CN114289687A - Forming method of honeycomb mosaic block hot end part for gas turbine - Google Patents
Forming method of honeycomb mosaic block hot end part for gas turbine Download PDFInfo
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- CN114289687A CN114289687A CN202111654309.9A CN202111654309A CN114289687A CN 114289687 A CN114289687 A CN 114289687A CN 202111654309 A CN202111654309 A CN 202111654309A CN 114289687 A CN114289687 A CN 114289687A
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- 238000000034 method Methods 0.000 title claims abstract description 19
- 239000000919 ceramic Substances 0.000 claims abstract description 65
- 239000000463 material Substances 0.000 claims abstract description 20
- 238000003754 machining Methods 0.000 claims abstract description 11
- 239000007788 liquid Substances 0.000 claims abstract description 7
- 238000004140 cleaning Methods 0.000 claims abstract description 6
- 238000005245 sintering Methods 0.000 claims abstract description 6
- 238000002791 soaking Methods 0.000 claims abstract description 6
- 238000005728 strengthening Methods 0.000 claims abstract description 5
- 238000003825 pressing Methods 0.000 claims description 22
- 238000009415 formwork Methods 0.000 claims description 19
- 238000005266 casting Methods 0.000 claims description 16
- 229910045601 alloy Inorganic materials 0.000 claims description 14
- 239000000956 alloy Substances 0.000 claims description 14
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 10
- 229920000742 Cotton Polymers 0.000 claims description 5
- 238000001035 drying Methods 0.000 claims description 5
- 239000003822 epoxy resin Substances 0.000 claims description 5
- 229920000647 polyepoxide Polymers 0.000 claims description 5
- 238000004321 preservation Methods 0.000 claims description 5
- 239000002994 raw material Substances 0.000 claims description 5
- 238000009966 trimming Methods 0.000 claims description 5
- 229910001095 light aluminium alloy Inorganic materials 0.000 claims description 2
- 238000010146 3D printing Methods 0.000 abstract description 4
- 238000010892 electric spark Methods 0.000 abstract description 4
- 230000015556 catabolic process Effects 0.000 abstract description 2
- 238000004519 manufacturing process Methods 0.000 abstract 2
- 238000002844 melting Methods 0.000 abstract 1
- 230000008018 melting Effects 0.000 abstract 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- 230000002159 abnormal effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000005495 investment casting Methods 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
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Abstract
The invention relates to a method for forming a hot end part of a honeycomb insert block for a gas turbine, which comprises the following steps: machining to form a honeycomb ceramic core die, manufacturing a honeycomb ceramic core green body, sintering, finishing and soaking a strengthening liquid, installing a honeycomb mosaic block die and a honeycomb ceramic core, injecting a wax material, assembling a tree, manufacturing a shell, dewaxing, preheating, melting the material, pouring, cleaning and detecting. The invention has the advantages of short forming period, high yield, low cost and high efficiency, effectively solves the problems of long lead time, high cost, poor surface quality and the like existing in 3D printing and forming, and also effectively solves the problems of easy breakdown of blank materials by electric spark machining, low yield, long lead time, high cost and the like.
Description
Technical Field
The invention belongs to the precision casting industry, and particularly relates to a method for forming a hot end part of a honeycomb insert for a gas turbine.
Background
The existing method for forming the hot end part of the honeycomb insert for the gas turbine is 3D printing and electric spark machining, and the honeycomb insert for the gas turbine is large in size, complex in structure, abnormal and complex in 3D printing procedure, long in printing time, poor in surface quality, long in lead cycle, high in cost and poor in surface quality. The wall thickness of the honeycomb wall of the hot end part of the honeycomb insert block for the gas turbine is required to be 0.2-0.4mm, the hole depth is 5-6mm, and the plate thickness of the honeycomb is also 5-6mm, so that the plate where the honeycomb is located is very easy to be punctured in the electric spark machining process, 2000 holes are machined, and the machining time is particularly long, so that the problems of blank material puncturing, low yield, long lead cycle, high cost and the like exist.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provides a method for forming a hot end part of a honeycomb insert block for a gas turbine, which has the advantages of short casting forming time, high yield and low cost.
According to the technical scheme provided by the invention, the forming method of the hot end part of the honeycomb insert block for the gas turbine comprises the following steps:
s1, forming the honeycomb ceramic core mould by machining the honeycomb ceramic core mould blank, wherein the inner wall surface of the honeycomb ceramic core mould is fully distributed with columnar deep holes, the depth of each columnar deep hole is 5-6mm, the diameter of each columnar deep hole is 2-4mm, and the wall thickness between every two adjacent columnar deep holes is 0.2-0.4 mm;
s2, fixing the honeycomb ceramic core mould in a core pressing machine, injecting the raw material of the honeycomb ceramic core into the honeycomb ceramic core mould by the core pressing machine to obtain a honeycomb ceramic core green body, soaking the honeycomb ceramic core green body in a strengthening solution for 10-20min after sintering and trimming, taking out and naturally drying to obtain the honeycomb ceramic core, wherein columnar bulges are fully distributed on the outer surface of the honeycomb ceramic core, the height of the columnar bulges is 5-6mm, the diameter of the columnar bulges is 2-4mm, and a gap with the width of 0.2-0.4mm is formed between every two adjacent columnar bulges;
s3, firstly, mounting the honeycomb mosaic block mould on a wax pressing machine, opening the honeycomb mosaic block mould, then placing the honeycomb ceramic core into the honeycomb mosaic block mould, and finally injecting wax material through the wax pressing machine to enable the wax material to wrap the honeycomb ceramic core;
s4, firstly, assembling the honeycomb mosaic block mold into a tree, then making a shell, and finally dewaxing to form a mold shell cavity;
s5, firstly wrapping the formwork by using heat preservation cotton, putting the formwork into a preheating furnace to preheat to 1080-;
s6, cleaning and detecting the casting to obtain a finished product of the honeycomb mosaic block hot end component, wherein the inner wall surface of the finished product of the honeycomb mosaic block hot end component is fully distributed with columnar deep holes, the depth of each columnar deep hole is 5-6mm, the diameter of each columnar deep hole is 2-4mm, and the wall thickness between every two adjacent columnar deep holes is 0.2-0.4 mm.
Preferably, in step S1, the material of the honeycomb ceramic core mold blank is aircraft aluminum 7075.
Preferably, in step S2, the strengthening liquid is an epoxy resin ethanol solution with a mass concentration of 25% to 30%.
Preferably, in step S3, the wax material is KC4021 type wax material, and the wax injector is MPI type wax injector.
Preferably, in step S5, the vacuum casting furnace is a three-chamber vacuum casting furnace, and the master alloy is a K536 type alloy.
The invention has the advantages of short forming period, high yield, low cost and high efficiency, effectively solves the problems of long lead time, high cost, poor surface quality and the like existing in 3D printing and forming, and also effectively solves the problems of easy breakdown of blank materials by electric spark machining, low yield, long lead time, high cost and the like.
Detailed Description
The present invention will be further described with reference to the following specific examples.
Example 1
A forming method of a hot end part of a honeycomb insert block for a gas turbine comprises the following steps:
s1, forming a honeycomb ceramic core die by machining a honeycomb ceramic core die blank made of aviation aluminum 7075, wherein columnar deep holes are distributed on the inner wall surface of the honeycomb ceramic core die, the depth of each columnar deep hole is 5mm, the diameter of each columnar deep hole is 2mm, and the wall thickness between every two adjacent columnar deep holes is 0.2 mm;
s2, fixing the honeycomb ceramic core mould in a core pressing machine, injecting the raw material of the honeycomb ceramic core into the honeycomb ceramic core mould by the core pressing machine to obtain a honeycomb ceramic core green body, soaking the honeycomb ceramic core green body in an epoxy resin ethanol solution with the mass concentration of 25% for 10min after sintering and trimming, taking out and naturally drying to obtain the honeycomb ceramic core, wherein the outer surface of the honeycomb ceramic core is fully distributed with columnar bulges, the height of the columnar bulges is 5mm, the diameter of the columnar bulges is 2mm, and gaps with the width of 0.2mm are formed between the adjacent columnar bulges;
s3, firstly, mounting the honeycomb mosaic block mould on an MPI type wax pressing machine, opening the honeycomb mosaic block mould, then placing the honeycomb ceramic core into the honeycomb mosaic block mould, and finally injecting a KC4021 type wax material through the wax pressing machine to enable the wax material to wrap the honeycomb ceramic core;
s4, firstly, assembling the honeycomb mosaic block mold into a tree, then making a shell, and finally dewaxing to form a mold shell cavity;
s5, firstly wrapping the formwork with heat preservation cotton, putting the wrapped formwork into a preheating furnace to preheat to 1080 ℃, then putting a K536 type alloy into a three-chamber vacuum casting furnace to melt, pouring an alloy liquid into a preheated formwork cavity after the temperature of the alloy liquid reaches 1450 ℃, removing the formwork after the formwork is fully cooled, and finally removing a pouring channel system to obtain a casting;
s6, cleaning and detecting the casting to obtain a finished product of the honeycomb mosaic block hot end component, wherein cylindrical deep holes are distributed in the inner wall surface of the finished product of the honeycomb mosaic block hot end component, the depth of each cylindrical deep hole is 5mm, the diameter of each cylindrical deep hole is 2mm, and the wall thickness between every two adjacent cylindrical deep holes is 0.2 mm.
The yield of the hot end part of the honeycomb insert for a gas turbine manufactured by the method of example 1 was 85%.
Example 2
A forming method of a hot end part of a honeycomb insert block for a gas turbine comprises the following steps:
s1, forming a honeycomb ceramic core die by machining a honeycomb ceramic core die blank made of aviation aluminum 7075, wherein columnar deep holes are distributed on the inner wall surface of the honeycomb ceramic core die, the depth of each columnar deep hole is 5.5mm, the diameter of each columnar deep hole is 3mm, and the wall thickness between every two adjacent columnar deep holes is 0.3 mm;
s2, fixing the honeycomb ceramic core mould in a core pressing machine, injecting a honeycomb ceramic core raw material into the honeycomb ceramic core mould by using the core pressing machine to obtain a honeycomb ceramic core green body, soaking the honeycomb ceramic core green body in an epoxy resin ethanol solution with the mass concentration of 28% for 15min after sintering and trimming, taking out and naturally drying to obtain the honeycomb ceramic core, wherein the outer surface of the honeycomb ceramic core is fully distributed with columnar bulges, the height of each columnar bulge is 5.5mm, the diameter of each columnar bulge is 3mm, and a gap with the width of 0.3mm is formed between every two adjacent columnar bulges;
s3, firstly, mounting the honeycomb mosaic block mould on an MPI type wax pressing machine, opening the honeycomb mosaic block mould, then placing the honeycomb ceramic core into the honeycomb mosaic block mould, and finally injecting a KC4021 type wax material through the wax pressing machine to enable the wax material to wrap the honeycomb ceramic core;
s4, firstly, assembling the honeycomb mosaic block mold into a tree, then making a shell, and finally dewaxing to form a mold shell cavity;
s5, firstly wrapping the formwork with heat preservation cotton, putting the wrapped formwork into a preheating furnace to be preheated to 1100 ℃, then putting a K536 type alloy into a three-chamber vacuum casting furnace to be melted, pouring an alloy liquid into a preheated formwork cavity after the temperature of the alloy liquid reaches 1460 ℃, removing the formwork after the formwork is fully cooled, and finally removing a pouring channel system to obtain a casting;
s6, cleaning and detecting the casting to obtain a finished product of the honeycomb mosaic block hot end component, wherein the inner wall surface of the finished product of the honeycomb mosaic block hot end component is fully distributed with columnar deep holes, the depth of each columnar deep hole is 5.5mm, the diameter of each columnar deep hole is 3mm, and the wall thickness between every two adjacent columnar deep holes is 0.3 mm.
The yield of the hot end part of the honeycomb insert for a gas turbine manufactured by the method of example 2 was 92%.
Example 3
A forming method of a hot end part of a honeycomb insert block for a gas turbine comprises the following steps:
s1, forming a honeycomb ceramic core die by machining a honeycomb ceramic core die blank made of aviation aluminum 7075, wherein columnar deep holes are distributed on the inner wall surface of the honeycomb ceramic core die, the depth of each columnar deep hole is 6mm, the diameter of each columnar deep hole is 4mm, and the wall thickness between every two adjacent columnar deep holes is 0.4 mm;
s2, fixing the honeycomb ceramic core mould in a core pressing machine, injecting the raw material of the honeycomb ceramic core into the honeycomb ceramic core mould by the core pressing machine to obtain a honeycomb ceramic core green body, soaking the honeycomb ceramic core green body in an epoxy resin ethanol solution with the mass concentration of 30% for 20min after sintering and trimming, taking out and naturally drying to obtain the honeycomb ceramic core, wherein the outer surface of the honeycomb ceramic core is fully distributed with columnar bulges, the height of the columnar bulges is 6mm, the diameter of the columnar bulges is 4mm, and gaps with the width of 0.4mm are formed between the adjacent columnar bulges;
s3, firstly, mounting the honeycomb mosaic block mould on an MPI type wax pressing machine, opening the honeycomb mosaic block mould, then placing the honeycomb ceramic core into the honeycomb mosaic block mould, and finally injecting a KC4021 type wax material through the wax pressing machine to enable the wax material to wrap the honeycomb ceramic core;
s4, firstly, assembling the honeycomb mosaic block mold into a tree, then making a shell, and finally dewaxing to form a mold shell cavity;
s5, firstly wrapping the formwork with heat preservation cotton, putting the wrapped formwork into a preheating furnace to preheat to 1120 ℃, then putting a K536 type alloy into a three-chamber vacuum casting furnace to melt the alloy, pouring the alloy into a preheated formwork cavity after the temperature of the alloy reaches 1470 ℃, removing the formwork after the formwork is fully cooled, and finally removing a pouring channel system to obtain a casting;
s6, cleaning and detecting the casting to obtain a finished product of the honeycomb mosaic block hot end component, wherein cylindrical deep holes are distributed on the inner wall surface of the finished product of the honeycomb mosaic block hot end component, the depth of each cylindrical deep hole is 6mm, the diameter of each cylindrical deep hole is 4mm, and the wall thickness between every two adjacent cylindrical deep holes is 0.4 mm.
The yield of the hot end member of the honeycomb insert for a gas turbine manufactured by the method of example 3 was 93%.
Claims (5)
1. A forming method of a hot end part of a honeycomb insert block for a gas turbine is characterized by comprising the following steps:
s1, forming the honeycomb ceramic core mould by machining the honeycomb ceramic core mould blank, wherein the inner wall surface of the honeycomb ceramic core mould is fully distributed with columnar deep holes, the depth of each columnar deep hole is 5-6mm, the diameter of each columnar deep hole is 2-4mm, and the wall thickness between every two adjacent columnar deep holes is 0.2-0.4 mm;
s2, fixing the honeycomb ceramic core mould in a core pressing machine, injecting the raw material of the honeycomb ceramic core into the honeycomb ceramic core mould by the core pressing machine to obtain a honeycomb ceramic core green body, soaking the honeycomb ceramic core green body in a strengthening solution for 10-20min after sintering and trimming, taking out and naturally drying to obtain the honeycomb ceramic core, wherein columnar bulges are fully distributed on the outer surface of the honeycomb ceramic core, the height of the columnar bulges is 5-6mm, the diameter of the columnar bulges is 2-4mm, and a gap with the width of 0.2-0.4mm is formed between every two adjacent columnar bulges;
s3, firstly, mounting the honeycomb mosaic block mould on a wax pressing machine, opening the honeycomb mosaic block mould, then placing the honeycomb ceramic core into the honeycomb mosaic block mould, and finally injecting wax material through the wax pressing machine to enable the wax material to wrap the honeycomb ceramic core;
s4, firstly, assembling the honeycomb mosaic block mold into a tree, then making a shell, and finally dewaxing to form a mold shell cavity;
s5, firstly wrapping the formwork by using heat preservation cotton, putting the formwork into a preheating furnace to preheat to 1080-;
s6, cleaning and detecting the casting to obtain a finished product of the honeycomb mosaic block hot end component, wherein the inner wall surface of the finished product of the honeycomb mosaic block hot end component is fully distributed with columnar deep holes, the depth of each columnar deep hole is 5-6mm, the diameter of each columnar deep hole is 2-4mm, and the wall thickness between every two adjacent columnar deep holes is 0.2-0.4 mm.
2. The method for forming a hot end part of a honeycomb insert for a gas turbine according to claim 1, wherein: in step S1, the honeycomb ceramic core mold blank is made of aircraft aluminum 7075.
3. The method for forming a hot end part of a honeycomb insert for a gas turbine according to claim 1, wherein: in step S2, the strengthening liquid is an epoxy resin ethanol solution with a mass concentration of 25% to 30%.
4. The method for forming a hot end part of a honeycomb insert for a gas turbine according to claim 1, wherein: in step S3, the wax material is KC4021 type wax material, and the wax-pressing machine is an MPI type wax-pressing machine.
5. The method for forming a hot end part of a honeycomb insert for a gas turbine according to claim 1, wherein: in step S5, the vacuum casting furnace is a three-chamber vacuum casting furnace, and the master alloy is a K536 alloy.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202111654309.9A CN114289687A (en) | 2021-12-31 | 2021-12-31 | Forming method of honeycomb mosaic block hot end part for gas turbine |
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| CN202111654309.9A CN114289687A (en) | 2021-12-31 | 2021-12-31 | Forming method of honeycomb mosaic block hot end part for gas turbine |
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Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20070201980A1 (en) * | 2005-10-11 | 2007-08-30 | Honeywell International, Inc. | Method to augment heat transfer using chamfered cylindrical depressions in cast internal cooling passages |
| CN101077836A (en) * | 2007-06-19 | 2007-11-28 | 西安交通大学 | Method for preparing aluminum oxide base ceramic core |
| CN101941053A (en) * | 2009-07-08 | 2011-01-12 | 中国科学院金属研究所 | Preparation method of plate high-temperature alloy casting with high complexity |
| CN103586413A (en) * | 2013-11-18 | 2014-02-19 | 中国南方航空工业(集团)有限公司 | Precision casting method for multi-cavity structural part |
| US20180178278A1 (en) * | 2016-12-28 | 2018-06-28 | Mapna Group | Method for positioning core by soluble wax in investment casting |
| US20210276077A1 (en) * | 2018-07-18 | 2021-09-09 | Poly6 Technologies, Inc. | Articles and methods of manufacture |
| US20210394257A1 (en) * | 2021-05-04 | 2021-12-23 | Mapna Group | Method for stepped radial cooling passages in gas turbine blade |
-
2021
- 2021-12-31 CN CN202111654309.9A patent/CN114289687A/en active Pending
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20070201980A1 (en) * | 2005-10-11 | 2007-08-30 | Honeywell International, Inc. | Method to augment heat transfer using chamfered cylindrical depressions in cast internal cooling passages |
| CN101077836A (en) * | 2007-06-19 | 2007-11-28 | 西安交通大学 | Method for preparing aluminum oxide base ceramic core |
| CN101941053A (en) * | 2009-07-08 | 2011-01-12 | 中国科学院金属研究所 | Preparation method of plate high-temperature alloy casting with high complexity |
| CN103586413A (en) * | 2013-11-18 | 2014-02-19 | 中国南方航空工业(集团)有限公司 | Precision casting method for multi-cavity structural part |
| US20180178278A1 (en) * | 2016-12-28 | 2018-06-28 | Mapna Group | Method for positioning core by soluble wax in investment casting |
| US20210276077A1 (en) * | 2018-07-18 | 2021-09-09 | Poly6 Technologies, Inc. | Articles and methods of manufacture |
| US20210394257A1 (en) * | 2021-05-04 | 2021-12-23 | Mapna Group | Method for stepped radial cooling passages in gas turbine blade |
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