CN114101636B - Electroslag casting manufacturing method of impact type hydraulic generator runner bucket - Google Patents
Electroslag casting manufacturing method of impact type hydraulic generator runner bucket Download PDFInfo
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- CN114101636B CN114101636B CN202111401147.8A CN202111401147A CN114101636B CN 114101636 B CN114101636 B CN 114101636B CN 202111401147 A CN202111401147 A CN 202111401147A CN 114101636 B CN114101636 B CN 114101636B
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- 238000005266 casting Methods 0.000 title claims abstract description 106
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 45
- 238000003466 welding Methods 0.000 claims abstract description 13
- 238000012545 processing Methods 0.000 claims abstract description 8
- 238000010438 heat treatment Methods 0.000 claims abstract description 7
- 238000007689 inspection Methods 0.000 claims abstract description 7
- 239000011797 cavity material Substances 0.000 claims description 89
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 33
- 238000000034 method Methods 0.000 claims description 17
- 238000001816 cooling Methods 0.000 claims description 12
- 239000002893 slag Substances 0.000 claims description 9
- 229910000831 Steel Inorganic materials 0.000 claims description 8
- 238000005242 forging Methods 0.000 claims description 8
- 239000010959 steel Substances 0.000 claims description 8
- 239000007788 liquid Substances 0.000 claims description 7
- 238000007528 sand casting Methods 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
- 238000005096 rolling process Methods 0.000 claims description 4
- 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
- 230000008602 contraction Effects 0.000 claims description 2
- 239000000155 melt Substances 0.000 claims 1
- 239000000463 material Substances 0.000 abstract description 14
- 238000007711 solidification Methods 0.000 description 4
- 230000008023 solidification Effects 0.000 description 4
- 238000005299 abrasion Methods 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 239000013049 sediment Substances 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, in particular to a manufacturing method of an impact type hydraulic generator runner bucket. Manufacturing a runner bucket blank of the impact hydraulic generator by using an electroslag casting process, wherein the 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 heat treatment, the processing and the inspection are qualified, the bucket blanks are combined with a prefabricated wheel hub or bucket into a whole in one or more modes of welding, mechanical connection and casting, so that a complete impact type hydraulic generator wheel blank is formed. According to the invention, the bucket is manufactured by adopting a combined electrode mode of the fixed electrode and the movable electrode through an electroslag casting process, so that the bucket can be formed in a near net shape, 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, in particular to a manufacturing method of an impact type hydraulic generator runner bucket.
Background
Hydroelectric power generation is taken as a green clean energy source, is favorable for environmental protection and treatment, is paid attention to in the domestic and foreign energy source field for a long time, in recent years, along with the improvement of the output of a water turbine, the water head of the water turbine is higher and higher, an impact type water turbine is paid attention to, the requirement on a large-diameter impact type rotating wheel is increased increasingly, but the whole manufacturing of the large-diameter rotating wheel is limited by the processing capacity of equipment, and based on the rotating wheel design and manufacturing manufacturers, a split impact type rotating wheel structure form is provided, the rotating wheel consists of two parts of a bucket and a hub, the two parts are manufactured separately, and the two parts are combined in a welding, mechanical connection mode and the like to form a complete impact type rotating wheel.
Under the current state of the art, sand casting and die forging can be adopted for separately manufacturing bucket parts, wherein the bucket manufactured by adopting the sand casting process is unstable in quality, the high-level flaw detection requirement is difficult to meet, the sediment abrasion resistance is weak, the cavitation is not resistant, and the service life of the bucket is low; the bucket manufactured by adopting the die forging process has good blade quality, but is limited by the capability of forging equipment, and can only be manufactured for specific size of the bucket.
The casting material produced by the electroslag casting process is compact, the internal quality of the casting is equivalent to that of a forging, the highest level flaw detection requirements in various standards can be met, the casting material has higher cavitation resistance and mud and sand abrasion resistance for the water turbine overcurrent part, the service life of the water turbine overcurrent part can be prolonged, and the casting material has lower production cost compared with a die forging process.
The use of an electroslag casting process to manufacture an impact type runner bucket component is thus a promising technological route.
Disclosure of Invention
The invention aims to provide an electroslag casting manufacturing method of an impact hydraulic generator runner bucket, which adopts a combined electrode of a fixed electrode and a movable electrode, so that the bucket can be formed in a near net shape, the quality and the material utilization rate of the bucket are improved, and the production cost is reduced.
The technical scheme of the invention is as follows:
an electroslag casting manufacturing method of an impulse type hydraulic generator runner bucket, which uses an electroslag casting process to manufacture an impulse type hydraulic generator runner bucket blank.
According to the electroslag casting manufacturing method of the runner bucket of the impact type hydraulic generator, the 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.
According to the electroslag casting manufacturing method of the bucket of the impact type hydraulic generator runner, after a plurality of bucket blanks are qualified in heat treatment, processing and inspection, one or more than two modes of welding, mechanical connection and casting are adopted to be integrated with a prefabricated runner hub or bucket, so that a complete impact type hydraulic generator runner blank is formed.
According to the electroslag casting manufacturing method of the runner bucket of the impact hydraulic generator, the blank size of the runner bucket and the size of the crystallizer cavity are designed according to the shape of the runner bucket, and the fixed electrode and the movable electrode are designed according to the size of the crystallizer cavity, wherein the casting manufacturing method comprises the following steps: the fixed electrode and the mold cavity of the crystallizer are corresponding in shape and move along with each other, the movable electrode moves up and down, the movable electrode moves downwards continuously in the electroslag casting process, the liquid level of slag rises continuously, the whole electroslag casting process is completed, refined and melted molten steel is solidified and molded in the water-cooled crystallizer, and a runner bucket blank is manufactured.
In the electroslag casting manufacturing method of the impact type hydraulic generator runner bucket, a crystallizer cavity and a runner bucket blank are shaped along with each other, and one or two of copper or steel are adopted as cavity materials; the rest part of the crystallizer is made of 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 impact hydraulic generator runner bucket, a back-off crystallizer module is arranged at a part of a crystallizer according to the shape and the size of the runner bucket, and when a casting is solidified and contracted, a cavity space required by the contraction of the casting is increased; the yielding process of the yielding crystallizer is to extrude the yielding crystallizer to slide when the casting self solidifies and contracts, so as to complete self-adaptive yielding; or, adding a driving device on the outer side of the back-off crystallizer to finish the sliding process of the back-off crystallizer; the left and right sliding surfaces of the back-off crystallizer module are designed to have a sliding angle alpha according to the size and shape of the casting, and the angle is between 0 and 50 degrees.
In the electroslag casting manufacturing method of the impact type hydraulic generator runner bucket, the safety 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 mm-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 in the electroslag casting process, the insulating coating or the insulating block is arranged on the adjacent surfaces of the fixed electrode and the movable electrode, and the insulating layer or the insulating block is melted by slag in the electroslag casting process.
According to the electroslag casting manufacturing method of the impact type hydraulic generator runner bucket, solid slag is melted by striking an arc of a movable electrode at the beginning of the electroslag casting process, or liquid slag is adopted to strike an arc directly.
According to the electroslag casting manufacturing method of the impact type hydraulic generator runner bucket, the movable electrode is manufactured by one or more than two modes of forging, sand casting or rolling slab welding; the fixed electrode is manufactured by one or more than two modes of sand casting and rolling slab welding.
The design idea of the invention is as follows:
according to the shape and size characteristics of the bucket part, a proper crystallizer structure form and an electrode combination mode are selected, so that the quality and the material utilization rate of casting blanks 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 bucket of the rotating wheel of the impact 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 single bucket casting diagram.
FIG. 2 is a partial bucket (tip portion of bucket) casting.
FIG. 3 is an elevation view of a partial bucket casting mold.
Fig. 4 is a top view of fig. 3.
FIG. 5 is a front view of a tip portion start-up casting mold.
Fig. 6 is a sectional view of B-B in fig. 5.
FIG. 7 is an elevation view of a bucket root part start melt casting mold.
Fig. 8 is a cross-sectional view A-A of fig. 7.
FIG. 9 is an elevation view of a single bucket+complete hub start-up melt cast mold.
FIG. 10 is a diagram of a single bucket + complete hub casting made using the crystallizer of FIG. 9.
In the figure, 1-crystallizer, 2-fixed electrode, 3-movable electrode, 4-back crystallizer module, 5-crystallizer cavity, 6-cavity outline, 7-bucket tip part, 8-bucket root part, 9-part wheel hub, 10-water diversion blade and 11-complete wheel hub.
Detailed Description
In the concrete implementation process, the blank forging and transportation of the large-diameter 2.5-4.0 m impact type hydraulic generator runner are very difficult, and even the runner with the extra large diameter exceeding 4m cannot be manufactured and transported, especially for hydropower stations with complex traffic conditions such as Tibet and the like. In order to solve the problems, the rotary wheel design and manufacturer provides a split type impact hydraulic generator rotary wheel structure, namely the rotary wheel consists of two parts of a bucket and a hub, wherein the bucket and the hub are manufactured separately, and finally the whole impact hydraulic generator rotary wheel is manufactured in a welding, mechanical connection and other modes. Based on the technical route of the structural form of the rotating wheel, the invention provides an electroslag casting manufacturing method of the rotating wheel bucket of the impact type hydraulic generator for manufacturing bucket parts. According to the bucket shape, the bucket blank size and the crystallizer cavity size are designed, and according to the crystallizer cavity size, the fixed electrode and the movable electrode are designed, wherein the fixed electrode is similar to the crystallizer cavity in shape and can move up and down along with the crystallizer cavity, the movable electrode continuously moves down in the casting process, the slag liquid level continuously rises, the whole casting process is completed, refined molten steel is solidified and molded in the water-cooled crystallizer, and the bucket blank is manufactured.
The invention is further illustrated by the following examples.
Example 1
In this embodiment, a method for manufacturing an electroslag casting of an impact hydraulic generator runner bucket specifically includes the following steps:
1. bucket parameters: the material is 06Cr13Ni5Mo, the weight is 162kg, and the shape is shown in figure 2, and is only the bucket tip part 7 of the bucket;
2. the casting mode is as follows: the whole casting process is completed in one station in the casting process, and one side of the bucket tip part 7 is used as the initial position of the arc-guiding section;
3. and (3) designing a crystallizer: with the crystallizer 1 as shown in fig. 3-4, the crystallizer 1 is an upper-lower combined structure of a second layer crystallizer and a first layer crystallizer, wherein: the first layer of the crystallizer consists of five fixed crystallizer modules, the second layer of the crystallizer consists of five fixed crystallizer modules and a back-off 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 back-off crystallizer module 4, the front part of the back-off 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 in the shape of a bucket tip part 7, the back two sides of the back-off crystallizer module 4 and the back-off direction of the back-off crystallizer module 4 form an included angle (sliding angle) alpha of 10 degrees, and the crystallizer cavity 5 is made of copper.
The function of the back-off crystallizer module 4 is: the die cavity space required by the shrinkage of the casting can be increased when the casting is solidified and shrunk, and cracks of the casting in the solidification process are avoided.
4. Electrode design: the electrodes in the mold cavity 5 are in a combined electrode form of two fixed electrodes 2 and one movable electrode 3, the electrode is placed in the mold, the electrode is shown in fig. 4, the movable electrode 3 is positioned in the mold cavity 5 to form a water diversion blade 10, the movable electrode 3 is in a shape-following structure with the mold cavity to form the water diversion blade 10, the fixed electrodes 2 are symmetrically arranged on two sides of the movable electrode 3, and the fixed electrodes 2 are in a shape-following structure with the mold cavity to form two sides of the water diversion blade 10.
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) a casting process: the movable electrode is started in a solid state;
6. and (3) obtaining an electroslag casting bucket blank of the runner of the impact hydraulic generator after casting, and welding the bucket blank with the processed runner hub into a whole after heat treatment, processing and inspection are qualified, so as to complete the manufacture of the whole runner.
Example 2
In this embodiment, a method for manufacturing an electroslag casting of an impact hydraulic generator runner bucket specifically includes the following steps:
1. bucket parameters: the material is 06Cr13Ni4Mo, the weight is 308kg, the shape is shown in figure 1, the bucket comprises a complete bucket and a part of hub 9, the bucket is of 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 part of hub 9;
2. the casting mode is as follows: the casting is sequentially carried out at two casting stations, and one side of the bucket tip part 7 is used as the initial position of the arc-guiding section;
3. and (3) designing a crystallizer: as shown in fig. 5 to 6, the mold 1 used for casting is a combined mold having a split structure of an upper portion and a lower portion. The crystallizer at the upper part is a third layer crystallizer forming one section of the bucket root part 8 and part of the hub 9, and the third layer crystallizer consists of five fixed crystallizer modules; the crystallizer at the lower part is an upper-lower combined structure of the second layer crystallizer and the 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 the crystallizer consists of six fixed crystallizer modules, and the second layer of the crystallizer consists of five fixed crystallizer modules and one yielding crystallizer module. 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 back-off crystallizer module 4, the front part of the back-off 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 in the shape of a complete bucket and part of a hub 9, the back two sides of the back-off crystallizer module 4 and the back-off direction of the back-off crystallizer module 4 form an included angle (sliding angle) alpha of 12 degrees, and the material of the crystallizer cavity 5 is copper.
The function of the back-off crystallizer module 4 is: the die cavity space required by the shrinkage of the casting can be increased when the casting is solidified and shrunk, and cracks of the casting in the solidification process are avoided.
4. Electrode design: the electrodes in the mold cavity 5 are in a combined electrode form of two fixed electrodes 2 and one movable electrode 3, the electrode is placed in the mold, the electrode is shown in fig. 6, the movable electrode 3 is positioned in the mold cavity 5 and forms the back of the water diversion blade 10, the movable electrode 3 is in a shape-following 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 a shape-following structure with the mold cavity forming the water diversion blade 10 and the mold cavity 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 side length of 20mm is stuck on the surface of the fixed electrode 2;
5. and (3) a casting process: the movable electrode is started in a solid state;
6. and (3) obtaining an electroslag casting bucket blank of the runner of the impact hydraulic generator after casting, and welding the bucket blank with the processed runner hub into a whole after heat treatment, processing and inspection are qualified, so as to complete the manufacture of the whole runner.
Example 3
In this embodiment, a method for manufacturing an electroslag casting of an impact hydraulic generator runner bucket specifically includes the following steps:
1. bucket parameters: the material is 06Cr13Ni4Mo, the weight is 308kg, the shape is shown in figure 1, the bucket comprises a complete bucket and a part of hub 9, the bucket is of 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 part of hub 9;
2. the casting mode is as follows: the whole casting process is completed in one station in the casting process, and one side of part of the hub 9 is used as the initial position of the arc-guiding section;
3. and (3) designing a crystallizer: the crystallizer 1 shown in fig. 7-8 is adopted, the crystallizer 1 is an upper-lower combined structure of a third layer of crystallizer, a second layer of crystallizer and a first layer of crystallizer, the upper part of the second layer of crystallizer and the third layer of crystallizer are used for forming a bucket tip part 7, the lower part of the second layer of crystallizer and the first layer of crystallizer are used for forming a bucket root part 8 and a part of hub 9, the third layer of crystallizer is composed of six fixed crystallizer modules, the second layer of crystallizer is composed of five fixed crystallizer modules and a back-off crystallizer module, and the first layer of crystallizer is composed of six fixed crystallizer modules. 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 back-off crystallizer module 4, the front part of the back-off 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 in the shape of a complete bucket and part of a hub 9, the back two sides of the back-off crystallizer module 4 and the back-off direction of the back-off crystallizer module 4 form an included angle (sliding angle) alpha of 15 degrees, and the material of the crystallizer cavity 5 is steel.
The function of the back-off crystallizer module 4 is: the die cavity space required by the shrinkage of the casting can be increased when the casting is solidified and shrunk, and cracks of the casting in the solidification process are avoided.
4. Electrode design: the electrodes are in a combined electrode form of two fixed electrodes 2 and two movable electrodes 3, the electrode is placed in the crystallizer, the electrode is shown in fig. 8, the two movable electrodes 3 are respectively positioned at the back of a bucket formed in a mold cavity 5, each movable electrode 3 corresponds to one fixed electrode 2, the fixed electrodes 2 are symmetrically arranged at two sides in the mold cavity 5, and the fixed electrodes 2 are in a shape-following structure with the mold cavity forming the water diversion blade 10 and the mold cavity 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 20mm cubic side length is stuck on the surface of the fixed electrode;
5. and (3) a casting process: the movable electrode is started in a liquid state;
6. and (3) obtaining an electroslag casting bucket blank of the runner of the impact hydraulic generator after casting, and welding the bucket blank with the processed runner hub into a whole after heat treatment, processing and inspection are qualified, so as to complete the manufacture of the whole runner.
Example 4
In this embodiment, a method for manufacturing an electroslag casting of an impact hydraulic generator runner bucket specifically includes 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 of 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 require separate manufacturing of the hub after all of the bucket components in the wheel are connected together.
2. The casting mode is as follows: the whole casting process is completed in one station in the casting process, and one side of the complete hub 11 is used as the starting position of the arc striking section;
3. and (3) designing a crystallizer: with the crystallizer 1 shown in fig. 9, the C-C section in fig. 9 corresponds to fig. 8, the crystallizer 1 is a combined structure of a fourth layer of crystallizer, a third layer of crystallizer, a second layer of crystallizer and a first layer of crystallizer, the upper parts of the fourth layer of crystallizer and the third layer of crystallizer are used for forming the bucket tip part 7, the lower parts of the third layer of crystallizer and the upper parts of the second layer of crystallizer are used for forming the bucket root part 8, the lower parts of the second layer of crystallizer and the first layer of crystallizer are used for forming the complete hub 11, the fourth layer of crystallizer is composed of six fixed crystallizer modules, the third layer of crystallizer is composed of five fixed crystallizer modules and a block of yielding crystallizer module, and the first layer of crystallizer and the second layer of crystallizer are respectively composed of six fixed crystallizer modules. 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 back-off crystallizer module 4, the front part of the back-off 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 in the shape of a complete bucket and a complete hub 11, the back two sides of the back-off crystallizer module 4 and the back-off direction of the back-off crystallizer module 4 form an included angle (sliding angle) alpha of 15 degrees, and the material of the crystallizer cavity 5 is copper.
The function of the back-off crystallizer module 4 is: the die cavity space required by the shrinkage of the casting can be increased when the casting is solidified and shrunk, and cracks of the casting in the solidification process are avoided.
4. Electrode design: the electrodes are in a combined electrode form of two fixed electrodes 2 and two movable electrodes 3, the electrode is placed in the crystallizer, the electrode is shown in fig. 8, the two movable electrodes 3 are respectively positioned at the back of a bucket formed in a mold cavity 5, each movable electrode 3 corresponds to one fixed electrode 2, the fixed electrodes 2 are symmetrically arranged at two sides in the mold cavity 5, and the fixed electrodes 2 are in a shape-following structure with the mold cavity forming the water diversion blade 10 and the mold cavity 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 18mm cubic side length is stuck on the surface of the fixed electrode;
5. and (3) a casting process: the movable electrode is started in a liquid state;
6. and (3) obtaining an electroslag casting bucket blank of the runner of the impact hydraulic generator after casting, and welding the bucket blank with the processed runner hub into a whole after heat treatment, processing and inspection are qualified, so as to complete the manufacture of the whole runner.
Claims (6)
1. The electroslag casting manufacturing method of the impact type hydraulic generator runner bucket is characterized in that an electroslag casting process is used for manufacturing an impact type hydraulic generator runner bucket blank;
according to the size of a rotating wheel bucket blank and the size of a crystallizer cavity, a fixed electrode and a movable electrode are designed according to the size of the crystallizer cavity, wherein: the fixed electrode corresponds to the mold cavity shape of the crystallizer and moves up and down along with the mold cavity shape, the movable electrode continuously moves down in the electroslag casting process, the slag liquid level continuously rises, the whole electroslag casting process is completed, refined and melted molten steel is solidified and molded in the water-cooled crystallizer, and a runner bucket blank is manufactured;
the electrode in the mold cavity adopts a mode of combining two fixed electrodes and a movable electrode, the movable electrode is positioned in the mold cavity to form a water diversion blade, the movable electrode and the mold cavity to form the water diversion blade are in a conformal structure, the fixed electrodes are symmetrically arranged on two sides of the movable electrode, and the fixed electrodes and the mold cavity to form two sides of the water diversion blade are in a conformal structure;
or, the electrode in the mold cavity adopts a mode of combining two fixed electrodes and a movable electrode, the movable electrode is positioned at the back of the water diversion blade formed in the mold cavity, the movable electrode and the cavity forming the back of the water diversion blade are in a conformal structure, the fixed electrodes are symmetrically arranged at two sides of the movable electrode, and the fixed electrodes and the cavity forming the water diversion blade and the cavities forming two sides of the water diversion blade are in a conformal structure;
or the electrodes are in the form of two fixed electrodes and two movable electrode combined electrodes, the two movable electrodes are respectively positioned at the back of a bucket formed in a mold cavity, each movable electrode corresponds to one fixed electrode, the fixed electrodes are symmetrically arranged at two sides in the mold cavity, and the fixed electrodes are in a conformal structure with the mold cavity forming the water diversion blade and the mold cavities forming the two sides of the water diversion blade;
according to the shape and the size of the rotating wheel bucket, a back-off crystallizer module is arranged at the part of the crystallizer, and when the casting is solidified and contracted, the cavity space required by the contraction of the casting is increased; the yielding process of the yielding crystallizer is to extrude the yielding crystallizer to slide when the casting self solidifies and contracts, so as to complete self-adaptive yielding; or, adding a driving device on the outer side of the back-off crystallizer to finish the sliding process of the back-off crystallizer; the left and right sliding surfaces of the back-off crystallizer module are designed to have a sliding angle alpha according to the size and shape of the casting, and the angle is between 0 and 50 degrees;
in order to ensure the safe distance between the fixed electrode, the movable electrode and the mold cavity 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.
2. The electroslag casting manufacturing method of an impact hydraulic generator runner bucket according to claim 1, wherein after heat treatment, processing and inspection pass, a plurality of bucket blanks are integrated with a prefabricated runner hub or bucket by adopting one or more modes of welding, mechanical connection and casting connection to form a complete impact hydraulic generator runner blank.
3. The electroslag casting manufacturing method of the runner bucket of the impact hydraulic generator according to claim 1, wherein a mold cavity and a runner bucket blank are formed in a follow-up mode, and one or two of copper or steel are adopted as cavity materials; the rest part of the crystallizer is made of 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.
4. The electroslag casting manufacturing method of an impact hydraulic generator runner bucket according to claim 1, wherein the safety 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 mm-300 mm; the distance between the fixed electrode and the movable electrode is 2-100 mm.
5. The method for electroslag casting manufacturing of an impact hydraulic generator runner bucket according to claim 1, wherein the start of the electroslag casting process melts solid slag by arc striking of a movable electrode or directly adopts liquid slag for arc striking.
6. The electroslag casting manufacturing method of an impact type hydraulic generator runner bucket according to claim 1, wherein the movable electrode is manufactured by one or more of forging, sand casting or rolling slab welding; the fixed electrode is manufactured by one or more than two modes of sand casting and rolling slab welding.
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| CN202111401147.8A CN114101636B (en) | 2021-11-19 | 2021-11-19 | Electroslag casting manufacturing method of impact type hydraulic generator runner bucket |
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Citations (5)
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