CN114101636A - Electroslag smelting casting manufacturing method for runner bucket of impulse type hydraulic generator - Google Patents
Electroslag smelting casting manufacturing method for runner bucket of impulse type hydraulic generator Download PDFInfo
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- CN114101636A CN114101636A CN202111401147.8A CN202111401147A CN114101636A CN 114101636 A CN114101636 A CN 114101636A CN 202111401147 A CN202111401147 A CN 202111401147A CN 114101636 A CN114101636 A CN 114101636A
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- 238000005266 casting Methods 0.000 title claims abstract description 115
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 38
- 238000003723 Smelting Methods 0.000 title claims description 11
- 239000000463 material Substances 0.000 claims abstract description 16
- 238000003466 welding Methods 0.000 claims abstract description 12
- 239000002893 slag Substances 0.000 claims abstract description 10
- 238000010438 heat treatment Methods 0.000 claims abstract description 7
- 238000007689 inspection Methods 0.000 claims abstract description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 22
- 238000000034 method Methods 0.000 claims description 19
- 238000001816 cooling Methods 0.000 claims description 12
- 229910000831 Steel Inorganic materials 0.000 claims description 8
- 239000010959 steel Substances 0.000 claims description 8
- 239000007788 liquid Substances 0.000 claims description 7
- 238000005242 forging Methods 0.000 claims description 6
- 238000007528 sand casting Methods 0.000 claims description 6
- 238000007711 solidification Methods 0.000 claims description 6
- 230000008023 solidification Effects 0.000 claims description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 5
- 229910052802 copper Inorganic materials 0.000 claims description 5
- 239000010949 copper Substances 0.000 claims description 5
- 239000007787 solid Substances 0.000 claims description 4
- 239000011248 coating agent Substances 0.000 claims description 3
- 238000000576 coating method Methods 0.000 claims description 3
- 238000012545 processing Methods 0.000 claims description 3
- 238000005096 rolling process Methods 0.000 claims description 2
- 238000003754 machining Methods 0.000 abstract description 5
- 230000004927 fusion Effects 0.000 abstract 1
- 238000005299 abrasion Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 230000008602 contraction Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
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- 238000010248 power generation Methods 0.000 description 1
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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 invention is applied to the field of electroslag casting, and particularly relates to an electroslag casting manufacturing method of an impulse type hydraulic generator runner bucket. Manufacturing a runner bucket blank of the impact type hydraulic generator by using an electroslag casting process, wherein an electrode selected during electroslag casting is one or two of a movable electrode and a fixed electrode according to the shape and the size of the runner bucket; wherein, the number of the movable electrodes is one or more than two, and the number of the fixed electrodes is one or more than two. After the bucket blanks are subjected to heat treatment, machining and qualified inspection, the bucket blanks are combined with the prefabricated rotating wheel hub or bucket into a whole by adopting one or more modes of welding, mechanical connection and casting connection to form a complete impulse type hydraulic generator rotating wheel blank. The invention adopts a combined electrode mode of the fixed electrode and the movable electrode and utilizes an electric slag fusion casting process to manufacture the bucket, so that the bucket can be shaped nearly net, the manufacturing quality and the material utilization rate of the bucket are improved, and the production cost is greatly reduced.
Description
Technical Field
The invention is applied to the field of electroslag casting, and particularly relates to an electroslag casting manufacturing method of an impulse type hydraulic generator runner bucket.
Background
Hydroelectric power generation is taken as a green clean energy, is beneficial to environmental protection and management, and is long-standing emphasized in the energy field at home and abroad, in recent years, with the improvement of the output of a water turbine, the water head of a hydropower station is higher and higher, an impact hydropower station is concerned, the demand on a large-diameter impact runner is increased day by day, but the integral manufacture of the large-diameter runner is limited by the processing capacity of equipment.
Under the current technological level, sand casting and die forging can be adopted for independently manufacturing bucket parts, wherein the bucket manufactured by adopting the sand casting process has unstable quality, is difficult to meet the requirement of high-level flaw detection, has weak silt abrasion resistance and cavitation erosion resistance, and has short service life; the bucket manufactured by adopting the die forging process has good blade quality, but is limited by the capability of forging equipment, and can be manufactured only for the specific size of the bucket.
The casting produced by the electroslag casting process is compact in material, the internal quality of the casting is equivalent to that of a forged piece, the flaw detection requirement of the highest level in all standards can be met, the water turbine flow passage component has high cavitation resistance and silt abrasion resistance, the service life of the water turbine flow passage component can be prolonged, and the production cost is lower compared with that of a die forging process.
Therefore, the manufacturing of the impact type runner bucket part by using the electroslag casting process is a promising technical route.
Disclosure of Invention
The invention aims to provide an electroslag casting manufacturing method of a runner bucket of an impulse type hydraulic generator.
The technical scheme of the invention is as follows:
an electroslag smelting casting method for the runner bucket of impact hydraulic generator features that the electroslag smelting casting process is used to make the blank of runner bucket.
According to the electroslag casting manufacturing method of the runner bucket of the impulse type hydraulic generator, according to the shape and the size of the runner bucket, an electrode selected during electroslag casting is one or two of a movable electrode and a fixed electrode; wherein, the number of the movable electrodes is one or more than two, and the number of the fixed electrodes is one or more than two.
The electroslag smelting casting manufacturing method of the impulse type hydraulic generator runner bucket is characterized in that after a plurality of bucket blanks are subjected to heat treatment, processing and qualified inspection, the bucket blanks are combined with a prefabricated runner hub or bucket into a whole by adopting one or more of welding, mechanical connection and casting connection, so that a complete impulse type hydraulic generator runner blank is formed.
The electroslag smelting casting manufacturing method of the runner bucket of the impulse type hydraulic generator is characterized in that the blank size of the runner bucket and the size of a mold cavity of a crystallizer are designed according to the shape of the runner bucket, and a fixed electrode and a movable electrode are designed according to the size of the mold cavity of the crystallizer, wherein: the fixed electrode and the crystallizer cavity are corresponding in shape and follow the shape, the movable electrode moves up and down, the movable electrode continuously moves down in the electroslag casting process, the liquid level of molten slag continuously rises to finish the whole electroslag casting process, and the refined molten steel is solidified and formed in the water-cooled crystallizer to prepare a runner bucket blank.
The electroslag smelting casting manufacturing method of the runner bucket of the impulse type hydraulic generator is characterized in that a mold cavity of a crystallizer and a runner bucket blank follow-up mold, and the material of the mold cavity adopts one or two of copper or steel; the rest materials of the crystallizer are steel; the crystallizer consists of one or more than two layers of crystallizers, each layer of crystallizer consists of one or more than two crystallizer modules, and each crystallizer module is respectively provided with a water cooling system for cooling the cavity surface.
According to the electroslag casting manufacturing method of the runner bucket of the impulse type hydraulic generator, a conceding crystallizer module is arranged on the local part of a crystallizer according to the shape and the size of the runner bucket, and when a casting is solidified and contracted, the cavity space required by the contraction of the casting is increased; in the concession process of the concession crystallizer, the casting extrudes the concession crystallizer during solidification shrinkage to enable the concession crystallizer to slide, and self-adaptive concession is completed; or, a driving device is added on the outer side of the conceding crystallizer to complete the slipping process of the conceding crystallizer; the left and right slip surfaces of the concession crystallizer module are designed to have a slip angle alpha according to the size and the shape of a casting, and the angle is 0-50 degrees.
According to the electroslag casting manufacturing method of the runner bucket of the impulse type hydraulic generator, the safe distance between the movable electrode and the mold cavity of the crystallizer is 3-100 mm; the safety distance between the fixed electrode and the mold cavity of the crystallizer is 3-300 mm; the distance between the fixed electrode and the movable electrode is 2-100 mm.
In order to ensure the safe distance between the fixed electrode, the movable electrode and the mold cavity of the crystallizer in the electroslag casting process, an insulating coating or an insulating block is arranged on the adjacent surfaces of the fixed electrode and the movable electrode, and the insulating coating or the insulating block is melted by slag in the electroslag casting process.
The electroslag casting manufacturing method of the runner bucket of the impulse type hydraulic generator starts the electroslag casting process and starts arc striking by the movable electrode to melt solid slag, or directly adopts liquid slag to strike arc.
The electroslag casting manufacturing method of the runner bucket of the impulse type hydraulic generator is characterized in that the movable electrode is manufactured by one or more than two modes of forging, sand casting or tailor welding of rolled plate blanks; the fixed electrode is manufactured by one or more than two modes of sand casting and rolling plate blank tailor welding.
The design idea of the invention is as follows:
according to the characteristics of the shape and the size of the bucket part, the invention selects a proper crystallizer structural form and an electrode combination mode, so that the casting blank quality and the material utilization rate are optimal.
The invention has the advantages and beneficial effects that:
1. the invention improves the quality of the bucket and prolongs the service life of the runner bucket of the impact type hydraulic generator.
2. The invention can improve the utilization rate of casting materials and shorten the production and manufacturing period.
Drawings
FIG. 1 is a drawing of a single bucket casting.
Fig. 2 is a partial bucket (bucket tip) casting view.
Fig. 3 is a front view of a partial bucket casting crystallizer.
Fig. 4 is a top view of fig. 3.
Fig. 5 is a front view of the initial casting crystallizer with the bucket tip part.
Fig. 6 is a sectional view taken along line B-B in fig. 5.
Fig. 7 is a front view of the bucket root portion of the initial casting mold.
Fig. 8 is a sectional view taken along line a-a of fig. 7.
Fig. 9 is a front view of a single bucket + full hub start casting crystallizer.
Fig. 10 is a diagram of a single bucket + full hub casting made using the crystallizer of fig. 9.
In the figure, 1-crystallizer, 2-fixed electrode, 3-movable electrode, 4-yielding crystallizer module, 5-crystallizer cavity, 6-cavity outline, 7-bucket tip part, 8-bucket root part, 9-part hub, 10-water dividing blade and 11-complete hub.
Detailed Description
In the specific implementation process, the blank of the runner is difficult to forge and transport for the impact type hydraulic generator runner with the major diameter of 2.5-4.0 m, and even the blank can not be manufactured and transported for the runner with the extra-large diameter of more than 4m, especially for hydropower stations with complicated traffic conditions such as Tibet and the like. In order to solve the problems, a runner design and manufacturer provides a structural form of a split impact type hydraulic generator runner, namely the runner is composed of two parts, namely a bucket and a hub, the bucket and the hub are separately manufactured, and finally the whole impact type hydraulic generator runner is manufactured in a welding mode, a mechanical connection mode and the like. Based on the technical route of the structure form of the rotating wheel, the invention provides an electroslag casting manufacturing method of the rotating wheel bucket of the impulse type hydraulic generator for manufacturing bucket parts. The size of a bucket blank and the size of a crystallizer cavity are designed according to the shape of the bucket, a fixed electrode and a movable electrode are designed according to the size of the crystallizer cavity, wherein the shape of the fixed electrode is similar to that of the crystallizer cavity, the movable electrode can move up and down, the movable electrode continuously moves downwards in the casting process, the liquid level of molten slag continuously rises to finish the whole casting process, and refined molten steel is solidified and formed in a water-cooled crystallizer to prepare the bucket blank.
The present invention will be described in further detail below with reference to examples.
Example 1
In the embodiment, the electroslag casting manufacturing method of the runner bucket of the impulse type hydraulic generator specifically comprises the following steps:
1. bucket parameters: the material is 06Cr13Ni5Mo, the weight is 162kg, the shape is shown in figure 2, and the material is only the tip part 7 of the bucket;
2. a casting mode: in the casting process, the whole casting process is finished at one station, and one side of the bucket tip part 7 is used as the initial position of an arc striking section;
3. designing a crystallizer: the crystallizer 1 shown in fig. 3-4 is adopted, the crystallizer 1 is a combined structure of a second layer crystallizer and a first layer crystallizer, wherein: the first layer of crystallizer consists of five fixed crystallizer modules, the second layer of crystallizer consists of five fixed crystallizer modules and one yielding crystallizer module, and each crystallizer module is provided with a water cooling system for cooling the cavity surface.
The second layer of the crystallizer 1 comprises a conceding crystallizer module 4, the front part of the conceding crystallizer module 4 and the inner side of the crystallizer 1 form a crystallizer cavity 5, the cavity outline 6 of the crystallizer cavity 5 is the shape of a bucket tip part 7, the included angle (slip angle) alpha formed by the two sides of the rear part of the conceding crystallizer module 4 and the conceding direction of the conceding crystallizer module 4 is 10 degrees, and the material of the crystallizer cavity 5 is copper.
The function of the concession crystallizer module 4 is: the cavity space required by the casting shrinkage can be increased when the casting is solidified and shrunk, and the casting is prevented from generating cracks in the solidification process.
4. Designing an electrode: the electrodes in the mold cavity 5 of the mold are in a form of a combined electrode comprising two fixed electrodes 2 and one movable electrode 3, the electrodes are placed in the mold in a form shown in fig. 4, the movable electrode 3 is positioned at a position where a water diversion blade 10 is formed in the mold cavity 5 of the mold, the movable electrode 3 and the mold cavity where the water diversion blade 10 is formed are in a conformal structure, the fixed electrodes 2 are symmetrically arranged on two sides of the movable electrode 3, and the fixed electrodes 2 and the mold cavities where the water diversion blade 10 is formed are in conformal structures.
The distance between the movable electrode 3 and the fixed electrode 2 is 14mm, the distance between the movable electrode 3 and the crystallizer cavity 5 is 20mm, the distance between the fixed electrode 2 and the crystallizer cavity 5 is 20mm, and an insulating layer is coated on the surface of the fixed electrode 2;
5. and (3) casting: the movable electrode arcing adopts a solid arcing mode;
6. and obtaining an electroslag casting bucket blank of the impulse type hydraulic generator runner after casting, and welding the electroslag casting bucket blank and the machined runner hub into a whole after heat treatment, machining and inspection are qualified, so that the whole runner is manufactured.
Example 2
In the embodiment, the electroslag casting manufacturing method of the runner bucket of the impulse type hydraulic generator specifically comprises the following steps:
1. bucket parameters: the material is 06Cr13Ni4Mo, the weight is 308kg, the shape is as shown in figure 1, wherein the bucket comprises a complete bucket and a partial hub 9, the bucket is an integral structure of a bucket tip part 7 and a bucket root part 8, and the bucket root part 8 is connected with the partial hub 9;
2. a casting mode: the casting is carried out in two casting stations in sequence, and one side of the bucket tip part 7 is used as the initial position of an arc striking section;
3. designing a crystallizer: as shown in fig. 5-6, the crystallizer 1 used for casting is a combined crystallizer with a split structure of an upper part and a lower part. The crystallizer positioned at the upper part is a third-layer crystallizer which forms a section of a bucket root part 8 and a part of a hub 9 and consists of five fixed crystallizer modules; the crystallizer positioned at the lower part is an upper and lower combined structure of a second-layer crystallizer and a first-layer crystallizer and is used for forming the other section of the bucket root part 8 and the bucket tip part 7, wherein: the first layer of crystallizer consists of six fixed crystallizer modules, and the second layer of crystallizer consists of five fixed crystallizer modules and one yielding crystallizer module. And each crystallizer module is respectively provided with a water cooling system for cooling the cavity surface.
The second layer of the crystallizer 1 comprises a conceding crystallizer module 4, the front part of the conceding crystallizer module 4 and the inner side of the crystallizer 1 form a crystallizer cavity 5, the cavity outline 6 of the crystallizer cavity 5 is the shape of a complete bucket and a part of a hub 9, the two sides of the rear part of the conceding crystallizer module 4 form an included angle (sliding angle) alpha with the conceding direction of the conceding crystallizer module 4 of 12 degrees, and the material of the crystallizer cavity 5 is copper.
The function of the concession crystallizer module 4 is: the cavity space required by the casting shrinkage can be increased when the casting is solidified and shrunk, and the casting is prevented from generating cracks in the solidification process.
4. Designing an electrode: the electrodes in the mold cavity 5 of the mold are in a form of a combined electrode comprising two fixed electrodes 2 and one movable electrode 3, the electrodes are placed in the mold in a form shown in fig. 6, the movable electrode 3 is positioned at the back of a water diversion blade 10 formed in the mold cavity 5 of the mold, the movable electrode 3 is in a conformal structure with the mold cavity forming the back of the water diversion blade 10, the fixed electrodes 2 are symmetrically arranged at two sides of the movable electrode 3, and the fixed electrodes 2 are in conformal structures with the mold cavity forming the water diversion blade 10 and the mold cavities forming two sides of the water diversion blade 10.
The distance between the movable electrode 3 and the crystallizer cavity 5 is 25mm, the distance between the fixed electrode 2 and the crystallizer cavity 5 is 15mm, the distance between the movable electrode 3 and the fixed electrode 2 is 14mm, and an insulating block with a cubic length of 20mm is adhered to the surface of the fixed electrode 2;
5. and (3) casting: the movable electrode arcing adopts a solid arcing mode;
6. and obtaining an electroslag casting bucket blank of the impulse type hydraulic generator runner after casting, and welding the electroslag casting bucket blank and the machined runner hub into a whole after heat treatment, machining and inspection are qualified, so that the whole runner is manufactured.
Example 3
In the embodiment, the electroslag casting manufacturing method of the runner bucket of the impulse type hydraulic generator specifically comprises the following steps:
1. bucket parameters: the material is 06Cr13Ni4Mo, the weight is 308kg, the shape is as shown in figure 1, wherein the bucket comprises a complete bucket and a partial hub 9, the bucket is an integral structure of a bucket tip part 7 and a bucket root part 8, and the bucket root part 8 is connected with the partial hub 9;
2. a casting mode: in the casting process, the whole casting process is finished at one station, and one side of part of the hub 9 is used as the initial position of an arc striking section;
3. designing a crystallizer: the crystallizer 1 shown in fig. 7-8 is adopted, the crystallizer 1 is a vertical combined structure of a third-layer crystallizer, a second-layer crystallizer and a first-layer crystallizer, the upper part of the second-layer crystallizer and the third-layer crystallizer are used for forming a bucket tip part 7, the lower part of the second-layer crystallizer and the first-layer crystallizer are used for forming a bucket root part 8 and a part of wheel hubs 9, the third-layer crystallizer consists of six fixed crystallizer modules, the second-layer crystallizer consists of five fixed crystallizer modules and one yielding crystallizer module, and the first-layer crystallizer consists of six fixed crystallizer modules. And each crystallizer module is respectively provided with a water cooling system for cooling the cavity surface.
The second layer of the crystallizer 1 comprises a conceding crystallizer module 4, the front part of the conceding crystallizer module 4 and the inner side of the crystallizer 1 form a crystallizer cavity 5, the cavity outline 6 of the crystallizer cavity 5 is the shape of a complete bucket and a part of a hub 9, the two sides of the rear part of the conceding crystallizer module 4 form an included angle (sliding angle) alpha of 15 degrees with the conceding direction of the conceding crystallizer module 4, and the material of the crystallizer cavity 5 is steel.
The function of the concession crystallizer module 4 is: the cavity space required by the casting shrinkage can be increased when the casting is solidified and shrunk, and the casting is prevented from generating cracks in the solidification process.
4. Designing an electrode: the electrodes are combined by two fixed electrodes 2 and two movable electrodes 3, the electrodes are placed in the crystallizer in the form shown in fig. 8, the two movable electrodes 3 are respectively positioned at the back of a bucket formed in a cavity 5 of the crystallizer, each movable electrode 3 corresponds to one fixed electrode 2, the fixed electrodes 2 are symmetrically arranged at two sides in the cavity 5 of the crystallizer, and the fixed electrodes 2 are in a conformal structure with the cavity forming a water diversion blade 10 and the cavities forming two sides of the water diversion blade 10.
The distance between the movable electrode 3 and the crystallizer cavity 5 is 30mm, the minimum distance between the fixed electrode 2 and the crystallizer cavity is 5mm, the distance between the corresponding movable electrode 3 and the corresponding fixed electrode 2 is 10mm, and an insulating block with a cube with the side length of 20mm is adhered to the surface of the fixed electrode;
5. and (3) casting: the movable electrode arcing adopts a liquid arcing mode;
6. and obtaining an electroslag casting bucket blank of the impulse type hydraulic generator runner after casting, and welding the electroslag casting bucket blank and the machined runner hub into a whole after heat treatment, machining and inspection are qualified, so that the whole runner is manufactured.
Example 4
In the embodiment, the electroslag casting manufacturing method of the runner bucket of the impulse type hydraulic generator specifically comprises the following steps:
1. bucket parameters: the material is 06Cr13Ni5Mo, the weight is 560kg, the shape is shown in figure 10, the bucket comprises a complete bucket and a complete hub 11, the bucket is an integral structure of a bucket tip part 7 and a bucket root part 8, and the bucket root part 8 is connected with the complete hub 11; wherein the complete hub 11 does not need to be manufactured separately after all bucket parts in the wheel are connected together.
2. A casting mode: in the casting process, the whole casting process is completed at one station, and one side of the complete hub 11 is used as the initial position of an arc striking section;
3. designing a crystallizer: the crystallizer 1 shown in fig. 9 is adopted, a cross section C-C in fig. 9 is equivalent to fig. 8, the crystallizer 1 is an upper and lower combined structure of a fourth-layer crystallizer, a third-layer crystallizer, a second-layer crystallizer and a first-layer crystallizer, the upper parts of the fourth-layer crystallizer and the third-layer crystallizer are used for forming a bucket tip part 7, the lower part of the third-layer crystallizer and the upper part of the second-layer crystallizer are used for forming a bucket root part 8, the lower part of the second-layer crystallizer and the first-layer crystallizer are used for forming a complete hub 11, the fourth-layer crystallizer consists of six fixed crystallizer modules, the third-layer crystallizer consists of five fixed crystallizer modules and one yielding crystallizer module, and the first-layer crystallizer and the second-layer crystallizer consist of six fixed crystallizer modules respectively. And each crystallizer module is respectively provided with a water cooling system for cooling the cavity surface.
The third layer of the crystallizer 1 comprises a concession crystallizer module 4, the front part of the concession crystallizer module 4 and the inner side of the crystallizer 1 form a crystallizer cavity 5, the cavity outline 6 of the crystallizer cavity 5 is the shape of a complete bucket and a complete hub 11, the two sides of the rear part of the concession crystallizer module 4 form an included angle (sliding angle) alpha of 15 degrees with the concession direction of the concession crystallizer module 4, and the material of the crystallizer cavity 5 is copper.
The function of the concession crystallizer module 4 is: the cavity space required by the casting shrinkage can be increased when the casting is solidified and shrunk, and the casting is prevented from generating cracks in the solidification process.
4. Designing an electrode: the electrodes are combined by two fixed electrodes 2 and two movable electrodes 3, the electrodes are placed in the crystallizer in the form shown in fig. 8, the two movable electrodes 3 are respectively positioned at the back of a bucket formed in a cavity 5 of the crystallizer, each movable electrode 3 corresponds to one fixed electrode 2, the fixed electrodes 2 are symmetrically arranged at two sides in the cavity 5 of the crystallizer, and the fixed electrodes 2 are in a conformal structure with the cavity forming a water diversion blade 10 and the cavities forming two sides of the water diversion blade 10.
The distance between the movable electrode 3 and the crystallizer cavity 5 is 25mm, the minimum distance between the fixed electrode 2 and the crystallizer cavity 5 is 4mm, the distance between the corresponding movable electrode 3 and the corresponding fixed electrode 2 is 11mm, and an insulating block with a cubic length of 18mm is adhered to the surface of the fixed electrode;
5. and (3) casting: the movable electrode arcing adopts a liquid arcing mode;
6. and obtaining an electroslag casting bucket blank of the impulse type hydraulic generator runner after casting, and welding the electroslag casting bucket blank and the machined runner hub into a whole after heat treatment, machining and inspection are qualified, so that the whole runner is manufactured.
Claims (10)
1. An electroslag smelting casting method for the runner bucket of an impact hydraulic generator is characterized in that an electroslag smelting casting process is used for manufacturing a blank of the runner bucket of the impact hydraulic generator.
2. The electroslag casting method for manufacturing a runner bucket of an impulse type hydraulic generator as claimed in claim 1, wherein the electrode selected for electroslag casting is one or both of a movable electrode and a fixed electrode according to the shape and size of the runner bucket; wherein, the number of the movable electrodes is one or more than two, and the number of the fixed electrodes is one or more than two.
3. The electroslag casting method for manufacturing a runner bucket of an impulse type hydraulic generator as claimed in claim 1, wherein a plurality of bucket blanks are combined with a prefabricated runner hub or bucket into a whole by one or more of welding, mechanical connection and casting after heat treatment, processing and inspection are qualified, so as to form a complete impulse type hydraulic generator runner blank.
4. The electroslag casting manufacturing method of the runner bucket of the impulse type hydraulic generator as set forth in claim 1, wherein the runner bucket blank size and the mold cavity size are designed according to the runner bucket shape, and the fixed electrode and the movable electrode are designed according to the mold cavity size, wherein: the fixed electrode and the crystallizer cavity are corresponding in shape and follow the shape, the movable electrode moves up and down, the movable electrode continuously moves down in the electroslag casting process, the liquid level of molten slag continuously rises to finish the whole electroslag casting process, and the refined molten steel is solidified and formed in the water-cooled crystallizer to prepare a runner bucket blank.
5. The electroslag smelting casting process of the runner bucket of the impulse type hydraulic generator as set forth in claim 4, wherein the mold cavity is formed with the runner bucket blank, and the mold cavity is made of one or both of copper and steel; the rest materials of the crystallizer are steel; the crystallizer consists of one or more than two layers of crystallizers, each layer of crystallizer consists of one or more than two crystallizer modules, and each crystallizer module is respectively provided with a water cooling system for cooling the cavity surface.
6. The electroslag casting method for manufacturing the runner bucket of the impulse type hydraulic generator as claimed in claim 4, wherein a conceding crystallizer module is provided at a part of the crystallizer according to the shape and size of the runner bucket, so as to increase the cavity space required by the shrinkage of the casting when the casting is solidified and shrunk; in the concession process of the concession crystallizer, the casting extrudes the concession crystallizer during solidification shrinkage to enable the concession crystallizer to slide, and self-adaptive concession is completed; or, a driving device is added on the outer side of the conceding crystallizer to complete the slipping process of the conceding crystallizer; the left and right slip surfaces of the concession crystallizer module are designed to have a slip angle alpha according to the size and the shape of a casting, and the angle is 0-50 degrees.
7. The electroslag smelting casting manufacturing method for the runner bucket of the impulse type hydraulic generator according to claim 4, wherein the safe distance between the movable electrode and the mold cavity is 3-100 mm; the safety distance between the fixed electrode and the mold cavity of the crystallizer is 3-300 mm; the distance between the fixed electrode and the movable electrode is 2-100 mm.
8. The electroslag casting method for manufacturing a runner bucket of an impulse type hydro-generator according to claim 1 or 7, wherein in order to secure a safe distance between the fixed electrode, the movable electrode and the mold cavity during the electroslag casting, the insulating layer or the insulating block is melted by the slag during the electroslag casting by providing the insulating coating or the insulating block on the adjacent surfaces of the fixed electrode, the movable electrode and the mold cavity.
9. The electroslag casting method for manufacturing a runner bucket of an impulse type hydraulic generator as claimed in claim 1 or 4, wherein the electroslag casting process is started by striking an arc with a movable electrode to melt solid slag or striking an arc with liquid slag directly.
10. The electroslag casting manufacturing method for the runner bucket of the impulse type hydraulic generator according to claim 1 or 4, wherein the movable electrode is manufactured by one or more than two of forging, sand casting or tailor welding of rolled slabs; the fixed electrode is manufactured by one or more than two modes of sand casting and rolling plate blank tailor welding.
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|---|---|---|---|---|
| CN2595499Y (en) * | 2003-01-21 | 2003-12-31 | 沈阳铸造研究所 | Retreatable crystallizer for electroslag smelting casting |
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