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WO2018039817A1 - 一种大型曲面叶片板坯的电渣熔合制造方法 - Google Patents

一种大型曲面叶片板坯的电渣熔合制造方法 Download PDF

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Publication number
WO2018039817A1
WO2018039817A1 PCT/CN2016/000587 CN2016000587W WO2018039817A1 WO 2018039817 A1 WO2018039817 A1 WO 2018039817A1 CN 2016000587 W CN2016000587 W CN 2016000587W WO 2018039817 A1 WO2018039817 A1 WO 2018039817A1
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Prior art keywords
curved blade
electroslag
slab
blade slab
casting
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PCT/CN2016/000587
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English (en)
French (fr)
Inventor
娄延春
熊云龙
陈瑞
宋照伟
王安国
王云霞
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China Academy of Machinery Shenyang Research Institute of Foundry Co Ltd
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Shenyang Research Institute of Foundry Co Ltd
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Priority to US15/756,024 priority Critical patent/US20190022746A1/en
Publication of WO2018039817A1 publication Critical patent/WO2018039817A1/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
    • B22D23/06—Melting-down metal, e.g. metal particles, in the mould
    • B22D23/10—Electroslag casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/04—Casting in, on, or around objects which form part of the product for joining parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/02—Special casting characterised by the nature of the product by its peculiarity of shape; of works of art
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/21—Manufacture essentially without removing material by casting

Definitions

  • the invention relates to a manufacturing process of a large aspect ratio curved casting, and particularly provides a method for manufacturing an electroslag fusion of a large curved blade slab.
  • the methods for producing such castings and forgings at home and abroad mainly include three methods of ordinary sand casting, forging and electroslag casting.
  • the invention provides a method for manufacturing electroslag fusion of a large curved blade slab, in particular, a large curved blade slab casting with large width-to-thickness ratio and large thickness difference, and the method mainly uses electroslag.
  • the fusing process fuses the molten metal melted by the consumable electrode with one or two electroslag precast slabs placed in advance in the crystallizer to form a large curved panel blank casting.
  • the invention relates to a method for manufacturing electroslag fusion of a large curved blade slab, which is characterized in that: according to the shape and sectional size of the curved blade slab, the blade slab is divided into 2-3 regions (see Figure 1-2), wherein:
  • the prefabricated curved panel blank is prepared by electroslag casting technology in advance on the one-side or double-sided part with large thickness variation and filling difficulty, and placed in the side of the inner cavity of the crystallizer in advance; then the self-consumption electrode is fabricated by electroslag fusion process
  • the molten metal liquid is fused with one or two electroslag precast slabs placed in the crystallizer to form a large curved blade slab casting.
  • the large curved blade slab casting prepared by the method of the invention has good internal and surface quality, can improve material utilization rate, shorten processing period and improve quality, especially high fatigue resistance and high resistance to crack generation. Expand performance.
  • the process is more suitable for the production of large or super large curved blade slab castings with a width to thickness ratio of >10 and a single weight of more than 10 tons.
  • the main components of electroslag fusion slag system are mass percentage: CaF 2 : 50-62%, Al 2 O 3 : 25-35%, CaO: 3 8%, trace components
  • the amount added is not more than 5% of the total mass of the slag system; the multi-slag system is formed, wherein the trace component is one or more of MgO, SiO 2 and TiO 2 , and the thickness of the slag layer is equivalent diameter of the curved blade slab crystallizer 12 to 25%;
  • Electroslag fusion process parameters voltage: 70-120V, current density: 20000-60000A/m 2 ;
  • feeding process using the intermittent feeding method for feeding, during the feeding period, firstly reduce the normal current to the minimum feeding current within 2 to 5 minutes, keep it for 1 to 2 minutes; The current reduced to a constant rate of 70 to 80% of the normal casting current in 3 minutes, so repeated 4 to 5 times, each time the highest current is 70 to 80% of the previous highest current, and the last time is reduced to zero.
  • the electroslag fusion manufacturing method of the large curved blade slab of the invention is characterized in that the single side precast slab can be fused or the double side precast slab can be fused by the electroslag casting process.
  • the electroslag fusion manufacturing method of the large curved blade slab of the invention is characterized in that: due to the relatively complicated precast curved panel blank, the consumable electrode selected for the electroslag casting precast slab is a sand casting electrode, and the electroslag fusion process is selected.
  • the consumable electrode is a steel plate welding electrode. According to the size of the inner cavity of the blade slab mold, the self-consumption electrode filling ratio is 0.15-0.4.
  • the method for manufacturing electroslag fusion of the large curved blade slab of the present invention is characterized in that the large curved blade slab alloy material comprises: low carbon martensitic stainless steel 06Cr13Ni4Mo, 06Cr13Ni5Mo or 06Cr16Ni5Mo; ultra low carbon martensitic stainless steel 04Cr13Ni4Mo or 04Cr13Ni5Mo.
  • the present invention has the following advantages:
  • Electroslag casting is a special casting technology that integrates refining, solidification and solidification. By adjusting the slag ratio and optimizing the process, the inclusions in the consumable electrode can be further removed and the distribution pattern can be changed and reduced.
  • the harmful elements such as P and S in the curved blade slab and the gas contents such as N, H and O improve the purity of the material.
  • Electroslag fusion curved blade slab can meet the mechanical properties and flaw detection requirements of the same material forgings. It has uniform chemical composition, compact structure, no looseness, shrinkage hole and other defects. The inclusions are dispersed and have high fatigue resistance. Performance and high resistance to crack generation and expansion.
  • the electroslag fusion process effectively solves the problem of filling quality of large blade slabs, and the internal and surface quality of the prepared large curved blade slab castings is good.
  • the process is more suitable for the production of large or super large curved blade slab castings with a width to thickness ratio of >10 and a single weight of more than 10 tons.
  • Figure 1 is a schematic view showing the structure of a single-sided fusion prefabricated slab.
  • Figure 2 is a schematic view showing the structure of a double-sided fusion prefabricated slab.
  • Fig. 3 is a schematic view showing a manufacturing method of electroslag fusion of a large curved blade slab.
  • the selected blade slab material is martensitic stainless steel 06Cr13Ni4Mo, and the maximum width of the blade is about 4300 mm, the maximum height is 3400 mm, and the maximum thickness is obtained. It is 310mm and the minimum thickness is 65mm.
  • the precast slab I 5 and the precast slab II6 are respectively placed in the I zone and the III zone in the crystallizer, and then the transformer 1 is connected to the bottom water tank 4, the II zone and the electrode 3 through a wire to form a circuit, and the electrode 3 is in the liquid slag. 9 is melted by the resistance heat, and the liquid metal passes through the slag pool to form the molten metal pool 8.
  • the strong water-cooled crystallizer the spiral groove of the inner wall of the crystallizer having a certain angle of elevation, increasing the cooling strength
  • the preformed slab I 5 and the preformed slab II 6 are fused together.
  • Zone I, Zone II and Zone III together form the curved blade slab required for the experiment.
  • the selected slag ratio is CaF 2 : 60%, Al 2 O 3 : 32%, CaO: 6 %, MgO: 2% form a quaternary slag system, the thickness of the slag layer is 20% of the equivalent diameter of the curved blade slab mold;
  • 3 power supply parameter selection according to the casting size, the geometric parameters of the electrode and the crystallizer, and the melting process
  • the casting voltage is 115V and the current density is 22000A/m 2 ; during the 4-fold period, the normal current is firstly reduced to the minimum feeding current for 4 minutes within 4 minutes; then the minimum feeding current is uniformly increased within 2 minutes. Up to 70% of the normal casting current, repeated 4 times, each time the highest melting current is 70% of the previous highest casting current, the last time reduced to zero.
  • the large curved blade slab prepared by the invention meets the requirements of the drawings, and has good internal and surface quality.
  • the mechanical properties of the compact after conventional heat treatment are R P0.2 /650Mpa, R m /845Mpa, A/26%, Z /62%, KV 2 /101J.
  • the X-shaped curved blade slab of a power station is manufactured, and the martensitic stainless steel with material of 06Cr16Ni5Mo is selected.
  • the prepared blade slab has a maximum width of 2600 mm, a maximum height of 2100 mm, a maximum thickness of 220 mm, and a minimum thickness of 30 mm.
  • a precast slab is placed on the side of the mold, the electrode is melted under the resistance heat of the liquid slag, and the liquid metal passes through the slag pool to form a molten metal pool.
  • the liquid metal liquid It is solidified and fused with pre-formed slabs placed in advance in the crystallizer to form a curved blade slab as required by the experiment.
  • the selected filling ratio is 0.26;
  • 2 the selected slag ratio is CaF 2 : 60%, Al 2 O 3 : 35%, CaO: 5% formation
  • 3 power supply parameter selection according to the casting size, the geometric parameters of the electrode and the mold and the casting process, the casting voltage is determined to be 85V and the current density is 35000A / m 2 ; 4 during the feeding period, firstly reduce the normal current to the minimum feeding current within 3 minutes to keep the minimum feeding current for 2 minutes; then increase the minimum feeding current to the normal casting current at a constant rate within 2 minutes. %, repeated 4 times, each time the highest melting current is 70% of the previous highest casting current, and the last time is reduced to zero.
  • the prepared large-scale curved blade slab is subjected to profile inspection, its dimensions meet the requirements of the drawings, and the surface has no slag groove defects; the mechanical properties of the compact after conventional heat treatment are R P0.2 /634Mpa, R m /810Mpa, A/25 %, Z/55%, KV 2 /105J, meet the requirements for use.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)

Abstract

一种大型曲面叶片板坯的电渣熔合制造方法，首先根据曲面叶片板坯外形尺寸，将充型难度大的部分首先利用电渣熔铸技术制作出预制曲面板坯（5、6），放置在结晶器（2）侧边。再利用电渣熔合工艺将自耗电极（3）熔化的金属液与放置在结晶器内的1块或2块电渣预制板坯熔合在一起，形成大型曲面叶片板坯铸件。采用该方法制备的大曲面叶片板坯铸件内部及表面质量良好，可提高材料利用率、缩短加工工期，提高质量，特别是具有较高抗疲劳性能、较高抗裂纹生成和扩展性能。该方法更适合生产宽厚比大、薄厚度不均匀的大型曲面叶片板坯类铸件，如宽厚比＞10、单重在10吨以上的大型或超大型曲面叶片板坯铸件。

Description

一种大型曲面叶片板坯的电渣熔合制造方法 技术领域
本发明涉及到大宽厚比曲面铸件制造工艺，特别提供了一种大型曲面叶片板坯的电渣熔合制造方法。
背景技术
装备制造领域，经常用到各种不规则的宽厚板类铸锻件，其特点是宽厚比大、断面形状不规则等。作为高端装备的重要基础部件之一，这种异形板类铸件的质量要求极为严格。例如：水轮发电机叶片铸件的质量问题几乎制约了水轮机组的整体运行寿命。
目前国内外生产此类铸锻件的方法主要有：普通砂型铸造、锻造和电渣熔铸三种工艺方法。
(1)受工艺本身局限性影响，普通砂型铸造产品常因内部质量较差难以满足使用要求；(2)采用锻扎板坯生产的宽厚板类铸锻件内部质量固然很好，但金属利用率极低，生产成本和工期大幅增加，且违背绿色制造理念；(3)电渣熔铸可根据产品外形轮廓直接生产出满足要求的宽厚板类铸锻件，凝固质量和力学性能优异，可达到同材质锻轧材标准。目前，发明人采用电渣熔铸方法已生产出整体叶片压坯，并已取得了发明专利(一种水轮机叶片压坯的电渣熔铸制造方法，公开号：CN 104174834A)。但该工艺只对宽厚比相对较小的板坯类铸件有效，对于宽厚比大(宽厚比＞10)、断面形状复杂的大型板坯类铸件，受自耗电极制作及结晶器冷却条件限制，电渣熔铸产生的金属液不能充分溢流到薄边最远区域，造成铸件薄边成形质量不好，限制了该方法的进一步应用。
除上述三种方法可生产宽厚板类铸锻件外，日本专利(JP 1999019791A)和中国专利(公开号：CN 102029378A)还各自提出了一种将两块原始坯料利用电 渣工艺熔合在一起的新方法。但这两种方法只适用于等厚钢板或者铸锭的熔接，对于横截面为不规则形状的大宽厚比铸件很难适用。
发明内容
本发明提供了一种大型曲面叶片板坯的电渣熔合制造方法，特别是对于宽厚比大、薄厚边相差也较大的大型曲面叶片板坯类铸件效果更好，该方法主要是利用电渣熔合工艺将自耗电极熔化的金属液与提前放置在结晶器内的1块或2块电渣预制板坯熔合在一起，形成大型曲面板坯铸件。
本发明技术方案如下：
一种大型曲面叶片板坯的电渣熔合制造方法，其特征在于：首先根据曲面叶片板坯外形及断面尺寸，将叶片板坯分为2-3个区域(见图1-2)，其中：断面厚度变化大、充型困难的单侧或双侧部分提前用电渣熔铸技术制作出预制曲面板坯，并提前放置在结晶器内腔侧边；再利用电渣熔合工艺将自耗电极熔化的金属液与放置在结晶器内的1～2块电渣预制板坯熔合在一起，最终形成大型曲面叶片板坯铸件。
采用本发明所述方法所制备的大曲面叶片板坯铸件其内部及表面质量良好，可提高材料利用率、缩短加工工期，提高质量，特别是具有较高抗疲劳性能、较高抗裂纹生成和扩展性能。该工艺更适合生产宽厚比＞10、单重在10吨以上的大型或超大型曲面叶片板坯铸件。
具体电渣熔合工艺步骤如下：
(1)、渣系与渣量控制：电渣熔合渣系的主要成分为质量百分比：CaF2：50～62％，Al2O3：25～35％，CaO：3～8％，微量成分加入量不高于渣系总质量的5％；构成多元渣系，其中微量成分为MgO、SiO2、TiO2之一种或多种，渣层厚度为曲面叶片板坯结晶器等效直径的12～25％；
(2)、电渣熔合工艺参数：电压：70～120V、电流密度：20000～60000A/m2；
(3)、补缩工艺：采用间断补缩方式进行补缩，补缩期内，首先在2～5分钟以内将正常电流匀速降低到最小补缩电流，保持1～2分钟；再将最小补缩电流在3分钟内匀速升高到正常熔铸电流的70～80％，如此反复4～5次，每次最高电流都为前次最高电流的70～80％，最后1次减小到零。
本发明所述大型曲面叶片板坯的电渣熔合制造方法，其特征在于：利用电渣熔铸工艺既可以熔合单侧预制板坯，也可熔合双侧预制板坯。
本发明所述大型曲面叶片板坯的电渣熔合制造方法，其特征在于：由于预制曲面板坯相对复杂，电渣熔铸预制板坯选用的自耗电极为砂型铸造电极，而电渣熔合工艺选用的自耗电极则为钢板拼焊电极。根据叶片板坯结晶器内腔尺寸，自耗电极填充比为0.15～0.4。
本发明所述大型曲面叶片板坯的电渣熔合制造方法，其特征在于，所述大型曲面叶片板坯合金材料包括：低碳马氏体不锈钢06Cr13Ni4Mo、06Cr13Ni5Mo或06Cr16Ni5Mo；超低碳马氏体不锈钢04Cr13Ni4Mo或04Cr13Ni5Mo。
与现有技术相比，本发明具有如下优点：
(1)电渣熔铸是一种集精炼提纯、凝固成形于一体的特种铸造技术，通过调整熔渣配比、优化工艺，可以进一步去除自耗电极中的夹杂物并改变其分布形态，降低曲面叶片板坯中的P、S等有害元素和N、H、O等气体含量，提高了材料纯净度。
(2)电渣熔合曲面叶片板坯可达到同材质锻件力学性能和探伤指标要求，其化学成分均匀、组织致密、无疏松、缩孔等缺陷，夹杂物呈弥散分布，同时具有较高抗疲劳性能及较高抗裂纹生成和扩展性能。
(3)曲面叶片板坯铸件在结晶器中凝固，冷却速度快，结晶器尺寸精度高、变形小，因而铸件表面光洁、加工余量小，达到近净成形目的。
(4)采用电渣熔合工艺有效地解决了大型叶片板坯的充型质量难题，所制备的大曲面叶片板坯铸件内部及表面质量良好。该工艺更适合生产宽厚比＞10、单重在10吨以上的大型或超大型曲面叶片板坯铸件。
附图说明
图1单侧熔合预制板坯结构示意图。
图2双侧熔合预制板坯结构示意图。
图3大型曲面叶片板坯的电渣熔合制造方法示意图。
其中，1、变压器，2、组合式水冷结晶器，3、电极，4、底水箱，5、预制板坯I，6、预制板坯II，7、电渣熔合区，8、金属熔池，9、液态熔渣。
具体实施方式
实施例1：
参考图2、图3，本发明所述某大型曲面叶片板坯的电渣熔合制造方法，选取的叶片板坯材料为马氏体不锈钢06Cr13Ni4Mo，叶片最大宽度约4300mm，最大高度为3400mm，最大厚度为310mm，最小厚度为65mm。
首先将预制板坯I 5和预制板坯II6分别放置在结晶器内的I区和III区，然后变压器1通过导线连接底水箱4、II区和电极3形成一个回路，电极3在液态熔渣9的电阻热作用下熔化，液态金属穿过渣池形成金属熔池8，在强水冷结晶器(结晶器内壁铜板有一定升角的螺旋形凹槽，增大冷却强度)的作用下，将预制板坯I 5和预制板坯II 6熔合在一起。最终，I区、II区和III区共同形成实验所要求制备的曲面叶片板坯。
①结合II区压坯结晶器内腔尺寸，制备随形钢板电极，选用的填充比为0.3； ②选用的渣系配比为CaF2：60％、Al2O3：32％、CaO：6％、MgO：2％形成四元渣系，渣层厚度为曲面叶片板坯结晶器等效直径的20％；③供电参数选择：根据铸件尺寸、电极与结晶器的几何参数及熔铸工艺，确定熔铸电压115V、电流密度为22000A/m2；④补缩期内，首先在4分钟以内将正常电流匀速降低到最小补缩电流，保持1分钟；再将最小补缩电流在2分钟内匀速升高到正常熔铸电流的70％，反复4次，每次的最高熔铸电流都为前次最高熔铸电流的70％，最后1次减小到零。
通过本发明制备的大型曲面叶片板坯，尺寸符合图纸要求，内部及表面质量良好，经常规热处理后压坯的力学性能为RP0.2/650Mpa，Rm/845Mpa，A/26％，Z/62％，KV2/101J。
实施例2：
本次实验所示的某电站X形曲面叶片板坯制造，选取材质为06Cr16Ni5Mo的马氏体不锈钢。制备的叶片板坯最大宽度2600mm，最大高度为2100mm，最大厚度为220mm，最小厚度30mm。
首先将1个预制板坯放置在结晶器内的侧边，电极在液态熔渣的电阻热作用下熔化，液态金属穿过渣池形成金属熔池，在水冷结晶器的作用下，液态金属液凝固并与提前放置在结晶器内的预制板坯熔合在一起，共同形成实验所要求制备的曲面叶片板坯。
①结合结晶器剩余的内腔尺寸，制备随形钢板电极，选用的填充比为0.26；②选用的渣系配比为CaF2：60％、Al2O3：35％、CaO：5％形成三元渣系，渣层厚度为曲面叶片板坯结晶器等效直径的21％；③供电参数选择：根据铸件尺寸、电极与结晶器的几何参数及熔铸工艺，确定熔铸电压85V、电流密度为35000A /m2；④补缩期内，首先在3分钟以内将正常电流匀速降低到最小补缩电流，保持2分钟；再将最小补缩电流在2分钟内匀速升高到正常熔铸电流的70％，反复4次，每次的最高熔铸电流都为前次最高熔铸电流的70％，最后1次减小到零。
制备的大型曲面叶片板坯经型线检验，其尺寸满足图纸要求，且表面无渣沟缺陷；经常规热处理后压坯的力学性能为RP0.2/634Mpa，Rm/810Mpa，A/25％，Z/55％，KV2/105J，满足使用要求。
上述实施例只为说明本发明的技术构思及特点，其目的在于让熟悉此项技术的人士能够了解本发明的内容并据以实施，并不能以此限制本发明的保护范围。凡根据本发明精神实质所作的等效变化或修饰，都应涵盖在本发明的保护范围之内。

Claims (5)

  1. 一种大型曲面叶片板坯的电渣熔合制造方法，其特征在于：首先根据曲面叶片板坯外形及断面尺寸，将叶片板坯分为2-3个区域，其中：断面厚度变化大、充型困难的单侧或双侧部分提前用电渣熔铸技术制作出预制曲面板坯，并提前放置在结晶器内腔侧边；再利用电渣熔合工艺将自耗电极熔化的金属液与放置在结晶器内的1～2块电渣预制板坯熔合在一起，最终形成大型曲面叶片板坯铸件。
  2. 按照权利要求1所述大型曲面叶片板坯的电渣熔合制造方法，其特征在于，具体电渣熔合工艺步骤如下：
    (1)、渣系与渣量控制：电渣熔合渣系的主要成分为质量百分比：CaF2：50～62％，Al2O3：25～35％，CaO：3～8％，微量成分≤5％；构成多元渣系，其中微量成分为MgO、SiO2、TiO2之一种或多种，渣层厚度为曲面叶片板坯结晶器等效直径的12～25％；
    (2)、电渣熔合工艺参数：电压：70～120V、电流密度：20000～60000A/m2；
    (3)、补缩工艺：补缩期内，首先在2～5分钟以内将正常电流匀速降低到最小补缩电流，保持1～2分钟；再将最小补缩电流在3分钟内匀速升高到正常熔铸电流的70～80％，如此反复4～5次，每次最高电流都为前次最高电流的70～80％，最后1次减小到零。
  3. 按照权利要求1所述大型曲面叶片板坯的电渣熔合制造方法，其特征在于：既可以熔合曲面叶片单侧预制板坯，也可熔合双侧预制板坯。
  4. 按照权利要求1所述大型曲面叶片板坯的电渣熔合制造方法，其特征在于：电渣熔铸预制板坯选用自耗电极为砂型铸造电极，电渣熔合工艺选用钢板拼焊电极；自耗电极填充比为0.15～0.4。
  5. 按照权利要求1所述大型曲面叶片板坯的电渣熔合制造方法，其特征在于，所述大型曲面叶片板坯合金材料包括：低碳马氏体不锈钢06Cr13Ni4Mo、06Cr13Ni5Mo或06Cr16Ni5Mo；超低碳马氏体不锈钢04Cr13Ni4Mo或04Cr13Ni5Mo。
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