CN114029449A - Casting method of heavy-duty gas turbine diffusion casing casting - Google Patents
Casting method of heavy-duty gas turbine diffusion casing casting Download PDFInfo
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- CN114029449A CN114029449A CN202111205144.7A CN202111205144A CN114029449A CN 114029449 A CN114029449 A CN 114029449A CN 202111205144 A CN202111205144 A CN 202111205144A CN 114029449 A CN114029449 A CN 114029449A
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- 238000005266 casting Methods 0.000 title claims abstract description 151
- 238000000034 method Methods 0.000 title claims abstract description 50
- 238000009792 diffusion process Methods 0.000 title claims abstract description 48
- 239000004576 sand Substances 0.000 claims abstract description 41
- 239000002023 wood Substances 0.000 claims abstract description 29
- 238000010438 heat treatment Methods 0.000 claims abstract description 20
- 238000000137 annealing Methods 0.000 claims abstract description 14
- 238000000465 moulding Methods 0.000 claims abstract description 13
- 230000007547 defect Effects 0.000 claims abstract description 11
- 238000004519 manufacturing process Methods 0.000 claims abstract description 8
- 238000002156 mixing Methods 0.000 claims abstract description 7
- 238000003723 Smelting Methods 0.000 claims abstract description 6
- 239000007787 solid Substances 0.000 claims abstract description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 47
- 229910000831 Steel Inorganic materials 0.000 claims description 23
- 239000010959 steel Substances 0.000 claims description 23
- 238000004321 preservation Methods 0.000 claims description 17
- 238000003466 welding Methods 0.000 claims description 14
- 239000003110 molding sand Substances 0.000 claims description 13
- 238000007689 inspection Methods 0.000 claims description 10
- 239000006004 Quartz sand Substances 0.000 claims description 9
- 238000003754 machining Methods 0.000 claims description 9
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical group [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 9
- 239000000919 ceramic Substances 0.000 claims description 8
- 239000000463 material Substances 0.000 claims description 7
- 238000004140 cleaning Methods 0.000 claims description 6
- 239000011248 coating agent Substances 0.000 claims description 6
- 238000000576 coating method Methods 0.000 claims description 6
- 150000002895 organic esters Chemical group 0.000 claims description 6
- 238000007670 refining Methods 0.000 claims description 6
- 238000004088 simulation Methods 0.000 claims description 6
- 238000007711 solidification Methods 0.000 claims description 6
- 230000008023 solidification Effects 0.000 claims description 6
- 238000005496 tempering Methods 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 5
- 238000005520 cutting process Methods 0.000 claims description 5
- 238000010586 diagram Methods 0.000 claims description 4
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 3
- 239000011230 binding agent Substances 0.000 claims description 3
- 239000003795 chemical substances by application Substances 0.000 claims description 3
- 238000010891 electric arc Methods 0.000 claims description 3
- 239000000843 powder Substances 0.000 claims description 3
- 238000002360 preparation method Methods 0.000 claims description 3
- 229910052845 zircon Inorganic materials 0.000 claims description 3
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims description 3
- 238000007599 discharging Methods 0.000 claims description 2
- 238000005498 polishing Methods 0.000 claims description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 238000001514 detection method Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 241001062472 Stokellia anisodon Species 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
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- 229910052751 metal Inorganic materials 0.000 description 1
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- 238000004904 shortening Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/088—Feeder heads
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
- B22C9/24—Moulds for peculiarly-shaped castings for hollow articles
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/26—Methods of annealing
- C21D1/32—Soft annealing, e.g. spheroidising
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/08—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for tubular bodies or pipes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
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Abstract
The invention provides a casting method of a heavy-duty gas turbine diffusion casing casting, which comprises the following steps: the method comprises the following steps: designing a casting process; step two: simulating, analyzing and optimizing by a computer; step three: manufacturing a solid wood model; step four: sand mixing; step five: molding and core making; step six: assembling the box; step seven: smelting and pouring; step eight: sand removal; step nine: softening annealing heat treatment; step ten: performing heat treatment; step eleven: and (5) post-treatment. Through the casting process design of the diffusion casing and the production process control method, the casting is solidified and shrunk in a subarea mode, the defects of sand inclusion, air holes, shrinkage porosity and deformation of the casting are avoided, and the heavy gas turbine diffusion casing casting with the quality meeting the technical requirements is obtained.
Description
Technical Field
The invention relates to a casting method of a heavy-duty gas turbine diffusion casing casting, and belongs to the technical field of casting.
Background
The gas turbine is key equipment in the energy field of national key development, the diffusion casing is a key part for mounting and supporting a combustor on the shell of the gas turbine, the outer diameter of the diffusion casing of the light gas turbine is not large, and a heat-resistant forging material is usually used, but the outer diameter of the diffusion casing of the heavy gas turbine is larger, and a heat-resistant casting material is generally used. For example, the diffusion casing steel casting of the H25 heavy-duty gas turbine has the casting outer diameter dimension of 2360mm and the height of 1030 mm; the casting weight is 4800 kg; the product quality requirement is high, the casting needs magnetic powder inspection, ultrasonic inspection, ray inspection, dye inspection, physical and chemical property inspection and metallographic inspection, the size needs three-dimensional scanning detection and comparison, and the first part needs the identification of Party A and a third party.
Under the prior art, the wood pattern is manufactured by combining a manual machining method and a woodworking machining method, the main size of the wood pattern is checked by a tape measure after the wood pattern is finished, but the appearance size which cannot be checked influences the local size of the casting; the number of the casting mold air outlets is large, the periphery of the casting mold air outlets is molding sand, the molding sand easily falls into a cavity in the casting mold storage and pouring process, and the casting piece is easy to have sand inclusion defects; after the casting mold closes the box, the surface of the mold core gets damp, and the surface of the casting is easy to generate air hole defects after molten steel is injected; after the casting is poured, the casting is cooled quickly in a sand mold, the casting has large internal stress, and when redundant metals such as a riser, a pouring gate, patching and the like are removed subsequently, microcracks and local deformation are easy to generate; the shape of the casting is complex, the thermal junctions are dispersed, the casting process design difficulty is high, the casting is easy to generate the defects of shrinkage porosity, shrinkage cavity and the like, and the nondestructive inspection requirement of the casting is difficult to meet.
Disclosure of Invention
The invention aims to provide a casting method of a heavy-duty gas turbine diffusion casing casting, which realizes the zonal solidification and shrinkage of the casting through a diffusion casing casting process design and a production process control method, and avoids the defects of sand inclusion, air holes, shrinkage porosity and deformation of the casting, thereby obtaining the heavy-duty gas turbine diffusion casing casting with the quality meeting the technical requirements.
In order to achieve the technical features, the invention is realized as follows: the casting method of the heavy-duty gas turbine diffuser casing casting comprises the following steps:
the method comprises the following steps: designing a casting process;
step two: simulating, analyzing and optimizing by a computer;
step three: manufacturing a solid wood model;
step four: sand mixing;
step five: molding and core making;
step six: assembling the box;
step seven: smelting and pouring;
step eight: sand removal;
step nine: softening annealing heat treatment;
step ten: performing heat treatment;
step eleven: and (5) post-treatment.
The specific operation process of the first step is that according to the structural characteristics of the diffusion casing casting, a secondary parting three-open box model is adopted, namely an upper model, a middle model and a lower model; three layers of risers are arranged at the end surfaces of the large and small semicircular shaft hubs and the large and external circle thermal junctions of the diffusion casing casting according to a modulus method MPieceCalculating the modulus of the key hot section of the casting in different areas according to the volume V/area A, and then calculating the modulus of the key hot section of the casting according to the MCap with heating means=1.1MPieceDetermining a riser modulus and selecting a riser with a suitable size; an external chill is arranged between the risers, a patch is arranged below the shaft hub riser, the casting is inconvenient to be provided with a hot section of the riser, the hot section is led into the riser through the patch, the respective directional feeding of the riser is realized, and the molten steel is finally solidified in the riser, so that the compactness of the internal structure of the casting of the diffusion casing is ensured; an open type pouring system is adopted, molten steel is poured at the bottom, and the molten steel stably rises in a cavity to fill the mold; in addition, in order to control the reducing rule of opening the gear of the big and small semicircular shaft hubs, a pull support is respectively arranged at the opening gear.
And the specific operation process of the second step is that according to parameters of a riser, a chill, a patch, a bracing and a gating system designed in the casting process of the diffusion casing casting in the first step, three-dimensional software and solidification simulation software are utilized to carry out numerical simulation analysis on a computer temperature field and a flow field, so that the rationality of the casting process is verified and the casting process is optimized.
The concrete operation process of the third step is that the wood mould is manufactured by combining a manual and woodworking machining method, a reducing rule and a drawing slope are arranged on the wood mould, and machining allowance is reserved; after the wood pattern is manufactured, the main size of the wood pattern is checked by using a measuring tape, and the whole shape of the wood pattern is recorded by using a three-dimensional scanning device and is compared with a three-dimensional graph of the wood pattern, so that the accuracy of the shape and the size of the wood pattern is ensured.
The concrete operation process of the fourth step is that a continuous sand mixer is used for mixing sand, the raw sand is quartz sand and chromite sand, the binder is modified water glass, the curing agent is organic ester, the granularity of the quartz sand is 20-50 meshes, the granularity of the chromite sand is 50-70 meshes, the adding amount of the modified water glass accounts for 2.2-2.8% of the adding amount of the sand, and the adding amount of the organic ester accounts for 12-15% of the adding amount of the modified water glass.
Placing a heat-insulating riser, a chill and a ceramic pipe runner according to the casting process requirement, wherein a thin-wall steel pipe is used as an air outlet; the method is characterized in that high-temperature resistant chromite sand molding sand with a certain thickness is used at the root parts of fillets and risers of the diffusion casing casting, quartz sand molding sand is used for the rest parts, and all the molding sand is used within the usable time and is tamped by a vibrating table or a wooden stick.
Coating alcohol-based zircon powder coating on the core, cleaning the cavity after core preparation, and closing the mold according to the sequence of downward molding, medium molding and upward molding; in order to prevent the surface of the casting from generating air hole defects, hot air is blown to the cavity after the casting is closed and baked for 4-6 hours, and the cavity is kept at a temperature of 80 +/-20 ℃ for pouring in a hot state.
Smelting molten steel by combining an electric arc furnace and an LF refining furnace, and pouring after the molten steel is calmed, wherein the pouring temperature is 1540-1570 ℃, and the pouring time is 50-70 seconds;
the concrete operation process of the step eight is that the diffusion casing casting is subjected to heat preservation in a sand mold for 60-65 hours and then shakeout cleaning is carried out;
the concrete operation process of the ninth step is that the diffusion casing casting is subjected to softening annealing treatment after sand removal, the temperature of the softening annealing treatment is 600 +/-20 ℃, the heat preservation time is 5-6 hours, and the diffusion casing casting is cooled in a furnace; and after softening and annealing, gas cutting the heat-insulating open riser, the heat-insulating blind riser, the ceramic pipe runner and the patch.
The specific operation process of the step ten comprises the steps of adopting a normalizing and tempering heat treatment mode, wherein the normalizing temperature is 880-900 ℃, the heat preservation time is 6-7 hours, discharging from a furnace for air cooling, the tempering temperature is 610-630 ℃, the heat preservation time is 6-7 hours, cooling in the furnace, refining grains, eliminating stress and improving the mechanical property of the material.
The concrete operation process of the eleventh step is to carry out rough machining, polishing, nondestructive inspection, weld repair, destressing heat treatment and three-dimensional scanning on the diffusion casing casting; repair welding using CO2Gas shielded welding repair, wherein the preheating temperature of a welding repair area is 100-200 ℃, the stress is eliminated integrally after welding, the heat treatment temperature is 600-620 ℃, and the heat preservation time is 8-9 hours; and recording all shapes of the diffusion casing casting by using a three-dimensional scanning device, and comparing the shapes with a three-dimensional diagram of a standard diffusion casing casting to ensure that the shapes and the sizes of the castings meet the requirements of drawings and specifications.
The invention has the following beneficial effects:
according to the diffusion casing casting process, a mode of combining a dead head, a cold iron and a patch is adopted, so that the zonal solidification feeding of the dead head is realized, and the compactness of the internal structure of a casting is ensured; the casting process is analyzed and optimized by utilizing computer numerical simulation, thereby ensuring the rationality of the casting process and shortening the trial production period of new products; the three-dimensional scanning detection method is used for the wood pattern, so that the accuracy of the shape and the size of the wood pattern is ensured; the casting mold vent hole uses a thin-wall steel pipe, so that the defect of sand inclusion caused by the fact that the molding sand falls into the casting from the vent hole is effectively prevented; after the casting mold is closed, hot air is blown into the cavity for baking, and casting is carried out in a hot state, so that the defect of air holes generated on the surface of a casting is prevented; the casting is subjected to softening annealing heat treatment before gas cutting of the casting head, so that the defects of microcracks and deformation of the casting are prevented, and the technical requirements of the steel casting of the diffusion case are met.
Drawings
The invention is further illustrated by the following figures and examples.
FIG. 1 is a first perspective three-dimensional view of a diffuser casing casting to be cast in accordance with the present invention.
FIG. 2 is a second perspective three-dimensional view of a diffuser casing casting to be cast in accordance with the present invention.
FIG. 3 is a three-dimensional view of a first perspective of the arrangement during the casting process of the present invention.
FIG. 4 is a three-dimensional view of a second perspective arrangement during the casting process of the present invention.
FIG. 5 is a front view of the arrangement during the casting process of the present invention.
FIG. 6 is a top plan view of the arrangement during the casting process of the present invention.
FIG. 7 is a simulation diagram of a computer numerical simulation casting process using simulation software according to the present invention.
In the figure: the device comprises a diffusion casing casting 1, a cold iron 2, a patch 3, a heat-insulating open riser 4, a thin-wall steel pipe 5, a heat-insulating blind riser 6, a ceramic pipe runner 7, a tension brace 8 and a test block 9.
Detailed Description
Embodiments of the present invention will be further described with reference to the accompanying drawings.
Referring to fig. 1-7, a method of casting a heavy duty gas turbine diffuser casing casting includes the steps of:
step one, casting process design: the structure of the diffusion casing casting 1 is as shown in figures 1 and 2, and a secondary parting three-open box model is adopted, namely an upper model, a middle model and a lower model; 2 heat-preservation blind risers 6 are arranged on the end face of a small semicircular shaft hub of the diffusion casing casting 1, 6 heat-preservation blind risers 6 are arranged on a large excircle of the small semicircular shaft hub, and 2 heat-preservation open risers 4 are arranged on the end face of a large semicircular shaft hub; 42 external chills 2 are arranged between the risers and on the lower end surface of the small semicircular shaft hub; 4 patches 3 are arranged below the risers of the large and small shaft hubs, and the hot junction which is inconvenient to arrange the risers is led into the risers through the patches, so that the respective directional feeding of the risers is realized, and the compactness of the internal structure of the casting is ensured; using an open type pouring system, performing bottom pouring on the molten steel to ensure that the molten steel is stably filled in the cavity; in order to control the reducing rule of opening the gear of the big and small semicircular shaft hubs, a pull support 8 is respectively arranged at the opening gear; 2 test blocks 9 with conjoined performance are arranged under the heat-insulating blind riser 6. As shown in fig. 3, 4, 5, 6.
Step two, simulating, analyzing and optimizing by a computer: according to parameters such as a heat-insulating open riser 4, a heat-insulating blind riser 6, a chilling block 2, a patch 3, a bracing 8, a pouring system and the like designed by a diffusion casing casting process, three-dimensional software is used for drawing a stereogram, solidification simulation software is used for carrying out computer numerical simulation analysis, the rationality of the casting process is verified, and the casting process is optimized, as shown in fig. 7.
Step three, manufacturing a solid wood model: the wood pattern manufacturing reduced scale is 1.8%, the pattern drawing inclination is 1 degree, and the allowance of a machined surface is 12 mm; after the wood pattern is manufactured, the main size of the wood pattern is checked by using a measuring tape, and the whole shape of the wood pattern is recorded by using a three-dimensional scanning device and is compared with a three-dimensional graph of the wood pattern, so that the accuracy of the shape and the size of the wood pattern is ensured.
Step four, sand mixing: the method comprises the following steps of mixing sand by using a continuous sand mixer, wherein raw sand comprises quartz sand and chromite sand, a binder comprises modified water glass, a curing agent comprises organic ester, the granularity of the quartz sand is 20-50 meshes, the granularity of the chromite sand is 50-70 meshes, the addition amount of the modified water glass accounts for 2.2-2.8% of the addition amount of the sand, and the addition amount of the organic ester accounts for 12-15% of the addition amount of the modified water glass.
Step five, molding and core making: placing an insulating open riser 4, an insulating blind riser 6, a chilling block 2 and a ceramic pipe runner 7 according to the casting process requirements; in order to prevent the molding sand from falling into the cavity from the vent hole, a thin-wall steel pipe 5 with the diameter of phi 30mm is used for the vent hole; in order to prevent the casting from being bonded with sand, high-temperature resistant chromite sand molding sand with the thickness of about 30mm is used at the fillet of the casting mould and the root of a riser, quartz sand molding sand is used for the rest of the casting mould, and all the molding sand is used in the available time and is tamped by a vibrating table or a wooden stick.
Step six, assembling the box: coating alcohol-based zircon powder coating on the mold core, cleaning a cavity after core preparation, drying and standing, and closing the mold according to the sequence of downward molding, medium molding and upward molding; in order to prevent the surface of the casting from generating air hole defects, hot air is blown to the cavity after the casting is closed and baked for 4-6 hours, and the cavity is kept at a temperature of 80 +/-20 ℃ for pouring in a hot state.
Step seven, smelting and pouring: the electric arc furnace is combined with an LF refining furnace to smelt molten steel, the molten steel is cast after being calmed, the casting temperature is 1540-1570 ℃, and the casting time is 50-70 seconds.
Step eight, sand removal: and (3) performing heat preservation on the diffusion casing casting 1 in a sand mold for 60 hours, and then performing shakeout cleaning.
Step nine, softening annealing heat treatment: in order to eliminate the stress of molten steel solidification and cooling of the diffusion casing casting 1 and prevent microcracks and deformation generated by gas cutting of the heat-insulating open riser 4, the heat-insulating blind riser 6, the ceramic pipe runner 7 and the patch 3, the diffusion casing casting 1 is subjected to softening annealing treatment after sand removal, the temperature of the softening annealing treatment is 600 +/-20 ℃, the heat-insulating time is 5-6 hours, and the diffusion casing casting is cooled in a furnace; and after softening annealing, gas cutting the heat-insulating open riser 4, the heat-insulating blind riser 6, the ceramic pipe runner 7 and the patch 3.
Step ten, performance heat treatment: and (3) adopting a normalizing and tempering heat treatment mode, wherein the normalizing temperature is 880-900 ℃, the heat preservation time is 6-7 hours, the material is discharged from the furnace and air-cooled, the tempering temperature is 610-630 ℃, the heat preservation time is 6-7 hours, and the material is cooled in the furnace, so that the aims of refining grains, eliminating stress and improving the mechanical property of the material are fulfilled.
Step eleven, post-treatment: the method comprises the following steps of rough machining, grinding and nondestructive inspection of a diffusion casing casting 1: UT + MT + RT, repair welding, stress removal heat treatment and three-dimensional scanning; repair welding using CO2Gas shielded welding repair, wherein the preheating temperature of a welding repair area is 100-200 ℃, the stress is eliminated integrally after welding, the heat treatment temperature is 600-620 ℃, and the heat preservation time is 8 hours; and recording all shapes of the diffusion casing casting 1 by using a three-dimensional scanning device, and comparing the shapes with a three-dimensional diagram of the diffusion casing casting 1 to ensure that the shapes and the sizes of the castings meet the requirements of the drawing and the specification.
Claims (10)
1. The casting method of the heavy-duty gas turbine diffuser casing casting is characterized by comprising the following steps:
the method comprises the following steps: designing a casting process;
step two: simulating, analyzing and optimizing by a computer;
step three: manufacturing a solid wood model;
step four: sand mixing;
step five: molding and core making;
step six: assembling the box;
step seven: smelting and pouring;
step eight: sand removal;
step nine: softening annealing heat treatment;
step ten: performing heat treatment;
step eleven: and (5) post-treatment.
2. The method of casting a heavy duty gas turbine diffuser casing casting of claim 1, wherein: the specific operation process of the first step is that according to the structural characteristics of the diffusion casing casting (1), a secondary parting three-open box model is adopted, namely an upper model, a middle model and a lower model; three layers of risers are arranged at the end surfaces of the large and small semicircular shaft hubs and the large and external circle thermal junctions of the diffusion casing casting (1) according to a modulus method MPieceCalculating the modulus of the key hot section of the casting in different areas according to the volume V/area A, and then calculating the modulus of the key hot section of the casting according to the MCap with heating means=1.1MPieceDetermining a riser modulus and selecting a riser with a suitable size; an external chill is arranged between the risers, a patch is arranged below the shaft hub riser, the casting is inconvenient to be provided with a hot section of the riser, the hot section is led into the riser through the patch, the respective directional feeding of the riser is realized, and the molten steel is finally solidified in the riser, so that the compactness of the internal structure of the diffusion casing casting (1) is ensured; an open type pouring system is adopted, molten steel is poured at the bottom, and the molten steel stably rises in a cavity to fill the mold; in addition, in order to control the reducing rule of opening the gear of the big and small semicircular shaft hubs, a pull support (8) is respectively arranged at the opening gear.
3. The method of casting a heavy duty gas turbine diffuser casing casting of claim 1, wherein: and the specific operation process of the second step is that according to the parameters of a riser, a chill, a patch, a bracing and a pouring system designed in the casting process of the diffusion casing casting (1) in the first step, three-dimensional software and solidification simulation software are utilized to carry out numerical simulation analysis on a computer temperature field and a flow field, so that the rationality of the casting process is verified and the casting process is optimized.
4. The method of casting a heavy duty gas turbine diffuser casing casting of claim 1, wherein: the concrete operation process of the third step is that the wood mould is manufactured by combining a manual and woodworking machining method, a reducing rule and a drawing slope are arranged on the wood mould, and machining allowance is reserved; after the wood pattern is manufactured, the main size of the wood pattern is checked by using a measuring tape, and the whole shape of the wood pattern is recorded by using a three-dimensional scanning device and is compared with a three-dimensional graph of the wood pattern, so that the accuracy of the shape and the size of the wood pattern is ensured.
5. The method of casting a heavy duty gas turbine diffuser casing casting of claim 1, wherein: the concrete operation process of the fourth step is that a continuous sand mixer is used for mixing sand, the raw sand is quartz sand and chromite sand, the binder is modified water glass, the curing agent is organic ester, the granularity of the quartz sand is 20-50 meshes, the granularity of the chromite sand is 50-70 meshes, the adding amount of the modified water glass accounts for 2.2-2.8% of the adding amount of the sand, and the adding amount of the organic ester accounts for 12-15% of the adding amount of the modified water glass.
6. The method of casting a heavy duty gas turbine diffuser casing casting of claim 1, wherein: the concrete operation process of the fifth step is that the heat-insulating riser, the chilling block (2) and the ceramic pipe runner (7) are placed according to the casting process requirements, and the thin-wall steel pipe (5) is used as the air outlet; the method is characterized in that high-temperature resistant chromite sand molding sand with a certain thickness is used at the root parts of fillets and risers of a diffusion casing casting (1), quartz sand molding sand is used for the rest parts, and all the molding sand is used within the available time and is tamped by a vibrating table or a wooden stick.
7. The method of casting a heavy duty gas turbine diffuser casing casting of claim 1, wherein: coating alcohol-based zircon powder coating on the core, cleaning the cavity after core preparation, and closing the mold according to the sequence of downward molding, medium molding and upward molding; in order to prevent the surface of the casting from generating air hole defects, hot air is blown to the cavity after the casting is closed and baked for 4-6 hours, and the cavity is kept at a temperature of 80 +/-20 ℃ for pouring in a hot state.
8. The method of casting a heavy duty gas turbine diffuser casing casting of claim 1, wherein: smelting molten steel by combining an electric arc furnace and an LF refining furnace, and pouring after the molten steel is calmed, wherein the pouring temperature is 1540-1570 ℃, and the pouring time is 50-70 seconds;
the concrete operation process of the step eight is that the diffusion casing casting (1) is subjected to heat preservation in a sand mold for 60-65 hours and then shakeout cleaning is carried out;
the concrete operation process of the ninth step is that the diffusion casing casting (1) is subjected to softening annealing treatment after sand removal, the temperature of the softening annealing treatment is 600 +/-20 ℃, the heat preservation time is 5-6 hours, and the diffusion casing casting is cooled in a furnace; and after softening annealing, gas cutting the heat-insulating open riser (4), the heat-insulating blind riser (6), the ceramic pipe pouring gate (7) and the patch (3).
9. The method of casting a heavy duty gas turbine diffuser casing casting of claim 1, wherein: the specific operation process of the step ten comprises the steps of adopting a normalizing and tempering heat treatment mode, wherein the normalizing temperature is 880-900 ℃, the heat preservation time is 6-7 hours, discharging from a furnace for air cooling, the tempering temperature is 610-630 ℃, the heat preservation time is 6-7 hours, cooling in the furnace, refining grains, eliminating stress and improving the mechanical property of the material.
10. The method of casting a heavy duty gas turbine diffuser casing casting of claim 1, wherein: the concrete operation process of the eleventh step is to carry out rough machining, polishing, nondestructive inspection, repair welding, stress removal heat treatment and three-dimensional scanning on the diffusion casing casting (1); repair welding using CO2Gas shielded welding repair, wherein the preheating temperature of a welding repair area is 100-200 ℃, the stress is eliminated integrally after welding, the heat treatment temperature is 600-620 ℃, and the heat preservation time is 8-9 hours; and recording all shapes of the diffusion casing casting (1) by using a three-dimensional scanning device, and comparing the shapes with a three-dimensional diagram of a standard diffusion casing casting to ensure that the shapes and the sizes of the castings meet the requirements of the drawing and the specification.
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