CN102756111A - Electroslag fusion casting manufacture method of rotating wheel blanks of impact type hydraulic generator - Google Patents
Electroslag fusion casting manufacture method of rotating wheel blanks of impact type hydraulic generator Download PDFInfo
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Abstract
The invention relates to the manufacture field of impact type rotating wheels, and in particular relates to an electroslag fusion casting manufacture method of rotating wheel blanks of an impact type hydraulic generator. The electroslag fusion casting manufacture method is an electroslag fusion casting technology for impact type rotating wheel integral casting blanks and individual rotating wheel water tank blanks. According to the method, self-consumable electrodes and the electroslag fusion casting technology are adopted; the rotating wheel integral casting blanks are produced by rotating wheel integral casting circular type blank crystallizers under an integral structure or an individual combined structure; and the individual rotating wheel water tank blanks are produced by rotating wheels water tank crystallizers under the integral structure or the individual combined structure. With the adoption of the method, the shortcomings of the current production technology of high water head impact type rotating wheel blanks can be solved; the near net forming impact type rotating wheel integral casting blank manufacture technology and the individual rotating wheel water tank blank manufacture technology are adopted; the produced rotating wheel blanks and the water tank blanks are high in fatigue resistance, high in crack generation and expansion resistance, long in service lives and high in use safety; and the quality and performance of the produced rotating wheel blanks and the water tank blanks are in line with those of forged blanks obtained by using the same materials; and the method has the advantages of low production cost, short production period and the like.
Description
Technical field
The present invention relates to the manufacturing field of impact type runner; Be specially a kind of electroslag smelting casting manufacturing approach of impingement type hydraulic generator runner blank; It is that the technology, particularly impact type runner block cast blank of hydrogenerator runner ferroalloy blank and the electroslag casting process of split type runner bucket blank are produced in electroslag smelting casting.
Background technology
Along with country to the adjustment of power construction structure and the attention of environmental protection, the develop actively water power has become the guilding principle that China power industry is built.Water power belongs to reproducible clean energy resource, helps environmental protection, and Hydropower Development improves design, manufacturing and the production capacity of large-scale high water head impulse water wheel unit, be promote national economic development with the demand that promotes development of machinery industry.
Along with the raising of output of hydraulic turbine, the power station head is increasingly high, and what the high head hydraulic turbine technology mainly embodied is the manufacturing of its impact type runner.The runner bucket is the core component in impact type power station, and the height of its manufacture level directly influences the security of efficient, life-span and the use of the hydraulic turbine, so runner The Study of Manufacturing Technology and development are all paid much attention in countries in the world.
For high water head impact type runner, its diameter is generally 0.6 ~ 4 meter, and bigger diameter can reach 5 meters, and main danger is bucket root cracking in the use, and the through crack wheel hub causes and flies bucket, and serious accident takes place.Simultaneously, because the runner manufacturing cost is higher, also increasingly high to the requirement in its service life.Domestic have four kinds of production technology production impact type runners usually:
The one, the unit sand mold casting, advantage is that production cost is low, shortcoming is to use the life-span minimum, is easy to produce the bucket accident that flies; The 2nd, the split manufacturing, promptly wheel hub and bucket are independent respectively makes, and through riveted joint or welding wheel hub and bucket is connected into an integral body then, and advantage is that manufacturing cost is lower, and shortcoming is to use security very poor.When runner moved, bucket received the effect of the pulse alternate load of water jet, and bucket is welded to joint on the wheel hub and will produces tired and ftracture; The 3rd, monoblock cast cake parison material, numerical control machine-shaping then, advantage is that manufacturing cost is low slightly, and molded lines is accurately exerted oneself, and shortcoming is to use the life-span low, and security is very poor; The 4th, forge cake parison material, numerical control machine-shaping then, advantage is that molded lines is accurately exerted oneself, and high life, security are fine, and shortcoming is that cost is high.
At present, both at home and abroad high water head impact type runner is made, and mainly adopts rough forging, the process of digital control processing then, and this is because Forging Technology can effectively reduce the runner defective, improves the safety in utilization of runner.But there is very big problem in this technology in actual production, at first is that the processing capacity of forging is big, and stock utilization is less than 50%; Secondly, for producing large-scale impact type runner, because the wheel footpath is bigger, needed forging stock generally needs up to ten thousand tons Large-scale Forging press to produce, and makes the manufacturing cost of runner high.
Summary of the invention
The object of the present invention is to provide a kind of electroslag smelting casting manufacturing approach of impingement type hydraulic generator runner blank; Mainly solve the deficiency of producing high water head impact type runner blank technology at present; Adopt the impact type runner block cast blank manufacturing technology and the split type runner bucket blank manufacturing technology of near-net-shape; Runner blank of being produced and bucket blank have the higher fatigue resistance ability, higher crack generates and scalability, and its quality and performance reach with the material rough forging.
The technical scheme that the present invention adopts is:
A kind of electroslag smelting casting manufacturing approach of impingement type hydraulic generator runner blank; Adopt consutrode and electroslag casting process to produce impingement type hydraulic generator runner blank; Impingement type hydraulic generator runner blank is impact type runner block cast blank or split type runner bucket blank; Wherein: runner block cast blank adopts the runner block cast cake type blank crystallizer of monoblock type or piecemeal combining structure form to produce, and split type runner bucket blank adopts the runner bucket crystallizer of integral body or piecemeal combining structure form to produce.
The electroslag smelting casting manufacturing approach of described impingement type hydraulic generator runner blank, consutrode adopt common smelting or refinery practice preparation, adopt casting technique to process the conformal consutrode close with mold shape.
The electroslag smelting casting manufacturing approach of described impingement type hydraulic generator runner blank in the runner block cast cake type blank crystallizer, adopts with type blank crystallizer, and all the design through nearly clean shape crystallizer improves stock utilization.
The electroslag smelting casting manufacturing approach of described impingement type hydraulic generator runner blank; Split type runner adopts consutrode and runner bucket crystallizer, and through the strand of electroslag casting process formation bucket, the strand of bucket is through digital control processing; Be fixed on the wheel hub with riveted joint, Bolt Connection or welding manner; The wheel hub blank is welded through electroslag smelting casting, the smart casting of melting, forging or steel plate, material and bucket material of the same race or xenogenesis material, and wherein wheel hub is monolithic or biplate structure; Be double wheel hub clamping bucket root junction during the biplate structure, thereby process complete impact type waterturbine wheel.
The electroslag smelting casting manufacturing approach of described impingement type hydraulic generator runner blank, electroslag casting process comprises the steps:
1) slag system and quantity of slag control
It is main that slag system adopts with the binary slag system, wherein CaF
255 ~ 85wt%, Al
2O
315 ~ 45wt%, the quantity of slag is the 1wt%～10wt% of foundry goods;
2) mode of igniting
Consutrode adopts solid-state in crystallizer or liquid slag is ignited, and its chemical composition is TiO with the percentage by weight
2: 30 ~ 65%, CaF
2: 30 ~ 65%, and add CaO and the MgO of 0wt% ~ 10wt% as required;
3) crystallizer is selected
The material of crystallizer selects full copper, all steel or copper steel compound, and runner block cast crystallizer or split type runner bucket crystallizer adopt monoblock type or combined type;
4) power supply parameter is selected
Confirm founding power, voltage, each respective electrical parameter of electric current according to the geometric parameter of casting dimension, electrode and crystallizer, note keeping the stable of voltage and current in the fusion-casting process; Wherein, Control of Voltage is at 50 ~ 115V, and Current Control is at 5000 ~ 20000A;
5) heat treating castings technology
Adopt anticracking heat treatment, normalizing and tempering process to heat-treat: anti-hot tearing and elimination internal stress heat treatment temperature are 300 ~ 900 ℃; The normalizing process temperature is 900 ~ 1100 ℃; The tempering process temperature is 450 ~ 750 ℃; Above-mentioned heat treated temperature retention time was by every 100mm effective thickness insulation 1-3 hour.
The electroslag smelting casting manufacturing approach of described impingement type hydraulic generator runner blank, the foundry goods alloying component is 20SiMn steel, Low Carbon Martensite Stainless Steel or Mo ultralow-carbon martensitic stainless steel after the founding.
The electroslag smelting casting manufacturing approach of described impingement type hydraulic generator runner blank, Low Carbon Martensite Stainless Steel are 06Cr13Ni4Mo, 06Cr13Ni5Mo or 06Cr16Ni5Mo; Mo ultralow-carbon martensitic stainless steel is 03Cr13Ni4Mo, 03Cr13Ni5Mo or 03Cr16Ni5Mo.
In the said step 1),, add MgO, CaO, CaCO according to actual alloy refining requirement
3, among the BaO one or more, it adds weight and is not higher than 30%.
In the said step 3), the copper steel graphite mold is meant with the carbon steel to be substrate, and the crystallizer die cavity is a fine copper, carbon steel and copper joint solder bond.
After the said step 5), require to adopt double tempering according to actual process, the temperature of double tempering was 500 ~ 700 ℃, by every 100mm effective thickness insulation 1-3 hour.
Advantage of the present invention and beneficial effect:
1, the present invention adopts whole impact type runner and the split impact type runner service life of electroslag casting process manufacturing and safety in utilization all to reach with the material forging products, and is best in quality.
2, process program runner blank of the present invention makes things convenient for digital control processing, and bucket water conservancy molded lines is accurate, the runner height of exerting oneself.
3, compare forging blank, runner blank refinement of the present invention, stock utilization is high, and the process-cycle is short, and the product cost declines to a great extent.
4, the split type runner fabrication scheme of the present invention, bucket and wheel hub can adopt unlike material, can reduce the stainless steel use amount, further reduce the runner cost.
5, process program of the present invention need not to use large-sized forging equipment to prepare blank, does not also use the large-sized numerical control process equipment, makes simple, efficient, low-cost.
6, electroslag smelting casting of the present invention is the technology of the refining consutrode being carried out double refining purification, casting; Adjustment through the slag proportioning; Can further remove the field trash in the consutrode and change its distributional pattern, reduce in the runner harmful elements such as S, the foundry goods matrix is pure.
7, foundry goods of the present invention solidifies in water mold, and cooling velocity is fast, solid-liquid forward position crystallization temperature gradient is big, since the foundry goods rapid solidification, foundry goods dense structure.
8, metal crystallizer dimensional accuracy of the present invention is high, distortion is little, thereby cast(ing) surface is bright and clean, allowance is little.Simultaneously, owing to adopt consecutive solidification technology, foundry goods does not have casting system and rising head, so using rate of metal is high, realizes the foundry goods near-net-shape; Be difficult for producing the common casting flaws such as slag inclusion, pore, shrinkage porosite and shrinkage cavity of sand-cast simultaneously.
9, metal crystallizer of the present invention has replaced sand mold, need not a large amount of nonmetal Modeling Materials such as binding agent and coating, and seldom solid waste discharge reduces the pollution to environment.
10, runner of the present invention can reach mechanical performance and the flaw detection requirement with the material forging; Defectives such as chemical composition is even, dense structure, dendrite refinement, little, no loose, the no slag inclusion shrinkage cavity of microscopic segregation; Field trash is disperse and distributes; Be superior to the external refining forging fatigue life and make runner, the not available isotropic advantage of forge piece is arranged again, have higher fatigue resistance ability and higher crack simultaneously and generate and scalability.
11, the present invention is because metal crystallizer can repeat repeatedly to use, and when producing a large amount of same size runner, the production cycle is very short, and cost is lower.
Description of drawings
Fig. 1 is founding consutrode of the present invention and block cast cake type blank crystallizer sketch map.
Fig. 2 is an A-A cutaway view among Fig. 1.
Fig. 3 is the split type bucket partial schematic diagram of the present invention.
Fig. 4 is a bucket blank crystallizer sketch map of the present invention.
Among the figure, 1 consutrode; 2 with type blank crystallizer; 3 buckets; 4 bucket blank crystallizers.
The specific embodiment
Shown in Fig. 1-2, prepare consutrode 1 with refinery practice, adopt the electroslag casting process moulding.Design is also made impact type runner blank with type blank crystallizer 2, and its hub portion is with type, and all the design through nearly clean shape crystallizer reaches the purpose that improves stock utilization.
Shown in Fig. 3-4; Split type runner adopts consutrode 1 and split type runner bucket crystallizer 4, and through the strand of electroslag casting process formation bucket 3, the strand of bucket 3 is through digital control processing; Be fixed on the wheel hub with modes such as riveted joint, Bolt Connection or welding that (the wheel hub blank can be made through electroslag smelting casting, the smart casting of melting or forging mode; Also can adopt steel plate to be welded, material can with bucket material of the same race or xenogenesis material), wherein wheel hub is monolithic or biplate structure; Be double wheel hub clamping bucket root junction during the biplate structure, thereby process complete impact type runner.
Among the present invention; Consutrode adopts common smelting or refinery practice preparation; Adopt casting technique to process the conformal consutrode close with mold shape; Its material is by the hydrogenerator runner material of refining, but according to material needs AOD (VOD) refining cast molding or intermediate frequency furnace (electric arc furnaces) melting casting.Use the conformal consutrode can reach the purpose of forced overflow for the electroslag smelting casting of thin wall space plane of bending or complicated abnormal shape spare.
Electroslag smelting casting operating process of the present invention is used to accomplish the task such as double refining purification, foundry goods near-net-shape of refining consutrode material, has following steps:
1) slag system and quantity of slag control
It is main that slag system adopts with the binary slag system, wherein CaF
255 ~ 85wt%, Al
2O
315 ~ 45wt%.And can add a small amount of MgO, CaO, CaCO according to actual alloy refining requirement
3, among the BaO one or more, it adds weight and is not higher than 30%.The quantity of slag is generally the 1wt% ~ 10wt% of foundry goods.
2) mode of igniting
Consutrode adopts solid-state in crystallizer or liquid slag is ignited, and its chemical composition is TiO with the percentage by weight
2: 30 ~ 65%, CaF
2: 30～65%, and can add CaO and the MgO of 0wt% ~ 10wt% as required.
3) crystallizer is selected
The material of crystallizer selects full copper, all steel or copper steel compound, and runner block cast cake type blank crystallizer adopts monoblock type or piecemeal fabricated structure form, and split type runner bucket crystallizer adopts integral body or piecemeal fabricated structure form.
Among the present invention, the compound crystallizer working face that is meant of copper steel is a copper coin, and non-working surface adopts steel plate, processes with the method for bimetallic welding, makes the crystallizer cooling best and cost is lower.
4) power supply parameter is selected
Geometric parameter according to casting dimension, electrode and crystallizer is confirmed each respective electrical parameters such as founding power, voltage, electric current, notes keeping the stable of voltage and current in the fusion-casting process.Wherein, Control of Voltage is at 50 ~ 115V, and Current Control is at 5000 ~ 20000A.
5) foundry goods alloying component (by weight percentage) after the founding
The 20SiMn steel:
| C | Si | Mn | P | S | Cr | Ni | Cu | Fe |
| 0.18～0.25 | 0.30~0.80 | 1.20~1.50 | ≤0.030 | ≤0.030 | ≤0.030 | ≤0.30 | ≤0.30 | Surplus |
Low Carbon Martensite Stainless Steel:
Mo ultralow-carbon martensitic stainless steel:
6) heat treating castings technology
For eliminating the potential of foundry goods internal stress, the performance mechanical property of materials, need in time heat-treat, adopt anticracking heat treatment+normalizing+tempering process, and adopt other heat treatments, to optimize the foundry goods combination property according to actual performance and technological requirement.
Anti-hot tearing and elimination internal stress heat treatment temperature are 300 ~ 900 ℃; The normalizing process temperature is 900 ~ 1100 ℃; The tempering process temperature is 450 ~ 750 ℃; And can require to adopt double tempering according to actual process, the temperature of double tempering is 500 ~ 700 ℃.Above-mentioned heat treated temperature retention time was by every 100mm effective thickness insulation 1-3 hour.
Mechanical performance after the heat treating castings:
Adopt low-alloy steel 20SiMn preparation to impact runner electroslag smelting casting blank.
1) the slag system batching adopts: CaF
270%, Al
2O
330%, the quantity of slag is 3% of a casting weight.
2) mode of igniting: consutrode adopts solid slag to ignite in crystallizer, and its chemical composition is TiO with the percentage by weight
2: 50%, CaF
2: 50%.
3) selection of crystallizer: adopt the copper steel graphite mold, its structure adopts monoblock type.
4) power consumption parameter: confirm that according to casting dimension, electrode and crystallizer physical dimension founding voltage is 50V, electric current 6500A.
Through electroslag casting process,, process 20SiMn steel impact type runner blank by the crystallizer moulding of setting shape.Its chemical composition is:
| C | Si | Mn | P | S | Cr | Ni | Cu | Fe |
| 0.20 | 0.7 | 1.20 | 0.020 | 0.013 | 0.010 | 0.10 | 0.10 | Surplus |
For eliminating the potential of foundry goods internal stress, the performance mechanical property of materials, need in time heat-treat, adopt anticracking heat treatment+normalizing+tempering process, and adopt other heat treatments, to optimize the foundry goods combination property according to actual performance and technological requirement.
In the present embodiment, anti-hot tearing and elimination internal stress heat treatment temperature are 570 ℃; The normalizing process temperature is 950 ℃; The tempering process temperature is 585 ℃; And can require to adopt double tempering according to actual process, the temperature of double tempering is 565 ℃.Above-mentioned heat treated temperature retention time was by every 100mm effective thickness insulation 2 hours.
The foundry goods mechanical performance is after the heat treatment:
| Yield strength | Tensile strength | Percentage elongation | The contraction percentage of area | Impact absorbing energy | Brinell hardness |
| σ s/MPa | σ b/MPa | δ 5/％ | ψ/％ | A kv/J | HB |
| 330 | 520 | 16 | 35 | 80 | 165 |
Adopt electroslag smelting casting to prepare the 06Cr13Ni4Mo steel drift and hit the runner blank.
1) the slag system batching adopts: CaF
255wt%, Al
2O
345wt%, the quantity of slag is 3.4% of a casting weight.
2) mode of igniting: consutrode adopts solid slag to ignite in crystallizer, and its chemical composition is TiO with the percentage by weight
2: 50%, CaF
2: 50%.
3) selection of crystallizer: adopt the copper steel graphite mold, its structure adopts the piecemeal combined type.
4) power consumption parameter: confirm that according to casting dimension, electrode and crystallizer physical dimension founding voltage is 75V, electric current 12000A.
Through electroslag casting process,, process 06Cr13Ni4Mo steel impact type runner blank by the crystallizer moulding of setting shape.Its chemical composition is:
For eliminating the potential of foundry goods internal stress, the performance mechanical property of materials, need in time heat-treat, adopt anticracking heat treatment+normalizing+tempering process, and adopt other heat treatments, to optimize the foundry goods combination property according to actual performance and technological requirement.
In the present embodiment, anti-hot tearing and elimination internal stress heat treatment temperature are 610 ℃; The normalizing process temperature is 1000 ℃; The tempering process temperature is 600 ℃; And can require to adopt double tempering according to actual process, the temperature of double tempering is 570 ℃.Above-mentioned heat treated temperature retention time was by every 100mm effective thickness insulation 3 hours.
The foundry goods mechanical performance is after the heat treatment:
Adopt electroslag smelting casting to prepare the 06Cr13Ni5Mo steel drift and hit the runner blank.
1) the slag system batching adopts: CaF
265wt%, Al
2O
335wt%, the quantity of slag is 2.5% of a casting weight.
2) mode of igniting: consutrode adopts solid slag to ignite in crystallizer, and its chemical composition is TiO with the percentage by weight
2: 45%, CaF
2: 55%.
3) selection of crystallizer: adopt the copper steel graphite mold, its structure adopts the piecemeal combined type.
4) power consumption parameter: confirm that according to casting dimension, electrode and crystallizer physical dimension founding voltage is 50V, electric current 7500A.
Through electroslag casting process,, process 06Cr13Ni5Mo steel impact type runner blank by the crystallizer moulding of setting shape.Its chemical composition is:
For eliminating the potential of foundry goods internal stress, the performance mechanical property of materials, need in time heat-treat, adopt anticracking heat treatment+normalizing+tempering process, and adopt other heat treatments, to optimize the foundry goods combination property according to actual performance and technological requirement.
In the present embodiment, anti-hot tearing and elimination internal stress heat treatment temperature are 580 ℃; The normalizing process temperature is 1010 ℃; The tempering process temperature is 580 ℃; And can require to adopt double tempering according to actual process, the temperature of double tempering is 570 ℃.Above-mentioned heat treated temperature retention time was by every 100mm effective thickness insulation 2 hours.
The foundry goods mechanical performance is after the heat treatment:
Adopt electroslag smelting casting to prepare the 06Cr16Ni5Mo steel drift and hit the runner blank.
1) the slag system batching adopts: CaF
275wt%, Al
2O
325wt%, the quantity of slag is 3.5% of a casting weight.
2) mode of igniting: consutrode adopts solid slag to ignite in crystallizer, and its chemical composition is TiO with the percentage by weight
2: 50%, CaF
2: 50%.
3) selection of crystallizer: adopt full Cu crystallizer, its structure adopts monoblock type.
4) power consumption parameter: confirm that according to casting dimension, electrode and crystallizer physical dimension founding voltage is 80V, electric current 14500A.
Through electroslag casting process,, process 06Cr16Ni5Mo steel impact type runner blank by the crystallizer moulding of setting shape.Its chemical composition is:
For eliminating the potential of foundry goods internal stress, the performance mechanical property of materials, need in time heat-treat, adopt anticracking heat treatment+normalizing+tempering process, and adopt other heat treatments, to optimize the foundry goods combination property according to actual performance and technological requirement.
In the present embodiment, anti-hot tearing and elimination internal stress heat treatment temperature are 590 ℃; The normalizing process temperature is 1030 ℃; The tempering process temperature is 600 ℃; And can require to adopt double tempering according to actual process, the temperature of double tempering is 590 ℃.Above-mentioned heat treated temperature retention time was by every 100mm effective thickness insulation 3 hours.
The foundry goods mechanical performance is after the heat treatment:
Embodiment 5
Adopt electroslag smelting casting to prepare the 03Cr13Ni5Mo steel drift and hit the runner blank.
1) the slag system batching adopts: CaF
260wt%, Al
2O
330wt%, CaCO
310wt%, the quantity of slag is 6% of a casting weight.
2) mode of igniting: consutrode adopts solid slag to ignite in crystallizer, and its chemical composition is TiO with the percentage by weight
2: 33%, CaF
2: 60%, CaO:3%, MgO:4%.
3) selection of crystallizer: adopt the copper steel graphite mold, its structure adopts monoblock type.
4) power consumption parameter: confirm that according to casting dimension, electrode and crystallizer physical dimension founding voltage is 88V, electric current 18000A.
Through electroslag casting process,, process 03Cr13Ni5Mo steel impact type runner blank by the crystallizer moulding of setting shape.Its chemical composition is:
For eliminating the potential of foundry goods internal stress, the performance mechanical property of materials, need in time heat-treat, adopt anticracking heat treatment+normalizing+tempering process, and adopt other heat treatments, to optimize the foundry goods combination property according to actual performance and technological requirement.
In the present embodiment, anti-hot tearing and elimination internal stress heat treatment temperature are 650 ℃; The normalizing process temperature is 1100 ℃; The tempering process temperature is 610 ℃; And can require to adopt double tempering according to actual process, the temperature of double tempering is 585 ℃.Above-mentioned heat treated temperature retention time was by every 100mm effective thickness insulation 1 hour.
The foundry goods mechanical performance is after the heat treatment:
Embodiment 6
Adopt electroslag smelting casting to prepare the split type impact runner of 03Cr16Ni5Mo steel bucket blank.
1) the slag system batching adopts: CaF
270wt%, Al
2O
320wt%, BaO 10wt%, the quantity of slag is 5% of a casting weight.
2) mode of igniting: consutrode adopts solid slag to ignite in crystallizer, and its chemical composition is TiO with the percentage by weight
2: 65%, CaF
2: 30%, CaO:5%.
3) selection of crystallizer: adopt the copper steel graphite mold, its structure adopts the piecemeal combined type.
4) power consumption parameter: confirm that according to casting dimension, electrode and crystallizer physical dimension founding voltage is 105V, electric current 19500A.
Through electroslag casting process,, process the split type impact type runner of 03Cr16Ni5Mo steel bucket blank by the crystallizer moulding of setting shape.Its chemical composition is:
For eliminating the potential of foundry goods internal stress, the performance mechanical property of materials, need in time heat-treat, adopt anticracking heat treatment+normalizing+tempering process, and adopt other heat treatments, to optimize the foundry goods combination property according to actual performance and technological requirement.
In the present embodiment, anti-hot tearing and elimination internal stress heat treatment temperature are 650 ℃; The normalizing process temperature is 1050 ℃; The tempering process temperature is 590 ℃; And can require to adopt double tempering according to actual process, the temperature of double tempering is 585 ℃.Above-mentioned heat treated temperature retention time was by every 100mm effective thickness insulation 2 hours.
The foundry goods mechanical performance is after the heat treatment:
The bucket blank is fixed on the wheel hub with modes such as riveted joints through machining, and wherein wheel hub is the biplate structure, two clamping bucket root junctions, thus process complete impingement runner.
Embodiment 7
Adopt electroslag smelting casting to prepare the split type impact runner of 03Cr16Ni5Mo steel bucket blank.
1) the slag system batching adopts: CaF
262wt%, Al
2O
318wt%, MgO 5wt%, CaO 5wt%, CaCO
35wt%, BaO 5wt%, the quantity of slag is 8% of a casting weight.
2) mode of igniting: consutrode adopts liquid slag to ignite in crystallizer, and its chemical composition is TiO with the percentage by weight
2: 30%, CaF
2: 65%, MgO:5%.
3) selection of crystallizer: adopt all steel monoblock type crystallizer.
4) power consumption parameter: confirm that according to casting dimension, electrode and crystallizer physical dimension founding voltage is 50V, electric current 20000A.
Through electroslag casting process,, process the split type impact type runner of 03Cr16Ni5Mo steel bucket blank by the crystallizer moulding of setting shape.Its chemical composition is:
For eliminating the potential of foundry goods internal stress, the performance mechanical property of materials, need in time heat-treat, adopt anticracking heat treatment+normalizing+tempering process, and adopt other heat treatments, to optimize the foundry goods combination property according to actual performance and technological requirement.
In the present embodiment, anti-hot tearing and elimination internal stress heat treatment temperature are 700 ℃; The normalizing process temperature is 1020 ℃; The tempering process temperature is 600 ℃; And can require to adopt double tempering according to actual process, the temperature of double tempering is 600 ℃.Above-mentioned heat treated temperature retention time was by every 100mm effective thickness insulation 2 hours.
The foundry goods mechanical performance is after the heat treatment:
The bucket blank is fixed on the wheel hub with modes such as riveted joint or Bolt Connection through machining, and wherein wheel hub is the biplate structure, thereby processes complete impingement runner.
Embodiment result shows, the present invention adopts the electroslag smelting casting technology, production impact type runner blank, the impact type runner internal soundness of production reaches with material rough forging quality standard, cost just with the material forging blank 50% or still less.
Claims (10)
1. the electroslag smelting casting manufacturing approach of an impingement type hydraulic generator runner blank; It is characterized in that; Adopt consutrode and electroslag casting process to produce impingement type hydraulic generator runner blank; Impingement type hydraulic generator runner blank is impact type runner block cast blank or split type runner bucket blank; Wherein: runner block cast blank adopts the runner block cast cake type blank crystallizer of monoblock type or piecemeal combining structure form to produce, and split type runner bucket blank adopts the runner bucket crystallizer of integral body or piecemeal combining structure form to produce.
2. according to the electroslag smelting casting manufacturing approach of the described impingement type hydraulic generator runner of claim 1 blank, it is characterized in that consutrode adopts common smelting or refinery practice preparation, adopts casting technique to process the conformal consutrode close with mold shape.
3. according to the electroslag smelting casting manufacturing approach of the described impingement type hydraulic generator runner of claim 1 blank; It is characterized in that; In the runner block cast cake type blank crystallizer, adopt with type blank crystallizer, all the design through nearly clean shape crystallizer improves stock utilization.
4. according to the electroslag smelting casting manufacturing approach of the described impingement type hydraulic generator runner of claim 1 blank, it is characterized in that split type runner adopts consutrode and runner bucket crystallizer; Form the strand of bucket through electroslag casting process; The strand of bucket is fixed on the wheel hub with riveted joint, Bolt Connection or welding manner through digital control processing, and the wheel hub blank is welded through electroslag smelting casting, the smart casting of melting, forging or steel plate; Material and bucket material of the same race or xenogenesis material; Wherein wheel hub is monolithic or biplate structure, is double wheel hub clamping bucket root junction during the biplate structure, thereby processes complete impact type waterturbine wheel.
5. according to the electroslag smelting casting manufacturing approach of the described impingement type hydraulic generator runner of claim 1 blank, it is characterized in that electroslag casting process comprises the steps:
1) slag system and quantity of slag control
It is main that slag system adopts with the binary slag system, wherein CaF
255 ~ 85wt%, Al
2O
315 ~ 45wt%, the quantity of slag is the 1wt%～10wt% of foundry goods;
2) mode of igniting
Consutrode adopts solid-state in crystallizer or liquid slag is ignited, and its chemical composition is TiO with the percentage by weight
2: 30 ~ 65%, CaF
2: 30 ~ 65%, and add CaO and the MgO of 0wt% ~ 10wt% as required;
3) crystallizer is selected
The material of crystallizer selects full copper, all steel or copper steel compound, and runner block cast crystallizer or split type runner bucket crystallizer adopt monoblock type or combined type;
4) power supply parameter is selected
Confirm founding power, voltage, each respective electrical parameter of electric current according to the geometric parameter of casting dimension, electrode and crystallizer, note keeping the stable of voltage and current in the fusion-casting process; Wherein, Control of Voltage is at 50 ~ 115V, and Current Control is at 5000 ~ 20000A;
5) heat treating castings technology
Adopt anticracking heat treatment, normalizing and tempering process to heat-treat: anti-hot tearing and elimination internal stress heat treatment temperature are 300 ~ 900 ℃; The normalizing process temperature is 900 ~ 1100 ℃; The tempering process temperature is 450 ~ 750 ℃; Above-mentioned heat treated temperature retention time was by every 100mm effective thickness insulation 1-3 hour.
6. according to the electroslag smelting casting manufacturing approach of the described impingement type hydraulic generator runner of claim 5 blank, it is characterized in that the foundry goods alloying component is 20SiMn steel, Low Carbon Martensite Stainless Steel or Mo ultralow-carbon martensitic stainless steel after the founding.
7. according to the electroslag smelting casting manufacturing approach of the described impingement type hydraulic generator runner of claim 6 blank, it is characterized in that Low Carbon Martensite Stainless Steel is 06Cr13Ni4Mo, 06Cr13Ni5Mo or 06Cr16Ni5Mo; Mo ultralow-carbon martensitic stainless steel is 03Cr13Ni4Mo, 03Cr13Ni5Mo or 03Cr16Ni5Mo.
8. according to the electroslag smelting casting manufacturing approach of the described impingement type hydraulic generator runner of claim 5 blank, it is characterized in that, in the said step 1),, add MgO, CaO, CaCO according to actual alloy refining requirement
3, among the BaO one or more, it adds weight and is not higher than 30%.
9. according to the electroslag smelting casting manufacturing approach of the described impingement type hydraulic generator runner of claim 5 blank; It is characterized in that in the said step 3), the copper steel graphite mold is meant with the carbon steel to be substrate; The crystallizer die cavity is a fine copper, carbon steel and copper joint solder bond.
10. according to the electroslag smelting casting manufacturing approach of the described impingement type hydraulic generator runner of claim 5 blank; It is characterized in that, after the said step 5), require to adopt double tempering according to actual process; The temperature of double tempering was 500 ~ 700 ℃, by every 100mm effective thickness insulation 1-3 hour.
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN104625650A (en) * | 2015-01-21 | 2015-05-20 | 重庆科技学院 | Manufacturing technology for runner of impulse turbine |
| CN107876739A (en) * | 2017-12-13 | 2018-04-06 | 沈阳市盛华特种铸造有限公司 | A kind of method of rotary wheel of water turbine three-dimension curved surface blade electroslag smelting casting straight forming |
| CN113560830A (en) * | 2021-08-30 | 2021-10-29 | 沈阳市盛华特种铸造有限公司 | Manufacturing method of electroslag casting cast-on impact runner |
| CN114101636A (en) * | 2021-11-19 | 2022-03-01 | 沈阳市盛华特种铸造有限公司 | Electroslag smelting casting manufacturing method for runner bucket of impulse type hydraulic generator |
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| CN113560830A (en) * | 2021-08-30 | 2021-10-29 | 沈阳市盛华特种铸造有限公司 | Manufacturing method of electroslag casting cast-on impact runner |
| CN114101636A (en) * | 2021-11-19 | 2022-03-01 | 沈阳市盛华特种铸造有限公司 | Electroslag smelting casting manufacturing method for runner bucket of impulse type hydraulic generator |
| CN114101636B (en) * | 2021-11-19 | 2023-12-22 | 沈阳市盛华特种铸造有限公司 | Electroslag casting manufacturing method of impact type hydraulic generator runner bucket |
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