A large-scale, thin wall duplex stainless steel impeller with complex geometry was deformed severely and unpredictably during casting and heat treatment processes resulted in dimensional failure for the final part. In...A large-scale, thin wall duplex stainless steel impeller with complex geometry was deformed severely and unpredictably during casting and heat treatment processes resulted in dimensional failure for the final part. In this paper, the distortion of the impeller during casting and heat treatment was calculated. A commercial software, Experto-ViewCast, was used to simulate the transient heat transfer, solidification and mechanical behaviors during the casting and the heat treatment process. The coupled set of governing differential equations for mass, energy and mechanical balance were solved by finite control volume and finite element method. A thermoelastic-visco-plastic rheological model was used to compute the constrained shrinkage of the casting. At each time increment, a coupling of the heat transfer and mechanics was performed. Comparison of the experimental measurements with the model predictions showed good agreement. From the calculated displacements of key points of the blade, the proper inverse displacements were determined to provide an optimum casting pattern and to achieve a uniform and reasonable machining allowance for both faces of the blade.展开更多
Distortion often appears at the corners of heavy turbine blade castings during heat treatment processes, so a great machining allowance is generally set in production which directly results in cost increase. In this p...Distortion often appears at the corners of heavy turbine blade castings during heat treatment processes, so a great machining allowance is generally set in production which directly results in cost increase. In this paper, a novel real-time measuring technology is developed for non-contact measuring the deformation behavior of heavy steel castings in heat treatment process. It was employed to measure the distortion and the temperature field of a batch of heavy turbine blade castings at cooling stage in normalizing process. Three inflection points appear in the distortion-time curves, and the residual distortion is affected by the regional area of not finished martensite transformation when the second inflection point appears. When the mean air temperature falls into the range of 10℃-20℃, the residual distortion is small; when it is lower than 10℃, positive distortion appears; when it is higher than 20℃, negative distortion appears. The distortion varies with seasonal temperature, which is directly responsible for the great machining allowance given in production.展开更多
文摘A large-scale, thin wall duplex stainless steel impeller with complex geometry was deformed severely and unpredictably during casting and heat treatment processes resulted in dimensional failure for the final part. In this paper, the distortion of the impeller during casting and heat treatment was calculated. A commercial software, Experto-ViewCast, was used to simulate the transient heat transfer, solidification and mechanical behaviors during the casting and the heat treatment process. The coupled set of governing differential equations for mass, energy and mechanical balance were solved by finite control volume and finite element method. A thermoelastic-visco-plastic rheological model was used to compute the constrained shrinkage of the casting. At each time increment, a coupling of the heat transfer and mechanics was performed. Comparison of the experimental measurements with the model predictions showed good agreement. From the calculated displacements of key points of the blade, the proper inverse displacements were determined to provide an optimum casting pattern and to achieve a uniform and reasonable machining allowance for both faces of the blade.
基金supported by the National Eleventh Five-Year Science and Technology Support Program of China (Grant No.2007BAF02B02)the Major Projects of Ministry of Science of China (Grant No.2009ZX04014-082)
文摘Distortion often appears at the corners of heavy turbine blade castings during heat treatment processes, so a great machining allowance is generally set in production which directly results in cost increase. In this paper, a novel real-time measuring technology is developed for non-contact measuring the deformation behavior of heavy steel castings in heat treatment process. It was employed to measure the distortion and the temperature field of a batch of heavy turbine blade castings at cooling stage in normalizing process. Three inflection points appear in the distortion-time curves, and the residual distortion is affected by the regional area of not finished martensite transformation when the second inflection point appears. When the mean air temperature falls into the range of 10℃-20℃, the residual distortion is small; when it is lower than 10℃, positive distortion appears; when it is higher than 20℃, negative distortion appears. The distortion varies with seasonal temperature, which is directly responsible for the great machining allowance given in production.
