CN104174834A - Electroslag casting production method for waterwheel blade green compact - Google Patents
Electroslag casting production method for waterwheel blade green compact Download PDFInfo
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- CN104174834A CN104174834A CN201410389905.2A CN201410389905A CN104174834A CN 104174834 A CN104174834 A CN 104174834A CN 201410389905 A CN201410389905 A CN 201410389905A CN 104174834 A CN104174834 A CN 104174834A
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- 238000005266 casting Methods 0.000 title claims abstract description 99
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 35
- 239000002893 slag Substances 0.000 claims abstract description 53
- 238000000034 method Methods 0.000 claims abstract description 38
- 239000000463 material Substances 0.000 claims abstract description 31
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 30
- 239000000126 substance Substances 0.000 claims abstract description 19
- 238000010438 heat treatment Methods 0.000 claims abstract description 18
- 238000005336 cracking Methods 0.000 claims abstract description 13
- 238000003723 Smelting Methods 0.000 claims description 38
- 229910052802 copper Inorganic materials 0.000 claims description 35
- 239000010949 copper Substances 0.000 claims description 35
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 29
- 229910000831 Steel Inorganic materials 0.000 claims description 27
- 239000010959 steel Substances 0.000 claims description 27
- 230000004927 fusion Effects 0.000 claims description 24
- 238000003466 welding Methods 0.000 claims description 21
- 239000000203 mixture Substances 0.000 claims description 18
- 238000002360 preparation method Methods 0.000 claims description 18
- 229910004261 CaF 2 Inorganic materials 0.000 claims description 17
- 238000005516 engineering process Methods 0.000 claims description 12
- 229910052751 metal Inorganic materials 0.000 claims description 12
- 239000002184 metal Substances 0.000 claims description 12
- 238000012545 processing Methods 0.000 claims description 12
- 229910052782 aluminium Inorganic materials 0.000 claims description 11
- 229910010413 TiO 2 Inorganic materials 0.000 claims description 8
- 229910001105 martensitic stainless steel Inorganic materials 0.000 claims description 8
- 238000012856 packing Methods 0.000 claims description 8
- 239000007787 solid Substances 0.000 claims description 8
- 238000013003 hot bending Methods 0.000 claims description 7
- 238000000465 moulding Methods 0.000 claims description 7
- 238000011161 development Methods 0.000 claims description 6
- 238000007528 sand casting Methods 0.000 claims description 6
- 239000003818 cinder Substances 0.000 claims description 5
- 239000000155 melt Substances 0.000 claims description 5
- 229910045601 alloy Inorganic materials 0.000 claims description 4
- 239000000956 alloy Substances 0.000 claims description 4
- 229910052799 carbon Inorganic materials 0.000 claims description 4
- 238000007670 refining Methods 0.000 claims description 3
- 229910000851 Alloy steel Inorganic materials 0.000 claims description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 2
- 229910000975 Carbon steel Inorganic materials 0.000 claims description 2
- 239000004411 aluminium Substances 0.000 claims description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 2
- 239000010962 carbon steel Substances 0.000 claims description 2
- 229910000734 martensite Inorganic materials 0.000 claims description 2
- 229910001220 stainless steel Inorganic materials 0.000 claims description 2
- 239000010935 stainless steel Substances 0.000 claims description 2
- 230000007547 defect Effects 0.000 abstract description 4
- 238000001514 detection method Methods 0.000 abstract description 2
- 239000000470 constituent Substances 0.000 abstract 1
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- 238000003825 pressing Methods 0.000 description 7
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- 229910052804 chromium Inorganic materials 0.000 description 6
- 229910052748 manganese Inorganic materials 0.000 description 6
- 229910052750 molybdenum Inorganic materials 0.000 description 6
- 229910052759 nickel Inorganic materials 0.000 description 6
- 238000012360 testing method Methods 0.000 description 6
- 229910052721 tungsten Inorganic materials 0.000 description 6
- 229910052720 vanadium Inorganic materials 0.000 description 6
- 238000005242 forging Methods 0.000 description 3
- 208000037656 Respiratory Sounds Diseases 0.000 description 2
- 239000010813 municipal solid waste Substances 0.000 description 2
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- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
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Abstract
An electroslag casting production method for a waterwheel blade green compact is characterized by comprising the following steps: confirming the outline of the blade green compact according to the intelligent three-dimensional expanded size of a water turbine blade; producing a crystallizer and a consumable electrode of the blade green compact; preparing the qualified blade green compact of the electroslag casting water turbine by optimizing electroslag casting process parameters and the anti-cracking heat treatment process. The method has the advantages that the detects of the conventional blade green compact of the water turbine can be overcome; a near-net forming green compact producing process is provided for the water turbine blade formed through heated-die pressing process; the produced blade green compact material is high in degree of purity, uniform in chemical constituents, compact in structure, free of defects such as looseness, slag inclusion and hole shrinkage, favorable in mechanical property, and higher in fatigue resistance performance, anti-cracking performance and expansibility, and can reach the mechanical property of forge pieces made of the same material and meet the requirements of flaw detection indexes.
Description
Technical field
The present invention relates to three-dimension curved surface pressed compact manufacturing process, a kind of electroslag smelting casting manufacture method of turbine blade pressed compact is provided especially.
Background technology
Along with the demand of large and medium hydro-generator group to high quality water turbine blade, Some Enterprises starts to adopt hot compression molding method to produce turbine blade both at home and abroad, the turbine blade of producing has been avoided sand casting blade shortcoming, have again that product quality is high, the duration is relatively short and do not destroy the advantages such as metal streamline, thereby this method is subject to certain attention in hydraulic turbine manufacturing industry at home and abroad.As the raw material of preparing hydraulic turbine hot moulding blade, the quality of mold pressing pressed compact and appearance and size are very large on the performance of blade, post-production amount and production cost impact.
At present, conventional mold pressing blade pressed compact has 2 kinds of structures conventionally, casts pressed compact and waits steel plate pressed compact.Casting pressed compact moulding process is simple, the pressed compact back side can directly be cast as the space curved surface of mounted blade figure requirement, pressed compact labor content is less, but due to casting technique restriction itself, the inherent quality of casting pressed compact is low, and routine casting defect is inevitable, pressed compact is second-rate, and casting pressed compact soldering and relief grinding correction workload are larger, and the production cycle is longer, and production efficiency is low; Deng steel plate, be the compact structures pattern that current mold pressing blade is more conventional, internal quality of steel plate is better, and defect is few.But for manufacturing vane curvature and the larger blade (as " X " type blade) of varied in thickness, because steel plate pressed compact is for waiting slab, cause the stock utilization of steel plate pressed compact low; The blade pressed compact back side is space curved surface, and surplus is widely different, and post-production amount is large, has greatly increased production cost, has restricted the development of turbine blade hot moulding technology.
Summary of the invention
For solving the deficiency of existing hot moulding turbine blade pressed compact, the invention provides a kind of electroslag smelting casting manufacture method of turbine blade pressed compact, can significantly improve blade pressed compact stock utilization, reduce processing capacity, shorten the processing duration, and leaf quality is improved, particularly there is higher fatigue resistance energy, compared with high resistance crackle, generate and scalability, can meet with material rough forging mechanical property requirements.
The invention provides a kind of electroslag smelting casting manufacture method of turbine blade pressed compact, according to turbine blade 3 D intelligent development size, make electroslag smelting casting blade pressed compact crystallizer, consutrode, by optimizing electroslag casting process, Anti-cracking Technology for Heating Processing, finally prepare qualified electroslag smelting casting blade pressed compact, it is characterized in that, described electroslag casting process concrete steps are as follows:
(1), slag system and the quantity of slag control: consider the variation of blade pressed compact coagulating property and chemical composition, choose reasonable electroslag smelting casting slag system, its main component is mass percent: CaF
2: 55～65%, Al
2o
3: 25～35%, according to actual alloy refining, require to add MgO, the CaO slag system that comes from different backgrounds and possess different abilities, its addition is not higher than 15% of slag system gross mass, and thickness of slag layer is generally 40～60% of crystallizer equivalent diameter;
(2), Igniting pattern: adopt solid slag or the melt cinder starting the arc, starting the arc material chemical composition mass percent is: TiO
2: 40～55%, CaF
2: 40～58%, MgO:2～5%; When adopting the solid slag starting the arc, between electrode and end water tank, place a signal supervisory instrument, by detecting electrode and starting the arc material Contact, potential change between electrode and end water tank, whether can detect consutrode has compressed and has been connected with water cooled bottom plate, electrode decrease speed is controlled, guaranteed that starting the arc material is not crushed or top is inclined to one side, finally realize the steady starting the arc of ESR Process; While adopting this device to carry out the solid slag starting the arc, a starting the arc success rate is more than 98%.
(3), power supply parameter is selected: according to the geometric parameter of casting dimension, electrode and crystallizer and founding, determine each respective electrical parameters such as founding power, voltage, electric current, note keeping the stable of voltage and current in fusion-casting process.Wherein Control of Voltage in 50～110V, Current Control at 5500～18000A;
(4), feeding: for the large flakiness ratio shaped piece of this class of blade pressed compact, adopt a kind of interruption feeding mode to carry out feeding, the specific embodiment is as follows: in the feeding phase, first at 3～8 minutes, with interior, normal current is at the uniform velocity reduced to minimum feeding electric current, keeps 2～5 minutes; Again minimum feeding electric current was at the uniform velocity elevated to 70～90% of normal fusion casting current in 2～5 minutes, 5～8 times so repeatedly, the highest each fusion casting current is all last time 70～90% of the highest fusion casting current, is finally reduced to zero for 1 time.
The electroslag smelting casting manufacture method of turbine blade pressed compact of the present invention, it is characterized in that: utilize finite element analysis software, turbine blade is carried out to 3 D intelligent expansion, by the positive blade mold pressing pressed compact that is plane, the back side and is curved surface of turbine blade generate, in conjunction with the mounted blade figure exporting, contrast blade dimensions figure and revised, and finally determine electroslag smelting casting pressed compact blank dimension.Be specially: first whole leaf model is divided into thousands of finite element grids, by unit mark label; By the blade having identified die mould in dummy mould, utilize point-tracking method to carry out the preliminary expansion of blade.Calculate the actual thickness of face of blade corresponding points, actual thickness is mapped to and launches face of blade, thereby generate the Expanding leaf back side.Again the blade after preliminary expansion is put into dummy mould, carry out secondary press after applying temperature field and other boundary condition, finally the mounted blade figure of output is contrasted to blade dimensions figure and revised.
The electroslag smelting casting manufacture method of turbine blade pressed compact of the present invention, it is characterized in that: crystallizer is selected: according to the blade mold pressing pressed compact appearance and size of launching, make electroslag smelting casting blade pressed compact separate assembling crystallizer, the separate assembling crystallizer material of made is the separate assembling crystallizer of full aluminium or copper steel welding, full crystalline aluminophosphate equipment matter is ZL114A, the water seam width of crystallizer internal cavity plate and gusset is 25～40mm, and crystallizer internal cavity is cast moulding method preparation; Copper steel welding crystallizer is that to take crystallizer exocoel and gusset be carbon steel sheet, crystallizer internal cavity is copper plate, and crystallizer can split be dismantled, keep in repair, the water seam width of copper steel welding crystallizer internal cavity plate and gusset is 15～35mm, and crystallizer internal cavity copper coin is the preparation of metal hot bending+machined manufacturing process.
The electroslag smelting casting manufacture method of turbine blade pressed compact of the present invention, it is characterized in that: consutrode used is sand casting electrode and steel plate butt welding electrode 2 classes, in conjunction with blade pressed compact crystallizer internal cavity size, prepare blade pressed compact conformal consutrode, the packing ratio of selecting is 0.3～0.45.
Blade pressed compact is due to solidification forming in water-cooled metal mould, and internal stress is larger, should carry out in time Anti-cracking heat treatment, otherwise easily crack.The electroslag smelting casting manufacture method of turbine blade pressed compact of the present invention, is characterized in that, blade pressed compact Anti-cracking Technology for Heating Processing is: the electroslag smelting casting blade pressed compact after devaning is heated to 800～900 ℃, is incubated after 4～6 hours, cool to room temperature with the furnace.
The electroslag smelting casting manufacture method of turbine blade pressed compact of the present invention, is characterized in that: described turbine blade pressed compact alloy comprises: steel alloy 20SiMn; Low Carbon Martensite Stainless Steel 06Cr13Ni4Mo, 06Cr13Ni5Mo or 06Cr16Ni5Mo; Mo ultralow-carbon martensitic stainless steel 04Cr13Ni4Mo, 04Cr13Ni5Mo.
Compared with prior art, the advantage having is as follows in the present invention:
(1) electroslag smelting casting is a kind of Special Processes of Metal Castings technique that integrates double refining purification, solidification forming, by adjusting slag proportioning, optimizing electroslag casting process, can further remove the field trash in consutrode and change its distributional pattern, reduce the gas contents such as harmful elements such as P, S in blade pressed compact and N, H, O, improved the degree of purity of material.
(2) foundry goods solidifies in crystallizer, and cooling velocity is fast, solid-liquid forward position crystallization temperature gradient is large, due to foundry goods rapid solidification, and foundry goods dense structure.Metal crystallizer dimensional accuracy is high, it is little to be out of shape, thereby cast(ing) surface is bright and clean, allowance is little, makes blade pressed compact reach near-net-shape object.
(3) electroslag smelting casting near-net-shape blade pressed compact can reach mechanical property and the flaw detection index request of same material forging, chemical composition evenly, dense structure, dendrite refinement, microscopic segregation be little, without defects such as loose, shrinkage cavities, field trash is disperse and distributes, be better than Clean Steel fatigue life, there is again the not available isotropic advantage of forging, there is higher fatigue resistance energy simultaneously and generate and scalability compared with high resistance crackle.
(4) metal crystallizer has substituted a large amount of nonmetal Modeling Materials such as sand mold, binding agent and coating, and solid waste discharge is reduced, and has reduced the pollution to environment, has realized green manufacturing.In addition, because metal crystallizer can repeatedly be used, when producing large flakiness ratio blade pressed compact, production procedure is short, has saved production cost and time especially.
The specific embodiment
Embodiment 1:
Choosing material is the martensitic stain less steel blade of 06Cr13Ni5Mo, preparation electroslag smelting casting blade pressed compact.
(1) utilize finite element analysis software, turbine blade is carried out to 3 D intelligent expansion, by the positive blade mold pressing pressed compact that is plane, the back side and is curved surface of turbine blade generate, determine the outer profile size of blade pressed compact, the about 350mm of length, maximum is wide is 220mm, and maximum ga(u)ge is 65mm, and minimum thickness is 13mm.
(2) selection of crystallizer, the separate assembling crystallizer of copper steel welding, and crystallizer can split dismounting, the crystallizer that inner chamber is copper plate, the water seam width of copper steel welding crystallizer internal cavity plate and gusset is 33mm, and crystallizer internal cavity copper coin is the preparation of metal hot bending+machined manufacturing process.
(3) in conjunction with blade pressed compact crystallizer internal cavity size, prepare blade pressed compact conformal consutrode, the packing ratio of selecting is 0.33, the consutrode of preparation is sand casting conformal electrode.
(4) electroslag casting process process:
1. slag system and quantity of slag proportioning, CaF
2: 65%, Al
2o
3: 25%, MgO:3%, CaO:7%, quantity of slag weight is 8.5% of blade pressed compact weight, thickness of slag layer is 45% of crystallizer equivalent diameter.
2. adopt the solid slag starting the arc, starting the arc material chemical composition be take mass percent as TiO
2: 55%, CaF
2: 50%, MgO:5%; Between electrode and end water tank, place a signal supervisory instrument, by detecting electrode and starting the arc material Contact, potential change between electrode and end water tank, detecting consutrode has compressed and has been connected with water cooled bottom plate, by electrode decrease speed is controlled, starting the arc material is not crushed or top is inclined to one side, finally consolidates slag starting the arc success rate 100%
3. power supply parameter is selected: according to the geometric parameter of casting dimension, electrode and crystallizer and founding, determine that founding voltage 55V, electric current are 6500A.
4. in the feeding phase, first at 6 minutes, with interior, normal current is at the uniform velocity reduced to minimum feeding electric current, keeps 4 minutes; Again minimum feeding electric current was at the uniform velocity elevated to 75% of normal fusion casting current in 4 minutes, 6 times repeatedly, the highest each fusion casting current is all last time 75% of the highest fusion casting current, is finally reduced to zero for 1 time.
(5) blade pressed compact Anti-cracking Technology for Heating Processing, is heated to 870 ℃ by the electroslag smelting casting blade pressed compact after devaning, and is incubated after 5 hours, cools to room temperature with the furnace.
By electroslag casting process, there is the crystallizer of setting shape to be shaped, prepared blade pressed compact blank.After testing, chemical composition is: C:0.048%, Si:0.58%, Mn:0.95%, P:0.035%, S:0.025%, Cr:12.5%, Ni:4.83%, Mo:0.59%, Cu:0.24%, V:0.05%, W:0.09%, N:0.015%, H:0.0003%, O:0.0076%, surplus is Fe.
After conventional heat treatment, the mechanical property of pressed compact is R
p0.2/ 610Mpa, Rm/805Mpa, A/24%, Z/49%, KV
2/ 137J.
Comparative example 2 chooses different electroslag casting process and has prepared blade the same manner as in Example 2, and corresponding technique is as follows:
(1) slag system and quantity of slag proportioning, CaF
2: 65%, Al
2o
3: 25%, MgO:3%, CaO:7%, quantity of slag weight is 8.5% of blade pressed compact weight, thickness of slag layer is 45% of crystallizer equivalent diameter.
(2) selection of crystallizer, the separate assembling crystallizer of copper steel welding, and crystallizer can split dismounting, the crystallizer that inner chamber is copper plate, the water seam width of copper steel welding crystallizer internal cavity plate and gusset is 35mm, and crystallizer internal cavity copper coin is the preparation of metal hot bending+machined manufacturing process.
(3) in conjunction with blade pressed compact crystallizer internal cavity size, prepare blade pressed compact conformal consutrode, the packing ratio of selecting is 0.46, the consutrode of preparation is sand casting conformal electrode.
(4) electroslag casting process process:
1. slag system and quantity of slag proportioning, CaF
2: 65%, Al
2o
3: 25%, MgO:3%, CaO:7%, quantity of slag weight is 8.5% of blade pressed compact weight, thickness of slag layer is 45% of crystallizer equivalent diameter.
2. adopt the melt cinder starting the arc, starting the arc material chemical composition be take mass percent as TiO
2: 45%, CaF
2: 53%, MgO:2%.
3. power supply parameter is selected: according to the geometric parameter of casting dimension, electrode and crystallizer and founding, determine that founding voltage 45V, electric current are 4500A.
4. in the feeding phase, first at 2 minutes, with interior, normal current is at the uniform velocity reduced to minimum feeding electric current, keeps 6 minutes; Again minimum feeding electric current was at the uniform velocity elevated to 60% of normal fusion casting current in 3 minutes, 3 times repeatedly, the highest each fusion casting current is all last time 60% of the highest fusion casting current, is finally reduced to zero for 1 time.
(5) blade pressed compact Anti-cracking Technology for Heating Processing, is heated to 700 ℃ by the electroslag smelting casting blade pressed compact after devaning, and is incubated after 2 hours, cools to room temperature with the furnace.
By electroslag casting process, there is the crystallizer of setting shape to be shaped, prepared blade pressed compact blank.After testing, chemical composition is: C:0.041%, Si:0.58%, Mn:0.95%, P:0.035%, S:0.025%, Cr:12.5%, Ni:4.83%, Mo:0.59%, Cu:0.24%, V:0.05%, W:0.09%, N:0.018%, H:0.0004%, O:0.0083%, surplus is Fe.
After conventional heat treatment, the mechanical property of pressed compact is R
p0.2/ 550Mpa, Rm/732Mpa, A/14%, Z/33%, KV
2/ 76J.
Known by contrasting two kinds of 06Cr13Ni5Mo martensitic stain less steel blade pressed compact chemical composition and mechanical properties under different process, select blade pressed compact chemical composition prepared by electroslag casting process parameter of the present invention and mechanical property reaches and higher than GB/T6967-2009 requirement, and when the electroslag casting process parameter of choosing is outside scheme of the present invention, the material degree of purity variation of blade pressed compact, and mechanical property is poor, part index number can not meet GB/T6967-2009 requirement.
Embodiment 2:
Choosing material is the martensitic stain less steel blade of 06Cr13Ni4Mo, preparation electroslag smelting casting blade pressed compact.
(1) utilize finite element analysis software, turbine blade is carried out to 3 D intelligent expansion, by the positive blade mold pressing pressed compact that is plane, the back side and is curved surface of turbine blade generate, determine the outer profile size of blade pressed compact, the about 500mm of length, maximum is wide is 300mm, and maximum ga(u)ge is 80mm, and minimum thickness is 15mm.
(2) selection of crystallizer, the separate assembling crystallizer of copper steel welding, and crystallizer can split dismounting, and copper steel welding crystallizer internal cavity plate is 20mm with the water seam width of gusset, and crystallizer internal cavity copper coin is prepared by metal hot bending+machined manufacturing process.
(3) in conjunction with blade pressed compact crystallizer internal cavity size, prepare blade pressed compact conformal consutrode, the packing ratio of selecting is 0.3, the consutrode of preparation is sand casting conformal electrode.
(4) electroslag casting process process:
1. slag system and quantity of slag proportioning, CaF
2: 65%, Al
2o
3: 30%, MgO:3%, CaO:2%, quantity of slag weight is 8% of blade pressed compact weight, thickness of slag layer is 40% of crystallizer equivalent diameter.
2. adopt the solid slag starting the arc, starting the arc material chemical composition be take mass percent as TiO
2: 45%, CaF
2: 53%, MgO:2%; Between electrode and end water tank, place a signal supervisory instrument, by detecting electrode and starting the arc material Contact, potential change between electrode and end water tank, detecting consutrode has compressed and has been connected with water cooled bottom plate, again electrode decrease speed is controlled, starting the arc material is not crushed or top is inclined to one side, finally consolidates slag starting the arc success rate 100%.
3. power supply parameter is selected: according to the geometric parameter of casting dimension, electrode and crystallizer and founding, determine that founding voltage 60V, electric current are 7500A.
4. in the feeding phase, first at 4 minutes, with interior, normal current is at the uniform velocity reduced to minimum feeding electric current, keeps 3 minutes; Again minimum feeding electric current was at the uniform velocity elevated to 70% of normal fusion casting current in 2 minutes, 5 times repeatedly, the highest each fusion casting current is all last time 70% of the highest fusion casting current, is finally reduced to zero for 1 time.
(5) blade pressed compact Anti-cracking Technology for Heating Processing: the electroslag smelting casting blade pressed compact after devaning is heated to 850 ℃, is incubated after 4 hours, cool to room temperature with the furnace.
By electroslag casting process, there is the crystallizer of setting shape to be shaped, prepared blade pressed compact blank.After testing, chemical composition is: C:0.05%, Si:0.55%, Mn:0.9%, P:0.0.03%, S:0.021%, Cr:11.5%, Ni:3.8%, Mo:0.6%, Cu:0.19%, V:0.19%, W:0.05%, N:0.012%, H:0.0001%, O:0.0075%, surplus is Fe.
After conventional heat treatment, the mechanical property of pressed compact is R
p0.2/ 600Mpa, Rm/825Mpa, A/25%, Z/60%, KV
2/ 105J.
Embodiment 3:
Choosing material is the martensitic stain less steel blade of 06Cr16Ni5Mo, preparation electroslag smelting casting X-shaped blade pressed compact.
(1) according to turbine blade 3 D intelligent development size, determine the outer profile size of blade pressed compact, the about 800mm of length of blade, maximum is wide is 500mm, maximum ga(u)ge is 150mm, minimum thickness 30mm.
(2) selection of crystallizer, all aluminium alloy separate assembling crystallizer, and crystallizer can split dismounting, the water seam width of crystallizer internal cavity plate and gusset is 30mm, crystallizer internal cavity is prepared by cast moulding method
(3) in conjunction with blade pressed compact crystallizer internal cavity size, prepare blade pressed compact conformal consutrode, the packing ratio of selecting is 0.41, the consutrode of preparation is steel plate butt welding electrode.
(4) electroslag casting process process:
1. slag system and quantity of slag proportioning, CaF
2: 58%, Al
2o
3: 34%, MgO:6%, CaO:2%, quantity of slag weight is 12% of blade pressed compact weight, thickness of slag layer is 51% of crystallizer equivalent diameter.
2. adopt the melt cinder starting the arc, starting the arc material chemical composition be take mass percent as TiO
2: 48%, CaF
2: 50%, MgO:2%.
3. power supply parameter is selected: according to the geometric parameter of casting dimension, electrode and crystallizer and founding, determine that founding voltage 80V, electric current are 9600A.
4. in the feeding phase, first at 6 minutes, with interior, normal current is at the uniform velocity reduced to minimum feeding electric current, keeps 3 minutes; Again minimum feeding electric current was at the uniform velocity elevated to 80% of normal fusion casting current in 5 minutes, 7 times repeatedly, the highest each fusion casting current is all last time 80% of the highest fusion casting current, is finally reduced to zero for 1 time.
(5) blade pressed compact Anti-cracking Technology for Heating Processing: the electroslag smelting casting blade pressed compact after devaning is heated to 880 ℃, is incubated after 4.5 hours, cool to room temperature with the furnace.
By electroslag casting process, there is the crystallizer of setting shape to be shaped, prepared blade pressed compact blank.After testing, chemical composition is: C:0.042%, Si:0.53%, Mn:0.68%, P:0.026%, S:0.019%, Cr:16.5%, Ni:5.7%, Mo:0.79%, Cu:0.15%, V:0.07%, W:0.04%, N:0.011%, H:0.0002%, O:0.0071%, surplus is Fe.
After conventional heat treatment, the mechanical property of pressed compact is R
p0.2/ 648Mpa, Rm/819Mpa, A/26%, Z/59%, KV
2/ 128J.
Embodiment 4:
Choosing material is the martensitic stain less steel blade of 04Cr13Ni4Mo, preparation electroslag smelting casting blade pressed compact.
(1) according to turbine blade 3 D intelligent development size, determine the outer profile size of blade pressed compact, the about 350mm of length, maximum is wide is 165mm, and maximum ga(u)ge is 56mm, and minimum thickness is 12mm.
(2) selection of crystallizer, the separate assembling crystallizer of copper steel welding, and crystallizer can split dismounting, the crystallizer that inner chamber is copper plate, the water seam width of copper steel welding crystallizer internal cavity plate and gusset is 24mm, and crystallizer internal cavity copper coin is the preparation of metal hot bending+machined manufacturing process.
(3) in conjunction with blade pressed compact crystallizer internal cavity size, prepare blade pressed compact conformal consutrode, the packing ratio of selecting is 0.33, the consutrode of preparation is steel plate butt welding electrode.
(4) electroslag casting process process:
1. slag system and quantity of slag proportioning, CaF
2: 60%, Al
2o
3: 25%, MgO:10%, CaO:5%, quantity of slag weight is 12% of blade pressed compact weight, thickness of slag layer is 55% of crystallizer equivalent diameter.
2. adopt the solid slag starting the arc, starting the arc material chemical composition be take mass percent as TiO
2: 52%, CaF
2: 44%, MgO:4%; Between electrode and end water tank, place a signal supervisory instrument, by detecting electrode and starting the arc material Contact, potential change between electrode and end water tank, detecting consutrode has compressed and has been connected with water cooled bottom plate, electrode decrease speed is controlled, starting the arc material is not crushed or top is inclined to one side, finally consolidates slag starting the arc success rate 99%
3. power supply parameter is selected: according to the geometric parameter of casting dimension, electrode and crystallizer and founding, determine that founding voltage 50V, electric current are 5500A.
4. in the feeding phase, first at 7 minutes, with interior, normal current is at the uniform velocity reduced to minimum feeding electric current, keeps 2 minutes; Again minimum feeding electric current was at the uniform velocity elevated to 80% of normal fusion casting current in 5 minutes, 5 times repeatedly, the highest each fusion casting current is all last time 80% of the highest fusion casting current, is finally reduced to zero for 1 time.
(5) blade pressed compact Anti-cracking Technology for Heating Processing: the electroslag smelting casting blade pressed compact after devaning is heated to 865 ℃, is incubated after 5.5 hours, cool to room temperature with the furnace.
By electroslag casting process, there is the crystallizer of setting shape to be shaped, prepared blade pressed compact blank.After testing, chemical composition is: C:0.02%, Si:0.52%, Mn:1.2%, P:0.019%, S:0.006%, Cr:12.8%, Ni:3.8%, Mo:0.64%, Cu:0.12%, V:0.07%, W:0.11%, N:0.012%, H:0.0002%, O:0.0068%, surplus is Fe.
After conventional heat treatment, the mechanical property of pressed compact is R
p0.2/ 708Mpa, Rm/845Mpa, A/28%, Z/55%, KV
2/ 152J.
Embodiment 5:
Choosing material is the martensitic stain less steel blade of 04Cr13Ni5Mo, preparation electroslag smelting casting blade pressed compact.
(1) according to turbine blade 3 D intelligent development size, determine the outer profile size of blade pressed compact, the about 1246mm of length, maximum is wide is 878mm, and maximum ga(u)ge is 152mm, and minimum thickness is 31mm.
(2) selection of crystallizer, the separate assembling crystallizer of copper steel welding, and crystallizer can split dismounting, the crystallizer that inner chamber is copper plate, the water seam width of copper steel welding crystallizer internal cavity plate and gusset is 25mm, and crystallizer internal cavity copper coin is the preparation of metal hot bending+machined manufacturing process.
(3) in conjunction with blade pressed compact crystallizer internal cavity size, prepare blade pressed compact conformal consutrode, the packing ratio of selecting is 0.45, the consutrode of preparation is steel plate butt welding electrode.
(4) electroslag casting process process:
1. slag system and quantity of slag proportioning, CaF
2: 65%, Al
2o
3: 25%, MgO:6%, CaO:4%, quantity of slag weight is 12% of blade pressed compact weight, thickness of slag layer is 55% of crystallizer equivalent diameter.
2. adopt the melt cinder starting the arc, starting the arc material chemical composition be take mass percent as TiO
2: 50%, CaF
2: 47%, MgO:3%.
3. power supply parameter is selected: according to the geometric parameter of casting dimension, electrode and crystallizer and founding, determine that founding voltage 95V, electric current are 14500A.
4. in the feeding phase, first at 8 minutes, with interior, normal current is at the uniform velocity reduced to minimum feeding electric current, keeps 2 minutes; Again minimum feeding electric current was at the uniform velocity elevated to 90% of normal fusion casting current in 3 minutes, 8 times repeatedly, the highest each fusion casting current is all last time 90% of the highest fusion casting current, is finally reduced to zero for 1 time.
(5) blade pressed compact Anti-cracking Technology for Heating Processing: the electroslag smelting casting blade pressed compact after devaning is heated to 830 ℃, is incubated after 4 hours, cool to room temperature with the furnace.
By electroslag casting process, there is the crystallizer of setting shape to be shaped, prepared blade pressed compact blank.After testing, chemical composition is: C:0.018%, Si:0.54%, Mn:1.26%, P:0.016%, S:0.007%, Cr:11.8%, Ni:5.83%, Mo:0.79%, Cu:0.19%, V:0.04%, W:0.03%, N:0.009%, H:0.0065%, O:0.0001%, surplus is Fe.
After conventional heat treatment, the mechanical property of pressed compact is R
p0.2/ 718Mpa, Rm/823Mpa, A/23%, Z/73%, KV
2/ 168J.
Above-described embodiment is only explanation technical conceive of the present invention and feature, and its object is to allow person skilled in the art can understand content of the present invention and implement according to this, can not limit the scope of the invention with this.All equivalences that Spirit Essence is done according to the present invention change or modify, within all should being encompassed in protection scope of the present invention.
Claims (5)
1. the electroslag smelting casting manufacture method of a turbine blade pressed compact, according to turbine blade 3 D intelligent development size, determine blade pressed compact appearance profile, make electroslag smelting casting blade pressed compact crystallizer, consutrode, by optimizing electroslag casting process, Anti-cracking Technology for Heating Processing, finally prepare qualified electroslag smelting casting blade pressed compact, it is characterized in that, described electroslag casting process concrete steps are as follows:
(1), slag system and the quantity of slag are controlled: electroslag smelting casting slag system main component is mass percent: CaF
2: 55～65%, Al
2o
3: 25～35%, according to actual alloy refining, require to add MgO, the CaO slag system that comes from different backgrounds and possess different abilities, its addition is not higher than 15% of slag system gross mass, and thickness of slag layer is 40～60% of crystallizer equivalent diameter;
(2), Igniting pattern: adopt solid slag or the melt cinder starting the arc, starting the arc material chemical composition mass percent is: TiO
2: 40～55%, CaF
2: 40～58%, MgO:2～5%; When adopting the solid slag starting the arc, between electrode and end water tank, place a signal supervisory instrument, by detecting electrode and starting the arc material Contact, the variation of current potential between electrode and end water tank, whether can detect consutrode has compressed and has been connected with water cooled bottom plate, electrode decrease speed is controlled, guaranteed that starting the arc material is not crushed or top is inclined to one side;
(3), power supply parameter is selected: Control of Voltage in 50～110V, Current Control at 5500～18000A;
(4), feeding: adopt interruption feeding mode to carry out feeding; In the feeding phase, first normal current is at the uniform velocity reduced to minimum feeding electric current in 3～8 minutes, keep 2～5 minutes, again minimum feeding electric current was at the uniform velocity elevated to 70～90% of normal fusion casting current in 2～5 minutes, 5～8 times so repeatedly, the highest each fusion casting current be all last time 70～90% of the highest fusion casting current, last be reduced to for 1 time zero.
2. according to the electroslag smelting casting manufacture method of turbine blade pressed compact described in claim 1, it is characterized in that: the crystallizer that electroslag smelting casting adopts is the separate assembling crystallizer of full aluminium or copper steel welding, crystallizer can split be dismantled, keep in repair; Wherein full crystalline aluminophosphate equipment matter is ZL114A, and the water seam width of crystallizer internal cavity plate and gusset is 25～40mm, and crystallizer internal cavity is cast moulding method preparation; Copper steel welding crystallizer is that to take crystallizer exocoel and gusset be carbon steel sheet, the crystallizer that inner chamber is copper plate, and copper steel welding crystallizer internal cavity plate is 15～35mm with the water seam width of gusset, crystallizer internal cavity copper coin is prepared by metal hot bending+machined manufacturing process.
3. according to the electroslag smelting casting manufacture method of turbine blade pressed compact described in claim 1, it is characterized in that: consutrode used is sand casting electrode and steel plate butt welding electrode 2 classes, in conjunction with blade pressed compact crystallizer internal cavity size, prepare blade pressed compact conformal consutrode, the packing ratio of selecting is 0.3～0.45.
4. according to the electroslag smelting casting manufacture method of turbine blade pressed compact described in claim 1, it is characterized in that, blade pressed compact Anti-cracking Technology for Heating Processing is: the electroslag smelting casting blade pressed compact after devaning is heated to 800～900 ℃, is incubated after 4～6 hours, cool to room temperature with the furnace.
5. according to the electroslag smelting casting manufacture method of turbine blade pressed compact described in claim 1, it is characterized in that: described turbine blade pressed compact alloy is steel alloy 20SiMn; Low Carbon Martensite Stainless Steel 06Cr13Ni4Mo, 06Cr13Ni5Mo or 06Cr16Ni5Mo; Mo ultralow-carbon martensitic stainless steel 04Cr13Ni4Mo, 04Cr13Ni5Mo.
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| CN114643346A (en) * | 2020-12-17 | 2022-06-21 | 沈阳铸造研究所有限公司 | Multi-element pre-melted slag for electroslag casting, and preparation method and application thereof |
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Denomination of invention: A Method for Manufacturing Hydraulic Turbine Blade Blanks by Electroslag Melting Casting Effective date of registration: 20231113 Granted publication date: 20160525 Pledgee: China Construction Bank Corporation Shenyang Tiexi Branch Pledgor: Shenyang Foundry Research Institute Co., Ltd. of China National Machinery Research Institute Group Registration number: Y2023210000280 |
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