CN114515818A - Manufacturing method and mold of aero-engine combustion chamber swirler - Google Patents
Manufacturing method and mold of aero-engine combustion chamber swirler Download PDFInfo
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- CN114515818A CN114515818A CN202011290672.2A CN202011290672A CN114515818A CN 114515818 A CN114515818 A CN 114515818A CN 202011290672 A CN202011290672 A CN 202011290672A CN 114515818 A CN114515818 A CN 114515818A
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- 238000004519 manufacturing process Methods 0.000 title claims description 19
- 238000002485 combustion reaction Methods 0.000 title claims description 12
- 238000005266 casting Methods 0.000 claims abstract description 23
- 210000005069 ears Anatomy 0.000 claims abstract description 18
- 239000002184 metal Substances 0.000 claims description 17
- 229910052751 metal Inorganic materials 0.000 claims description 17
- 238000003754 machining Methods 0.000 claims description 15
- 239000007788 liquid Substances 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 9
- 239000002131 composite material Substances 0.000 claims description 7
- 238000010438 heat treatment Methods 0.000 claims description 5
- 239000012530 fluid Substances 0.000 claims description 4
- 238000004891 communication Methods 0.000 claims description 3
- 238000007599 discharging Methods 0.000 claims description 3
- 238000005323 electroforming Methods 0.000 claims description 3
- 238000004018 waxing Methods 0.000 claims description 2
- 150000002739 metals Chemical class 0.000 claims 1
- 239000000463 material Substances 0.000 description 5
- 238000009415 formwork Methods 0.000 description 4
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- 230000007547 defect Effects 0.000 description 3
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- 239000002994 raw material Substances 0.000 description 3
- 239000000446 fuel Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
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- 239000012528 membrane Substances 0.000 description 2
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- 238000005553 drilling Methods 0.000 description 1
- 238000009760 electrical discharge machining Methods 0.000 description 1
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- 239000000155 melt Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
- B22C9/043—Removing the consumable pattern
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/082—Sprues, pouring cups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/20—Stack moulds, i.e. arrangement of multiple moulds or flasks
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
- B22C9/24—Moulds for peculiarly-shaped castings for hollow articles
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention relates to a mold for casting a swirler, wherein cavities of the mold comprise a first swirler cavity to an nth swirler cavity which are connected in series, n is more than or equal to 2, the adjacent swirler cavities are communicated end to end, and the serial direction of the swirler cavities is parallel to the axial direction of a swirler; the mold includes a top runner that leads from one end of the mold to a first swirler cavity; the die includes side runners that communicate with respective locations within each of the vortex type cavities corresponding to the first side mounting ears.
Description
Technical Field
The invention relates to the field of material processing, in particular to a manufacturing method and a die for a swirler of a combustion chamber of an aero-engine.
Background
The economy of the aero-engine is an important index and mainly reflects the high combustion efficiency and the reduction of oil consumption of a combustion chamber. In order to fully combust fuel, the advanced aircraft engine is designed through a nozzle structure, so that the fuel is fully mixed with high-pressure air. The swirler is a device for generating swirl air in a combustion chamber of an aircraft engine, and aims to enable fuel oil to be better mixed with air so as to achieve the purpose of full combustion.
The vortex generator mainly comprises a vortex generating device and a mounting device. The swirler may be cast from a corrosion resistant superalloy, and combined with electrochemical machining and machining. The air flow path is routed by a circle of non-concentric rotationally-oriented small blade structures due to the vortex generating device.
In order to solve the size requirement of the eddy current generating device, the air flow path is processed electrically. However, the square hole structure of the circle of the vortex generating device is machined electrically, and the working hours are about 40 hours. And because the vortex generating device is clamped for many times, the positioning influences the position relation between the vortex generating device and the mounting device, and the vortex forming effect is influenced.
The project aims at the structure of the swirler of the aero-engine and adopts an all-in-one processing idea. A method for manufacturing a multi-piece integrally cast and serially machined swirler is disclosed.
Disclosure of Invention
In the traditional casting process of the swirler, only one product can be cast in each mould, the yield is low, and the raw material waste is serious. The method provides a novel mold, and the mold can be used for obtaining a plurality of casting combined blanks connected in series through one-time casting, and separating the combined blanks connected in series after integral processing, so that a plurality of products can be obtained. The die improves the product yield of products, improves the utilization rate of raw materials and also improves the processing efficiency.
In addition, the inventor finds that the casting is easy to have loose defects when the series casting is carried out because the vortex device has a thick and thin abrupt annular structure. In order to solve the technical problem, the specific structure of the swirler is further skillfully utilized, besides the original top pouring channel of the mold, a side pouring channel is designed at the position of each swirler mounting lug, and the top pouring channel and the side pouring channel are jointly filled with liquid, so that the loose production in a casting can be avoided.
In some aspects, the present disclosure provides a mold for casting an aircraft engine combustion chamber swirler, wherein the swirler comprises: an annular body and a pair of mounting ears; the pair of mounting ears radially project from opposite sides of the annular body, the pair of mounting ears including a first side mounting ear and a second side mounting ear;
the cavity of the mold comprises a first swirler cavity to an nth swirler cavity which are connected in series, n is more than or equal to 2, the adjacent swirler cavities are communicated end to end, and the serial direction of the swirler cavities is parallel to the axial direction of the swirlers;
the mold includes a top runner that leads from one end of the mold to a first swirler cavity;
the die comprises a side pouring gate, the side pouring gate is located on one side of each swirler cavity, the side pouring gate comprises a plurality of branch circuits, and each branch circuit is communicated to the position, corresponding to the first side mounting lug, in each swirler cavity.
In some embodiments, the annular body comprises an annular vortex generator.
In some embodiments, the annular body further comprises an annular flow guide projecting axially from one side of the annular vortex generator.
In some embodiments, a pair of mounting ears project radially from opposite sides of the annular vortex generator or annular deflector.
In some embodiments, the first and nth swirler cavities are the swirler cavities closest to the two ends of the mold, respectively.
In some embodiments, the mold further comprises a main runner in fluid communication with the top and side runners, respectively, via a flow divider, and a flow divider for regulating the proportion of molten metal from the main runner to the top and side runners.
In some embodiments, projections of the respective swirler cavities in the series direction coincide with one another.
In some embodiments, a wax removal structure is disposed within each vortex-type cavity at a location corresponding to the second side mounting ear.
In some aspects, the present disclosure provides a method of making the mold of any one of the above, comprising the steps of:
1) providing a wax core with a preset shape;
2) wrapping the mould shell on the surface of the wax core;
3) opening a wax removing structure on the mould shell, heating to melt the wax core and discharging the wax core from the mould shell;
4) and plugging the dewaxing structure to obtain the mold.
In some aspects, the present disclosure provides a method of making a swirler, comprising the steps of:
1) casting using the mold of any of the above to produce a swirler composite blank comprising a plurality of swirler preforms in series.
In some embodiments, in step 1), the molten metal from the top pouring channel and the side pouring channel is converged at a position outside the corresponding mounting lug in each vortex-type cavity by adjusting the liquid inlet amount of the top pouring channel and the side pouring channel.
In some embodiments, molten metal from the top and side runners is joined at the interface of two adjacent swirler cavities by adjusting the amount of liquid feed to the top and side runners.
In some embodiments, a method of making a swirler further comprises the following steps.
2) Machining and/or electromachining the swirler combined blank;
3) separating the plurality of processed swirlers from each other.
In some embodiments, in step 2), the swirler combined blank is electroformed by using an electroforming device with a plurality of electrodes, and each electrode corresponds to one swirler rough blank during the machining process;
in some embodiments, in step 2), the plurality of swirler blanks are kept from separating during the machining.
Description of terms:
if the following terms are used in the present invention, they may have the following meanings:
various relative terms such as "front," "back," "top," and "bottom," "upper," "lower," "above," "below," and the like may be used to facilitate description of various embodiments. Relative terms are defined with respect to conventional orientations of the structure and do not necessarily indicate an actual orientation of the structure at the time of manufacture or use. The following detailed description is, therefore, not to be taken in a limiting sense. As used in the description and the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.
Electromachining (electrical discharge machining) refers to a method of machining a workpiece using the principle of electroerosion.
Machining refers to a method of a craftsman performing work on a workpiece with a tool, and includes, for example: turning, milling, planing, drilling, boring and grinding.
Advantageous effects
One or more technical schemes of the present disclosure have one or more of the following beneficial effects:
(1) the product yield is high. Conventional swirler castings, the swirler is cast one piece at a time. The method can collect multiple castings by one die, can improve the yield of a casting die product, and further improves the utilization rate of raw materials.
(2) A side pouring channel is creatively designed by utilizing the special structure of the swirler, and the side pouring channel is designed at the position of the mounting lug; the top pouring channel and the side pouring channels of the cavities of the vortex devices are filled with liquid together, so that the loose production in the casting can be avoided;
(3) the die is provided with a flow dividing device, and liquid levels of side injection and top injection are crossed at positions outside the mounting lugs by adjusting the flow of the top pouring channel and the side pouring channel, so that the service life of the swirler is prolonged;
(4) the special structure of the swirler is used for designing the pouring gate creatively, and the position of the mounting lug is used for designing the wax removing structure. Because the swirler is a thick and thin abrupt annular structure, when a plurality of castings are connected in series to form a tree, the locally thick position is easy to expand due to heating. In the process of wax removal again, the volume of the wax liquid is larger than the volume of the wax solid, and the expansion of the wax liquid can cause the deformation of the mold cavity. This disclosure scheme again each swirler die cavity one side position of installation ear has designed the structure of dewaxing, with the structure position opening of dewaxing before dewaxing for the wax material that melts can also discharge from the structure of dewaxing from the discharge of top runner, reduces wax material melting expansion and leads to membrane shell inflation, size discrepancy. After the wax removal is completed, the opening at the wax removal structure is resealed.
Drawings
FIG. 1 shows a top view of an aircraft engine combustion chamber swirler
FIG. 2 shows a B-B cross-sectional view of the swirler of FIG. 1
FIG. 3 shows a mold for casting a combustor swirler.
FIG. 4 shows a schematic view of machining a swirler composite blank.
Detailed Description
Embodiments of the present invention will be described in detail below with reference to examples, but those skilled in the art will appreciate that the following examples are only illustrative of the present invention and should not be construed as limiting the scope of the present invention. The examples, in which specific conditions are not specified, were conducted under conventional conditions or conditions recommended by the manufacturer. The reagents or instruments used are not indicated by the manufacturer, and are all conventional products commercially available.
FIG. 1 shows a top view of an aircraft engine combustion chamber swirler, and FIG. 2 shows a B-B cross-sectional view of the swirler of FIG. 1. As shown in FIGS. 1-2, the swirler includes an annular body 15 and a pair of mounting ears 13; a pair of mounting ears 13 extend radially from opposite sides of the annular body 15, the pair of mounting ears 13 including a first side mounting ear 131 and a second side mounting ear 132. The annular vortex generator 11 and the annular flow guide 12 have a common axis of symmetry 10.
In some embodiments, the annular body 15 includes an annular vortex generator 11.
In some embodiments, the annular body 15 further comprises an annular flow guide 12 axially protruding from one side of the annular vortex generator 11.
In some embodiments, a pair of mounting ears 13 extend radially from opposite sides of annular deflector 12.
In some embodiments, the annular vortex generator 11 is provided with a plurality of vortex blades circumferentially thereon.
In some embodiments, the mounting ears 13 are used to connect with mounting structures within the combustion chamber.
FIG. 3 shows a mold for casting a combustor swirler. The cavity of the mold comprises a first vortex device cavity 21, a second vortex device cavity 22 to an nth vortex device cavity 23 which are connected in series, wherein n is 6, the adjacent vortex device cavities (21, 22) are communicated end to end, and the serial direction of the vortex device cavities (namely the connecting line passing through the centers of all the vortex devices) is parallel to the direction of the axis 10 of all the vortex devices; the mold further includes a top runner 31, the top runner 31 leading from one end of the mold (e.g., the top end of the mold) to the first swirler cavity 21 location (i.e., from which an opening opens into the cavity); the mold includes a side runner 32, the side runner 32 is located at one side of each of the swirler cavities, and the side runner 32 includes a plurality of branches, and each branch leads to a position corresponding to the first side mounting lug 131 in each of the swirler cavities (i.e., a hole opens into the cavity from this position).
As shown in fig. 3, the side runners 31 are located beside the cavity of the swirler, and the side runners 31 include a main flow path and a plurality of branch flow paths, the main flow path extends in series along the cavity of the swirler, and the branch flow paths extend from the main flow path and are respectively communicated with the positions corresponding to the first side mounting lugs 131 in each cavity of the swirler.
The above embodiment has the following beneficial effects: firstly, a plurality of vortex devices are cast in series, so that the efficiency can be effectively improved; and secondly, the top pouring channel and the side pouring channels of the cavities of the vortex devices are filled with liquid together, so that the loose production in the casting can be avoided.
In some embodiments, as shown in FIG. 3, the mold further comprises a main runner 41 and a flow divider 42, the main runner 41 being in fluid communication with the top runner 31 and the side runners 32, respectively, via the flow divider 42. The tapping device 42 is able to regulate the proportion of molten metal that the main runner 41 dispenses into the top and side runners 31, 32.
The above embodiment has the following beneficial effects: by adjusting the ratio of the molten metal of the top runner 31 and the side runner 32, the convergence position of the molten metal of the top runner 31 and the side runner 32 entering the cavity of the swirler can be adjusted. Preferably, the skilled person can use ProCAST software to pre-model the flow of molten metal during casting by adjusting the flow rates of the top runner 31 and the side runners 32 so that they meet at a location outside the mounting ears 13. Because the metal liquid intersection position may have microscopic defects, and the force bearing part on the vortex device with the lug 13 is installed, the intersection position is avoided, which is helpful for improving the service life of the vortex device.
In some embodiments, projections of the respective swirler cavities in the series direction coincide with one another.
In some embodiments, the individual swirler cavities are equally spaced and oriented in the same direction.
Based on this, because each swirler is arranged regularly, when the cast product is processed integrally in the follow-up process, the cast product can be processed integrally by using the processing device with a plurality of electrodes/cutters without separating each swirler. The processing efficiency is improved.
In some embodiments, as shown in fig. 3, a wax ejection structure 33 is provided in each of the vortex type cavities at a location corresponding to the second side mounting ears 132.
In some embodiments, there is provided a method of making a mold of any of the above, comprising the steps of:
(1) providing a wax core with a preset shape;
(2) the surface of the wax core is wrapped with a mould shell;
(3) opening a wax removing structure on the mould shell, heating to melt the wax core and discharging the wax core from the mould shell;
(4) and (5) plugging the de-waxing structure to obtain the die.
In some embodiments, the formwork is a sand formwork.
In some embodiments, as shown in fig. 3, a wax ejection structure 33 is provided in each of the vortex type cavities at a location corresponding to the second side mounting ears 132. And arranging the wax removing structure 33 at the position corresponding to the second side mounting lug 132 in each vortex type cavity, opening the wax removing structure at the position after the formwork is dried and hardened, and heating to melt the wax core and discharge the wax core from the formwork. This embodiment has the following advantageous effects: because the swirler is of a thickness mutation annular structure, when a plurality of castings are connected in series to form a tree group, the local thicker position is easy to be heated and expanded; during the dewaxing process for preparing the mould, the wax material is melted and flows out from the top pouring channel 31 and the wax removing structure 33, so that the phenomenon that the wax material is melted and expanded to cause the expansion of the membrane shell and cause the dimensional over-tolerance is reduced.
FIG. 4 shows a schematic view of machining a swirler composite blank.
In some embodiments, there is provided a method of making a swirler, comprising the steps of:
(1) the mold casting described above is used to produce a swirler composite blank 50 comprising a plurality of swirler preforms (41, 42, 43, 44) in series.
In some embodiments, in step (1), molten metal from the top runner and the side runners is merged at a position other than the corresponding mounting lug 13 in each of the swirler cavities by setting the amount of liquid inlet to the top runner 31 and the side runners 32. The positions except the mounting lugs 13 are non-bearing positions, so that molten metal is converged at the positions, and the service life of the product is not reduced basically even if the secondary junction has fine defects.
In some embodiments, the technician may pre-model the flow of molten metal during casting using fluid analysis software (e.g., ProCAST software) by adjusting the flow rates of the top runner 31 and the side runners 32 to meet at a location outside the mounting ears 13.
In some embodiments, molten metal from the top and side runners is joined at the intersection of two adjacent swirler cavities by adjusting the amount of liquid feed to the top and side runners 31, 32. Because the junction of two adjacent swirler cavities can be removed in the machining process later, the position where molten metal meets basically does not exist in the swirler main body.
In some embodiments, the method of making a swirler further comprises the steps of:
(2) processing a swirler combined blank;
(3) separating the plurality of processed swirlers from each other.
In some embodiments, in step (2), the swirler composite blank is machined using a cutting tool.
In some embodiments, in step (2), the assembled swirler blank 50 is electroformed using an electroforming apparatus having a plurality of electrodes 62, each electrode 62 corresponding to a respective one of the swirler blanks (41, 42, 43, 44) during machining.
In some embodiments, the plurality of swirler preforms are kept from separating during the machining process. Therefore, the plurality of vortex devices can be processed at one time, and the processing efficiency is improved.
In some embodiments, the inner and outer cavities of the part are machined by the tool 61, the peripheral square groove structure is formed by the electrode 62, the deflector is machined by the tool 61, and the single swirler parts in the combined blank 50 are sequentially cut.
While specific embodiments of the invention have been described in detail, those skilled in the art will understand that: various modifications may be made in the details within the teachings of the disclosure, and these variations are within the scope of the invention. The full scope of the invention is given by the appended claims and any equivalents thereof.
Claims (10)
1. A mold for casting an aircraft engine combustion chamber swirler, wherein the swirler comprises: an annular body (15) and a pair of mounting ears (13), the annular deflector (12) projecting axially from one side of the annular vortex generator (11); the pair of mounting ears (13) radially project from opposite sides of the annular body (15), the pair of mounting ears (13) including a first side mounting ear (131) and a second side mounting ear (132);
the cavity of the mold comprises a first vortex device cavity (21) to an nth vortex device cavity (23) which are connected in series, n is more than or equal to 2, the adjacent vortex device cavities are communicated end to end, and the serial direction of the vortex device cavities is parallel to the axial direction of the vortex devices;
the mould comprises an overhead runner (31), the overhead runner (31) leading from one end of the mould to a first swirler cavity (21);
the die comprises a side pouring gate (32), the side pouring gate (32) is positioned on one side of each vortex type cavity, the side pouring gate (32) comprises a plurality of branch circuits, and each branch circuit is communicated to a position, corresponding to a first side mounting lug (131), in each vortex type cavity;
preferably, the annular body (15) comprises an annular vortex generator (11);
more preferably, the annular body (15) further comprises an annular flow guide device (12) axially protruding from one side of the annular vortex generator (11).
2. A mould according to claim 1, further comprising a main runner (41) and a flow divider device (42), the main runner (41) being in fluid communication with the top runner (31) and the side runners (32) respectively via the flow divider device (42), the flow divider device (42) being adapted to regulate the proportion of molten metal that is distributed by the main runner (41) to the top runner (31) and the side runners (32).
3. The mold of claim 1, projections of each swirler cavity in the series direction coinciding with one another.
4. The mold of claim 1, wherein a wax relief structure (33) is provided in each of the vortex-type cavities at a location corresponding to the second side mounting ears (132).
5. A method of making a mould according to any one of claims 1 to 4, comprising the steps of:
(1) providing a wax core with a preset shape;
(2) the surface of the wax core is wrapped with a mould shell;
(3) opening a wax removing structure on the mould shell, heating to melt the wax core and discharging the wax core from the mould shell;
(4) and (5) plugging the de-waxing structure to obtain the die.
6. A method of making a swirler comprising the steps of:
(1) casting using the mold of any of claims 1-4 to produce a swirler composite blank comprising a plurality of swirler preforms in series.
7. The production method according to claim 6, wherein in the step (1), molten metals from the top runner and the side runner are joined at a position other than the position corresponding to the mounting lug (13) in each of the cavity of the vortex type by setting the amount of the molten metal fed to the top runner (31) and the side runner (32).
8. The production method according to claim 7, wherein the molten metal from the top pouring channel and the side pouring channel is converged at the junction of two adjacent swirler cavities by adjusting the liquid inlet amount of the top pouring channel (31) and the side pouring channel (32).
9. The method of claim 6, further comprising the steps of.
(2) Machining and/or electromachining the swirler combined blank;
(3) separating the processed plurality of swirlers from each other.
10. The method of claim 9, wherein in step (2), the swirler composite blank (50) is electroformed using an electroforming device having a plurality of electrodes (62), each electrode (62) corresponding to a respective swirler blank during the machining;
preferably, the plurality of swirler blanks are kept from separating during machining.
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Cited By (1)
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WO2024049370A1 (en) * | 2022-08-29 | 2024-03-07 | Süleyman Demi̇rel Üni̇versi̇tesi̇ İdari̇ Ve Mali̇ İşler Dai̇re Başkanliği Genel Sekreterli̇k | A compact combustion chamber mold for a circulating fluidized bed boiler and a method of obtaining a combustion chamber with this mold |
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WO2024049370A1 (en) * | 2022-08-29 | 2024-03-07 | Süleyman Demi̇rel Üni̇versi̇tesi̇ İdari̇ Ve Mali̇ İşler Dai̇re Başkanliği Genel Sekreterli̇k | A compact combustion chamber mold for a circulating fluidized bed boiler and a method of obtaining a combustion chamber with this mold |
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