3-6 steel is weight percentage: C0.17～0.22%, Si0.30～0.60%, Mn0.80～1.20%, S≤0.015%, P≤0.02%, Cr0.4～0.9%, Ni0.6～1.1%, Mo0.40～0.7%, Fe surplus;
Described its composition proportion of GS-34CrNiMo6 steel is weight percentage: C0.30～0.37%, Si0.30～0.60%, Mn0.60～1.00%, S≤0.025%, P≤0.015%, Cr1.40～1.70%, Ni1.40～1.70%, Mo0.15～0.35%, Fe surplus;
Described its composition proportion of GS-42CrMo4 steel is weight percentage: C0.38～0.45%, Si0.30～0.60%, Mn0.60～1.00%, S≤0.025%, P≤0.025%, Cr0.80～1.20%, Mo0.20～0.30%, Fe surplus.
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| CN102962642B (en) * | 2012-11-16 | 2015-08-26 | 大连洁能重工机械有限公司 | Wind turbine torsion shaft processing technology |
| CN105543684B (en) * | 2015-12-23 | 2017-12-29 | 宝鼎科技股份有限公司 | Adjustable propeller blade left-right rotary base forging and manufacturing process |
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|---|---|---|---|---|
| CN201132211Y (en) * | 2007-09-24 | 2008-10-15 | 沈阳铸造研究所 | Crystallizer for electroslag casting of diaphram pump bent shaft |
| 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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| CN201132211Y (en) * | 2007-09-24 | 2008-10-15 | 沈阳铸造研究所 | Crystallizer for electroslag casting of diaphram pump bent shaft |
| 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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