CN107649664B - A kind of the electroslag smelting casting manufacturing method and device of the irregularly-shaped castings of three dimensional change - Google Patents
A kind of the electroslag smelting casting manufacturing method and device of the irregularly-shaped castings of three dimensional change Download PDFInfo
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- CN107649664B CN107649664B CN201610589758.2A CN201610589758A CN107649664B CN 107649664 B CN107649664 B CN 107649664B CN 201610589758 A CN201610589758 A CN 201610589758A CN 107649664 B CN107649664 B CN 107649664B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
- B22D23/06—Melting-down metal, e.g. metal particles, in the mould
- B22D23/10—Electroslag casting
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Abstract
The present invention relates to the irregularly-shaped castings field of electroslag smelting casting production three dimensional change, the electroslag smelting casting manufacturing methods and device of especially a kind of irregularly-shaped castings of three dimensional change.Electroslag smelting casting is used to complete the double refining purification of consutrode material, casting near-net-shape, and detailed process is as follows: 1) spray mold structure form uses combined type or split type；2) consutrode in fusion-casting process consists of two parts, i.e. guiding electrode and supplement electrode；Guiding electrode is profile-followed, fixation relative to crystallizer, and guiding electrode interior has guide channel；Supplementing electrode is float electrode, and supplement electrode is set in the guide channel；Electrode working forms in fusion-casting process are as follows: supplement electrode is constantly supplemented to melting electroslag position via guide channel, completes fusion-casting process.To which the present invention is mainly suitable for the castings of the irregularly-shaped castings of three dimensional change.
Description
Technical field
The present invention relates to the irregularly-shaped castings field of electroslag smelting casting production three dimensional change, especially a kind of abnormal shapes of three dimensional change
The electroslag smelting casting manufacturing method and device of casting.
Background technique
Electroslag smelting casting refines as a kind of collection and takes shape in integrated casting technique, is now widely used for high casting quality
It is required that field.Consutrode is placed in crystallizer molten state slag blanket by its founding generally using consutrode as founding raw material
Reflow process is completed, this process needs to keep the process safety distance of electrode and crystallizer internal cavity, and this requires in founding
Cheng Zhong, as the carry out consutrode of founding completes entire fusion-casting process as thawing constantly moves downward supplement.
For profiled piece, generally referring to castings crystallization device here does not have public chamber casting, i.e. consumable to float electrode
Electrode can not freely cooperation melts speed and moves up and down in founding crystallizer.On the other hand, some profile shapes part
Protrusion or recess so that consutrode with crystallization type chamber at a distance from it is larger so that consutrode melting during molten metal also
It is not solidified full of crystallization type chamber, and not can guarantee the integrality of Filling Processes of Castings, this is the limitation of current electroslag casting process
Place, as castings crystallization device do not have public chamber casting to float electrode and only rely on float electrode and be unable to complete founding to answer
Miscellaneous shape casting is the main bottleneck of current electroslag casting process.
Electroslag smelting casting in recent years is used widely in hydropower industry, especially hydrogenerator movable guide vane, and with
Attention of the country to adjustment and the environmental protection of power construction structure, positive Hydropower Development have become China's power industry construction
Guilding principle.Water power belongs to reproducible clean energy resource, is conducive to environmental protection, Hydropower Development, especially sediment content compared with
Design, manufacture and the production capacity of the poor large-sized water turbine unit of high water quality are promoted national economic development and are promoted mechanical
The demand of industrial development.
Core component of the runner as energy conversion critical component and hydrogenerator in turbine-generator units,
Quality and service life directly affect safety, efficiency of operation and the cost of turbine-generator units operation.Especially mixed-flow
The runner bucket of generator, axis stream generator, since it is huge using extensive market volume.
Currently, runner bucket mainly uses sand mould casting method to manufacture both at home and abroad, using the then numerical control of sand casting blank
The process of processing, and sand casting, due to the limitation of its technique, castings material density and quality are poor；And use sand
Mold casting slab, cooperation compression molding, though improving casting quality to a certain extent, sand casting quality disadvantage still cannot root
This solution；Slab is produced for electroslag smelting casting, cooperation compression molding manufactures work though overcoming the mass defect of sand-cast
Skill higher cost.
Summary of the invention
The purpose of the present invention is to provide the electroslag smelting casting manufacturing methods and device of a kind of irregularly-shaped castings of three dimensional change, main
Solve electroslag casting process can not founding complicated abnormal shape part, i.e., castings crystallization device to activity supplement electrode do not have public chamber casting
The casting of part.
The technical scheme is that
A kind of electroslag smelting casting manufacturing method of the irregularly-shaped castings of three dimensional change, electroslag smelting casting is for completing consutrode material
Double refining purification, casting near-net-shape, detailed process is as follows:
1) crystallizer selects
Spray mold structure form uses combined type or split type；
2) electrode form
Consutrode in fusion-casting process consists of two parts, i.e. guiding electrode and supplement electrode；Be oriented to electrode relative to
Crystallizer is profile-followed, fixation, and guiding electrode interior has guide channel；Supplementing electrode is float electrode, and supplement electrode is set
It is placed in the guide channel；
Electrode working forms in fusion-casting process are as follows: supplement electrode is constantly mended to melting electroslag position via guide channel
It fills, completes fusion-casting process.
The electroslag smelting casting manufacturing method of the irregularly-shaped castings of the three dimensional change, castings material are carbon steel, low-alloy steel
Or stainless steel.
The electroslag smelting casting manufacturing method of the irregularly-shaped castings of the three dimensional change, castings material include and are not limited to subscript
One of material described in standard: ASTM 743, ASTM 483, EN 10283, GB/T 6967, GB/T 11352, JB/T 5000.6,
JB/T 10384、JB/T 7349、JB/T 6405。
A kind of electroslag smelting casting manufacturing device of the irregularly-shaped castings of three dimensional change, the device are equipped with profile-followed crystallizer, crystallizer
Inner cavity is crystallization type chamber, crystallizes and consutrode is arranged in type chamber, and consutrode is made of guiding electrode and supplement electrode, is melted
Guiding electrode is fixed or removable during casting；It supplements electrode to be located in the guide channel of guiding electrode, supplement electrode is
Flexible electrode, supplement electrode constantly supplement metal to crystallizer melting position in guiding electrode interior.
The electroslag smelting casting manufacturing device of the irregularly-shaped castings of the three dimensional change, supplement electrode cross-section are round, rectangular
Or other arbitrary shapes.
The electroslag smelting casting manufacturing device of the irregularly-shaped castings of the three dimensional change, guiding electrode is one or more,
Supplementing electrode is one or more；When being oriented to electrode in the presence of two or more, position is fixed to each other between being oriented to electrode.
The electroslag smelting casting manufacturing device of the irregularly-shaped castings of the three dimensional change, guiding electrode is whole or Split assembled
Formula.
The electroslag smelting casting manufacturing device of the irregularly-shaped castings of the three dimensional change, for mixed-flow wheel generator blade hair
The electroslag smelting casting of base is crystallized using one or more guiding electrode in type chamber, and supplement electrode is flexible electrode, by leading
It is imported to electrode interior guide channel, before crystallizer group case, guiding electrode is fixed in crystallization type chamber, each to be oriented to electrode installation
Its mutual position is fixed after in place, and supplement electrode constantly carries out consumable to fusion-casting process by the guide channel in guiding electrode
Electrode supplement.
The electroslag smelting casting manufacturing device of the irregularly-shaped castings of the three dimensional change, the device include: supplement electrode, crystallizer
Type chamber, fixed guide electrode, activity-oriented electrode, crystallizer be upper layer and lower layer structure, be each responsible for blade flange section molding and
Blade-section molding；Crystallization type chamber cross section positioned at upper layer is circle, is provided with activity-oriented electrode, activity-oriented electricity
Setting supplement electrode in guide channel on the inside of pole；It is bar shaped positioned at the crystallization type chamber cross section of lower layer, is provided with fixation and leads
To electrode.
The electroslag smelting casting manufacturing device of the irregularly-shaped castings of the three dimensional change, for axial flow type hydro-turbo generator blade hair
The electroslag smelting casting of base assembles fixed guide electrode or supplement electrode and activity-oriented electrode respectively in crystallization type chamber, uses
The mode that profile-followed fixed guide electrode is combined with activity-oriented electrode, in order to the fusion cast process of casting；In left and right crystallizer
Before type chamber group case, profile-followed fixed guide electrode is fixed on to the designated position of crystallization type chamber, is equipped with and leads in activity-oriented electrode
To channel, electrode being supplemented by guide channel and constantly enters melting zone, consutrode supplement is carried out to fusion-casting process.
The advantages of the present invention are:
1, the present invention solves the technique bottleneck of complicated abnormal shape part electroslag smelting casting, and casting solidifies in water mold, cold
But speed is fast, solid-liquid forward position crystallization temperature gradient is big, and since casting quickly solidifies, cast structure is fine and close.
2, small using metal crystallizer dimensional accuracy height of the present invention, deformation, thus cast(ing) surface is bright and clean, machining allowance
It is small.Simultaneously as casting does not have casting system and riser, therefore metal utilization is high using consecutive solidification technique, casting is realized
Near-net-shape (machining allowance range is 3-20mm).Meanwhile being not likely to produce the common slag inclusion of sand-cast, stomata, shrinkage porosite and contracting
The casting flaws such as hole, and can satisfy flaw detection requirement more higher than sand casting.
3, the present invention is not necessarily to a large amount of nonmetallic moulding such as binder and coating using metal crystallizer instead of sand mold
Material, no solid waste discharge reduce the pollution to environment.
4, the present invention refining casting can reach same material forging mechanical performance and flaw detection require, chemical component uniformly, group
Knit fine and close, dendrite refinement, microscopic segregation it is small, without it is loose, without slag inclusion shrinkage cavity the defects of, field trash is in Dispersed precipitate, fatigue life
Better than Clean Steel, and have the advantages of isotropism not available for forge piece, at the same have higher fatigue resistance energy and compared with
High anti-crack generation and scalability.
5, of the invention since metal crystallizer can be repeated several times use, production efficiency can be effectively improved, reduction is produced into
This.
Detailed description of the invention:
Fig. 1 is electroslag smelting casting manufacturing device schematic diagram.Wherein, (a) is main view；It (b) is the A-A cross-sectional view of (a).
Fig. 2 is the guiding electrode and supplement electrode scheme of installation of consutrode.
Fig. 3 is the electroslag smelting casting manufacturing device schematic diagram of mixed-flow wheel generator blade blank.
Fig. 4 is the electroslag smelting casting manufacturing device schematic diagram of axial flow type hydro-turbo generator blade blank.
In figure, 1 guiding electrode；2 supplement electrodes；3 crystallization type chambers；4 fixed guide electrodes；5 activity-oriented electrodes；6 lead
To channel.
Specific embodiment
As shown in Figure 1, electroslag smelting casting manufacturing device of the present invention designs and manufacture profile-followed crystallizer, crystallizer internal cavity is crystallization
Type chamber 3 crystallizes and consutrode is arranged in type chamber 3, and consutrode is made of guiding electrode 1 and supplement electrode 2, fusion-casting process
Middle guiding electrode 1 can be fixed or removable, and supplement electrode 2 is located in the guide channel 6 of guiding electrode 1, supplements electrode 2
For flexible electrode, supplements electrode 2 and constantly supplement metal to crystallizer melting position inside guiding electrode 1, pass through near net-shaped knot
The design of brilliant device achievees the purpose that improve stock utilization.
In the specific implementation process, electroslag smelting casting of the present invention is used to complete double refining purification, the casting of consutrode material
The tasks such as part near-net-shape, wherein castings material, crystallizer and consutrode have the feature that
1) crystallizer selects
Spray mold structure form uses combined type or split type.
2) electrode form
As shown in Figure 1, the consutrode in fusion-casting process consists of two parts, that is, it is oriented to electrode 1 and supplement electrode 2.It leads
Relative to crystallizer it is profile-followed, fixed to electrode 1, is at this time a kind of electrode of fixation, being oriented to inside electrode 1 has guiding
Channel.Supplementing electrode 2 is a kind of float electrode, and the cross section of supplement electrode 2 can be round, rectangular or other arbitrary shapes,
Guiding electrode 1 can be whole or separate assembling (Fig. 2).Electrode working forms in fusion-casting process are as follows: supplement electrode 2 passes through
It is constantly supplemented from guide channel to melting electroslag position, completes fusion-casting process.Wherein, guiding electrode 1 can be one or
Two or more, supplement electrode 2 can be one or more.When being oriented to electrode 1 in the presence of two or more, it is oriented to 1 meta position of electrode
Set be fixed to each other (Fig. 3).Because of the difference of casting structure form, there are fixed guide electrode 4, activity-oriented electrode 5 and supplement electricity
The case where pole 2 exists simultaneously use, wherein fixed guide electrode 4 refers in fusion-casting process, electrode be located in crystallizer and
Opposite founding crystallizer is fixed (Fig. 4) in fusion-casting process.
3) castings material
Casting can be carbon steel, low-alloy steel or stainless steel, includes and is not limited to material (ASTM described in following standard
743、ASTM 483、EN 10283、GB/T 6967、GB/T 11352、JB/T 5000.6、JB/T 10384、JB/T 7349、
JB/T 6405), specific material is illustrated such as:
Carbon steel: ZG230-450, ZG270-500, ZG310-570 etc.；
Low-alloy steel: ZG20SiMn, ZG25Mn18Cr4 etc.；
Stainless steel: ZG10Cr13, ZG06Cr13Ni4Mo, ZG06Cr13Ni5Mo, ZG06Cr16Ni5Mo,
ZG00Cr13Ni4Mo, ZG00Cr13Ni5Mo, ZG00Cr16Ni5Mo etc..
In the following, by embodiment, the present invention is described in more detail.
Embodiment 1
As shown in Fig. 2, two lobed crystallizers and profile-followed guiding electrode are assembled by technique requirement, are led in the present embodiment
It is separate assembling to electrode 1, guiding electrode only shows wherein half in the guiding diagram of electrode 1.It is oriented to electrode 1 and is equipped with two
A guide channel 6 (cross section is respectively round or rectangle), two supplement electrodes 2 (cross section is respectively round or rectangle) are respectively
It is set in the corresponding guide channel 6 of cross-sectional shape, two supplement electrodes 2 are respectively by guide channel 6 constantly to founding
Process carries out consutrode supplement.
Embodiment 2
As shown in figure 3, in the present embodiment, the electroslag smelting casting of mixed-flow wheel generator blade blank is crystallized in type chamber 3
It is oriented to electrode 1 using 8 duct types, supplement electrode is flexible cylindrical, and supplement electrode is oriented to inside electrode 1 by duct type and is led
It is imported to channel 6.Before crystallizer group case, guiding electrode 1 is fixed on to the designated position of crystallization type chamber 3, it is each to be oriented to electrode 1
Its mutual position is fixed after installation is in place, supplement electrode by the guide channel 6 in guiding electrode 1 constantly to fusion-casting process into
Row consutrode supplement.
Embodiment 3
As shown in figure 4, electroslag smelting casting manufacturing device includes: supplement electrode 2, crystallization type chamber 3, fixes in the present embodiment
It is oriented to electrode 4, activity-oriented electrode 5 etc., crystallizer is upper layer and lower layer structure, is each responsible for the molding of blade flange section and blade part
It is divided into type.3 cross section of crystallization type chamber positioned at upper layer is circle, is provided with activity-oriented electrode 5, activity-oriented electrode 5
Setting supplement electrode 2 in the guide channel of inside.It is bar shaped positioned at 3 cross section of crystallization type chamber of lower layer, is provided with fixation and leads
To electrode 4.
The electroslag smelting casting of axial flow type hydro-turbo generator blade blank assembles fixed guide electricity respectively in crystallization type chamber 3
Pole 4 or supplement electrode 2 and activity-oriented electrode 5, the side combined using profile-followed fixed guide electrode 4 with activity-oriented electrode 5
Formula, in order to the fusion cast process of casting.Before left and right crystallizes 3 groups of casees of type chamber, profile-followed fixed guide electrode 4 is fixed on crystallization
The designated position of type chamber 3, guide channel is equipped in activity-oriented electrode 5, and supplement electrode 2 is constantly entered molten by guide channel
Tabetisol carries out consutrode supplement to fusion-casting process.
Embodiment the result shows that, the present invention be near-net-shape block cast blank manufacturing technology method, especially to water wheels send out
Motor blade is the electroslag casting method of near-net-shape, and spray produced has higher fatigue resistance energy, higher cracking resistance
Line generates and scalability, and quality and performance are not less than same material rough forging.Using electroslag smelting casting technology, casting hair is produced
The Internal Quality of Cast of base, production is not less than same material rough forging quality standard.
Claims (5)
1. a kind of electroslag smelting casting manufacturing method of the irregularly-shaped castings of three dimensional change, electroslag smelting casting is for completing consutrode material
Double refining purification, casting near-net-shape, which is characterized in that detailed process is as follows:
1) crystallizer selects
Spray mold structure form uses combined type or split type；
2) electrode form
Consutrode in fusion-casting process consists of two parts, i.e. guiding electrode and supplement electrode；Electrode is oriented to relative to crystallization
Device is profile-followed, fixation, and guiding electrode interior has guide channel；Supplementing electrode is float electrode, and supplement electrode is set to
In the guide channel；
Electrode working forms in fusion-casting process are as follows: supplement electrode is constantly supplemented to melting electroslag position via guide channel,
Complete fusion-casting process；
This method is using the electroslag smelting casting manufacturing device of the irregularly-shaped castings of three dimensional change, and the device is equipped with profile-followed crystallizer, crystallization
Device inner cavity is crystallization type chamber, crystallizes and consutrode is arranged in type chamber, and consutrode is made of guiding electrode and supplement electrode,
It is fixed or removable that electrode is oriented in fusion-casting process；It supplements electrode to be located in the guide channel of guiding electrode, supplements electrode
For flexible electrode, electrode is supplemented in guiding electrode interior and constantly supplements metal to crystallizer melting position；Guiding electrode includes: solid
Surely it is oriented to electrode, activity-oriented electrode, crystallizer is upper layer and lower layer structure, is each responsible for the molding of blade flange section and blade-section
Molding；Crystallization type chamber cross section positioned at upper layer is circle, is provided with activity-oriented electrode, leads on the inside of activity-oriented electrode
The setting supplement electrode into channel；It is bar shaped positioned at the crystallization type chamber cross section of lower layer, is provided with fixed guide electrode.
2. the electroslag smelting casting manufacturing method of the irregularly-shaped castings of three dimensional change described in accordance with the claim 1, which is characterized in that casting
Material is carbon steel, low-alloy steel or stainless steel.
3. the electroslag smelting casting manufacturing method of the irregularly-shaped castings of three dimensional change described in accordance with the claim 1, which is characterized in that supplement
Electrode cross-section is round, rectangular or other arbitrary shapes.
4. the electroslag smelting casting manufacturing method of the irregularly-shaped castings of three dimensional change described in accordance with the claim 1, which is characterized in that guiding
Electrode is whole or separate assembling.
5. the electroslag smelting casting manufacturing method of the irregularly-shaped castings of three dimensional change described in accordance with the claim 1, which is characterized in that for
The electroslag smelting casting of axial flow type hydro-turbo generator blade blank assembles fixed guide electrode, supplement electricity respectively in crystallization type chamber
Pole and activity-oriented electrode, using fixed guide electrode in such a way that activity-oriented electrode combines, in order to the founding of casting
Molding；Before left and right crystallizes type chamber group case, fixed guide electrode is fixed on to the designated position of crystallization type chamber, activity-oriented
Guide channel is equipped in electrode, supplement electrode constantly enters melting zone by guide channel, carries out consutrode to fusion-casting process
Supplement.
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| JP2012236212A (en) * | 2011-05-12 | 2012-12-06 | Japan Steel Works Ltd:The | Consumable electrode for electroslag remelting and method for manufacturing the same |
| CN103567419A (en) * | 2013-10-24 | 2014-02-12 | 沈阳市盛华特种铸造有限公司 | Manufacturing method for through-flow turbine continuous variable cross-section movable guide vanes through electroslag smelting casting |
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2016
- 2016-07-25 CN CN201610589758.2A patent/CN107649664B/en active Active
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
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| JPS5196735A (en) * | 1975-02-21 | 1976-08-25 | HOJODENKYOKUKENYOMOORUDO | |
| US4167963A (en) * | 1977-02-04 | 1979-09-18 | Terni-Societa Per L'industria E L'elettricita S.P.A. | Method and apparatus for feeding molten metal to an ingot during solidification |
| CN1104944A (en) * | 1993-12-24 | 1995-07-12 | 机械工业部沈阳铸造研究所 | Electric slag smelting and founding with fixed random self consumption electrode |
| CN1557584A (en) * | 2003-01-21 | 2004-12-29 | 沈阳铸造研究所 | Electroslag smelting casting guide vanes method |
| JP2012236212A (en) * | 2011-05-12 | 2012-12-06 | Japan Steel Works Ltd:The | Consumable electrode for electroslag remelting and method for manufacturing the same |
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