Li-Blades tsa Turbine: Lisebelisoa tsa ho Lahlela, Mamello le Litlhoko tsa ho sebetsa ka mokhoa o nepahetseng 

Li-turbine blades li sebetsa tlas'a phallo e feteletseng ea mocheso o phahameng oa mocheso, khatello ea mocheso oa cyclic, le mecha ea litaba e senyang, e leng se etsang hore e be e 'ngoe ea likarolo tse thata ka ho fetisisa bakeng sa ho lahlela ka nepo indastering ea matla. Lihlopheng tse ngata tsa ho reka thepa le tsa boenjiniere li tobane le liphephetso tse sa fetoheng tsa tlhahiso ha li batla mahare a turbine: liforomo tsa moea tse nang le marako a tšesaane li na le ho honyela le ho senyeha, liteishene tse pholileng tsa ka hare li lebisa ho robeheng ha mantlha, 'me thepa ea superalloy e baka ho thatafala ha machining le mathata a thata a taolo ea mamello.

Tataiso ena e akaretsa khetho ea lisebelisoa tsa alloy, taolo ea ts'ebetso ea ho etsa matsete, meeli ea sebopeho sa mocha o pholileng, litekanyetso tsa mamello ea boholo, litsela tse nepahetseng tsa mochini, le melao e felletseng ea tlhahlobo ea NDT bakeng sa mahare a turbine. E shebane le ho etsoa ha lehare le ipapisitseng le terata, ho u thusa ho fokotsa sekhechana sa ho lahlela, ho laola tumello ea mochini oa mochini, le ho qoba ho sebetsa hape ka theko e boima likarolong tse hanyetsanang le mocheso o phahameng le tse sa jeng.

1. Maemo a ho sebetsa le Mathata a Motheo a Tlhahiso ea Li-Blades tsa Turbine

Maqhubu a turbine a sebetsa tlas'a mocheso o sa khaotseng o phahameng, ho palama libaesekele tse futhumetseng, le ho bola ha sulfide. Mehato ea pele ea likhahla tsa turbine ea khase e ka boloka tšebeletso ea nako e telele ka holimo ho 900 ° C. Ho atolosoa ha mocheso khafetsa le ho honyela ho baka deformation ea creep le mapetsong a mokhathala oa mocheso.

Ho rarahana ha jiometri ho phahamisa bothata ba tlhahiso haholo:

• Botenya ba lebota le lesesaane la moea (hangata le ka tlase ho 1 mm) le baka ho tlatsoa ha alloy e fokolang le ho tiea ho sa lekanang.
• Litemana tse rarahaneng tsa ho pholisa ka hare li hloka li-cores tsa ceramic tse kentsoeng, tse fetohang habonolo kapa ho robeha ha li tšolloa.
• Likarolo tse kobehileng tse rarahaneng tse sa sebetseng li ke ke tsa hlahisoa ke lehlabathe le tloaelehileng. Ke feela vacuum precision casting e ka fanang ka likheo tse haufi tsa sebopeho sa marang-rang.
• Li-superalloy tse thehiloeng ho nickel li bonts'a mosebetsi o matla o batang o thata. Sena se potlakisa ho roala ha lisebelisoa le ho sitisa ho nepahala ha sebopeho nakong ea machining ea CNC.

Lintlha tse ka sehloohong tsa bohloko ba tlhahiso li kenyelletsa ho lahla porosity, core offset, ho sotha profile ea blade, machining deformation, le masoba a sa tsitsang a filimi a pholileng ho nepahala.

2. Khetho e Phahameng ea Mocheso oa Alloy bakeng sa Li-Blades tsa Cast Turbine

Ho khetha superalloy e nepahetseng ke motheo oa bophelo bo bolelele ba tšebeletso ea lehare. Boemo ba thepa bo tlameha ho tsamaisana le mocheso oa ts'ebetso, tikoloho e senyang, le litlhoko tsa khanyetso ea creep. Karolo ena e tsepamisitse maikutlo ho li-superalloy tsa mantlha tse thehiloeng ho nickel tse sebelisoang haholo bakeng sa matlapa a turbine.

2.1 Mephato e Meholo ea Superalloy bakeng sa Li-Blades tsa Turbine

• Inconel 718 (UNS N07718)
  Mocheso o tsoelang pele oa ts'ebeletso ho fihla ho 700 ° C, o nang le matla a matla a ho tsitsa le ts'ebetso e itekanetseng. E sebelisoa haholo bakeng sa li-turbine tsa mocheso o tlase le o mahareng le li-blade tsa compressor, tse fanang ka khanyetso e ntle ho khase e bolila le kutu e metsi.
• Inconel 625 (UNS N06625)
  Ho hanyetsa ka matla ho pitting le crevice corrosion, ho lumellana le litekanyetso tsa tšebeletso tse bolila tsa NACE MR0175. E sebetsa ka mokhoa o tsitsitseng ho fihlela ho 650 ° C 'me e lumellana le li-blade tse pepesehileng maemo a khase e senyang.
• Rene 80
  A common equiaxed cast cast superalloy e leka-lekaneng matla a mocheso o phahameng le khanyetso ea oxidation, e etselitsoeng mahare a bohareng ba sethala a sebetsang ka tlase ho 950°C.
• CMSX-4 (Alloy e le 'ngoe ea Crystal)
  Sehlopha sa maemo a holimo se hanyetsanang le li-blade tsa HPHT tsa mokhahlelo oa pele. Tšebeletso e tsoelang pele e ka fihla ho 1150 ° C ntle le ho phomola ho hlakileng. Ho tiisa ka Directional ho felisa meeli ea lijo-thollo ho ntlafatsa botsitso ba mocheso o phahameng.

2.2 Melao ea Khetho ea Lintho tse Thehiloeng ho Tikoloho ea Tšebeletso

1. Maemo a ho hola a khase e bolila le metsi a leoatle: Khetha Inconel 625 bakeng sa ho hanyetsa kutu (likarolo tse hananang le kutu).
2. Li-turbine tsa motlakase oa mocheso o bohareng (≤700 ° C): Inconel 718 ke khetho e theko e tlaase e nang le machinability e leka-lekaneng le ts'ebetso ea mechine.
3. Maqhubu a karolo e chesang ea turbine ea mocheso o phahameng (950-1150 ° C): Adopt Rene 80 equiaxed casting kapa CMSX-4 single-crystal directional solidification casting bakeng sa ts'ebetso e khahlanong le creep.
4. Qoba lintlha tse fetelletseng tsa maemo: Li-alloys tsa kristale e le 'ngoe li tlisa litšenyehelo tse phahameng haholo tsa ho lahla; li sebelise feela bakeng sa maemo a phahameng ka ho fetisisa a mocheso.

Netefatso e ntseng e emetse: Litekanyetso tse nepahetseng tsa ASTM, boemo ba kutu ea NACE le lintlha tsa nako e telele tsa ho phatloha ha sekhahla bakeng sa sehlopha ka seng sa alloy.

3. Precision Investment Casting Controls for Turbine Blades

Precision casting (Investment casting/ Ho lahla boka ba bokae) ke eona feela theknoloji e seng e holile ea ho hlahisa li-blade tsa turbine tse se nang letho tse nang le likanale tse futhumatsang ka hare. Taolo e fosahetseng ea ts'ebetso e tla lebisa ho shrinkage porosity, ho falla ha mantlha, le ho sotha ha profil ea lehare.

3.1 Mathata a Bohlokwa ho Blade Investment Casting

1. Ho tlatsa lebota le lesesaane: Superalloy e qhibilihisitsoeng e tiea kapele. Likarolo tse tšesaane tsa foil li na le ho etsa hore ho koalehe ka mokhoa o batang le ho se tlatse ka botlalo.
2. Ceramic core stability: Li-cores tse kentsoeng lia robeha kapa li fetoha tlas'a tšusumetso ea tšepe ea mocheso o phahameng, e bakang litselana tse pholileng tse koetsoeng.
3. Solidification shrinkage: Pholiso e sa leka-lekaneng e baka ho kheloha ho hoholo le ho honyela ka hare ho porosity.
4. Taolo ea sebopeho sa lijo-thollo: Lithollo tse leka-lekaneng li theha habonolo ntle le ho tiea ka tsela e eang, li fokotsa bophelo ba ho qhoma ha mocheso o phahameng.

3.2 Litaolo tsa Ts'ebetso ea Near-Net-Shape Casting

• Ho qhibiliha ha Vacuum & ho tšela: Qhibiliha li-superalloys tsa nickel tlas'a vacuum e phahameng ho fokotsa litaba tsa oksijene le ho qoba liphoso tsa ho kenyelletsa oxide. Preheat hlobo ea khetla ea ceramic ho 900-1100 ° C ho ntlafatsa metsi a tšepe e qhibilihisitsoeng.
• Taolo ea ho tiisa Directional: Beha mocheso o pholileng o laoloang (10-50 ° C / min pholileng rate) ho etsa lithollo tsa columnar kapa mehaho ea kristale e le 'ngoe, e leng ho ntlafatsang haholo ho hanyetsa mocheso o phahameng oa mocheso.
• HIP hot isostatic tobetsa: Tšoara likheo tsa ho lahlela ka HIP ho koala li-micro-pores tse ka hare le li-shrinkage cavities, ho ntlafatsa ts'ebetso ea ka hare le mokhathala.
• Matšeliso a ho honyela ha boka ba boka: Sekhahla sa ho fokotseha ha hlobo esale pele (hoo e ka bang 1.6% -1.7% bakeng sa tataiso ea bolelele) ho fokotsa ho fokotseha ha hlobo le ho laola ho kheloha ka kakaretso.

3.3 Motheo oa Mamello ea ho Lahla bakeng sa Li-Blades tsa Turbine

Ho mamellana ho se nang letho ho latela litekanyetso tsa ISO 8062 le VDG P690. Bakeng sa likheo tsa matsete a turbine blade blade:

• Phapang ea sebopeho sa boemo ba moea oa foil: ± 0.30 mm ka mor'a matšeliso a ho honyela.
• E khothalletsoang tumello ea machining e le 'ngoe: 0.3-1.5 mm; tumello e teteaneng e behelletsoeng holim'a ntlha e holofetseng ea lehare.
• Mamello ea botenya ba lebota ea mahare a sekoti: ± 0.15 mm bakeng sa likarolo tse tšesaane tse nang le marako.

Netefatso e ntseng e emetse: Limaraka tse felletseng tsa VDG P690 le litekanyetso tse nepahetseng tsa tumello ea machining bakeng sa boholo bo fapaneng ba lehare.

4. Litlhoko tsa ho Lahlela bakeng sa Mehaho ea ho Pholisa ka hare ho Blade

Li-blade tsa turbine tse se nang letho li itšetlehile ka likanale tse pholileng tsa ka hare ho fokotsa mocheso oa lehare. Boleng ba litemana tse pholileng bo khetholla ka ho toba katleho ea mocheso oa turbine, 'me tlhahiso ea mantlha e etsa qeto ea hore na mohaho o ka hare o ka thehoa ka ho feletseng.

4.1 Mekhoa e Tloaelehileng ea ho Pholisa Channel le Meeli ea Tlhahiso

Mehaho e tloaelehileng ea ho pholisa e kenyelletsa likanale tse nang le li-pass-pass tse ngata, likoti tse pholisang tse ka pele-pele, likheo tse moqotetsane tse moqotetsane, le li-pin-fin turbulence.

Meeli ea mantlha ea ho lahlela:

• Botenya ba lebota bo tlase bo sebetsang bo nang le li-cores tsa ceramic tse tšoanelehang le ho tšela vacuum: 0.5 mm. Boleng bona bo itšetlehile ka boholo ba lehare le mofuta oa alloy.
• Boholo bo fokolang ba karolo ea mantlha: bophara ba 0.5 mm bakeng sa li-cores tse nyane tsa lesoba la filimi e pholileng; li-cores tse tšesaane haholo li tla robeha nakong ea ho tšela.
• Likarolo tse tšesaane li hloka matla a mantlha a mantlha le katoloso e tlase ea mocheso ho thibela deformation tlas'a mocheso o phahameng.

4.2 Mehato ea Boqapi le Mehato e Khahlanong le Ho Khaoha

Li-ceramic cores tse thehiloeng ho aluminium ke khetho e ka sehloohong bakeng sa ho etsa matsete a turbine blade. Litlhoko tsa mantlha tsa ts'ebetso:

1. Refractoriness e phahameng: Hanela mocheso o ka holimo ho 1500 ° C ntle le ho nolofatsa nakong ea ho tšela alloy.
2. Katoloso e tlase ea mocheso (ka tlase ho 4×10⁻⁶/K) ho qoba ho phatloha ho hoholo ha mocheso le ho hoholeha ho hoholo.
3. Matla a itekanetseng a ho feto-fetoha (> 15 MPa) le monyetla o motle oa ho khoneha bakeng sa ho tlosoa ha lik'hemik'hale ka mor'a ho lahla.

Litharollo tsa bohlokoa tsa anti-fracture:

• Kenya likhopo tse tšehetsang likarolong tse telele le tse tšesaane tsa mantlha ho hanela tšusumetso ea phallo ea tšepe.
• Bapisa coefficient ea katoloso ea mocheso lipakeng tsa ceramic core le superalloy ho qoba ho phatloha ho sa tsamaisaneng ha mocheso.
• Laola core sintering shrinkage ka tlase ho 5% ho boloka botsitso ba sebopeho sa kanale sa kahare.

5. Precision Machining Tolerance & Processing Scheme

Le likheo tsa matsete tse haufi le sebopeho sa marang-rang li hloka mochini o nepahetseng oa 5-axis CNC ho fihlela profil ea aerodynamic le litlhoko tsa mamello ea kopano. Machining a Superalloy a na le bothata bo boholo ba mosebetsi, bo tlamehang ho laoloa ka mekhoa e ntlafalitsoeng ea ho itšeha.

5.1 Litlhokahalo tsa Mamello ea Dimensional bakeng sa Likarolo tsa Bohlokoa

1. Sebaka se kobehileng sa Airfoil: Mamello ea boemo ba GD&T ± 0.02 ~ 0.05 mm; bokaholimo ba Ra 0.8–1.6 μm ho fokotsa tahlehelo ea khohlano ea moea.
2. Motso oa lehare la sefate sa fir: Tensile kopano holim'a mamello ± 0.015 limilimithara; top finish Ra 0.2-0.8 μm ho qoba ho kopana le mokhathala tlas'a mojaro oa cyclic.
3. Sebaka sa ho tiisa sethaleng: Ho mamellana ha flatness ka hare ho 0,02 mm; taolo e tiileng ea ho batalla e thibela ho lutla ha khase pakeng tsa mela ea lehare.
4. Likoti tse pholileng tsa filimi: Ho mamella boemo ± 0.03 mm; mamello ea lesoba bophara ± 0.02 limilimithara, haholo sebetswa ke EDM ho ntša machining motlakase.

5.2 Mokhoa oa ho sebetsa le khetho ea lisebelisoa

Ts'ebetso e tloaelehileng ea ts'ebetso ea li-blade tsa turbine:

1. Kalafo ea ka mor'a ho lahlela: Ho tlosoa ha likhetla, ho ntša likhetla, ho qhomisoa ha lithunya, le ho teteka ha HIP.
2. Ho sebetsa ka thata: Tlosa chelete e ngata ea ho lahlela ka li-cutters tsa carbide tse koahetsoeng, boloka moeli oa ho qetela oa 0.2-0.4 mm.
3. Semi-finishing: 5-axis linkage milling ea libaka tse kobehileng tsa moea, laola ho senyeha ha machining ho bakoang ke mocheso o sehang.
4. Finishing: Ho sila ka lebelo le phahameng kapa ho sila ka holim'a metsi ho fihlela mamello ea ho qetela le ho ba mahoashe holimo.
5. Machining a bobeli: EDM e phunya masoba a manyane a filimi e pholileng holim'a lehare le ka pele le ka morao.

Litlhahiso tsa ho lokisa li-superalloys:

• Sebelisa lebelo le tlase la ho itšeha ho fokotsa boima ba mosebetsi; boloka sekhahla sa phepo se phahame ka mokhoa o utloahalang ho khaola lera le thata la bokaholimo.
• Qoba makhetlo a mangata a sa tebang a ho qetela a bentšang letlalo le thata le ho potlakisa ho roala ha lisebelisoa.

5.3 Taolo ea Litumello ho Fokotsa Sekhahla sa Scrap

Ho etsa deformation ho ke ke ha qojoa, ka hona, ho tlameha ho nahanoa ka tumello ea machining e sa lekanang ha u beha boholo bo se nang letho:

• Eketsa tumello ea ho sebetsa ka 0.3-0.5 mm ntlheng ea lehare, moeli o ka morao le libaka tse nang le mabota a masesaane a nang le ho honyela ho hoholo.
• Sebelisa 3D-blue-light scanning ho lekanya deformation ea 'nete pele u sebetsa, ebe u lokisa lenaneo la CNC ho lefella ho kheloha ha sebaka sa lehae.

6. NDT & Litekanyetso tsa Tlhahlobo ea Boleng bakeng sa Li-Blades tsa Cast Turbine

Sistimi e felletseng ea tlhahlobo e akaretsa netefatso ea thepa, litekanyo tsa boholo, tlhahlobo e sa senyeheng, le tlhahlobo ea boleng ba bokaholimo, e leng tlamo bakeng sa likarolo tse hanyetsanang le mocheso o phahameng tse sebelisoang ho li-turbine tsa khase.

6.1 Lintho tsa Teko e sa Senyeheng (NDT).

1. Teko ea Radiographic (tlhahlobo ea RT / X-ray): Tlhahlobo ea 100% ho fumana porosity ea ka hare ea shrinkage, li-inclusions le mefokolo e koalehileng ka har'a lehare la moea le motso.
2. Tlhahlobo ea Ultrasonic (UT): Sheba likarolo tsa metso e teteaneng bakeng sa mefokolo e tebileng ea ka hare eo X-ray e ke keng ea e tseba.
3. Teko ea Penetrant (PT): Lekola libaka tsohle tsa li-blade bakeng sa mapetso a manyane, haholo mathōkong a foil le likhoele tsa lehare.
4. CT scanning ea indasteri: Netefatsa botšepehi ba litemana tse pholileng tsa ka hare, fumana masala a mantlha le likoti tse pholileng tse koetsoeng tse ke keng tsa bonoa ke mekhoa e meng ea NDT.

Netefatso e ntseng e emetse: Litekanyetso tsa NADCAP aerospace NDT le limaraka tsa ho amohela bofokoli bakeng sa mehala ea lehare la turbine.

6.2 Tlhahlobo ea Boemo le Bokaholimo

• CMM (Mochini o lekanyang oa Coordinate): Tekanyo e felletseng ea 3D ea profaele ea foil ea moea, boholo ba motso oa lehare le boemo ba lesoba la filimi e pholileng ka ho nepahala ha tekanyo ho fihla ho ± 0.002 mm.
• Ho hlahlojoa ha laser ea Optical: Bapisa sebopeho sa lehare sa 'nete le mohlala oa CAD ho lekanya ho kheloha ha profil ka kakaretso.
• Teko ea ho ba mahoashe holimo: Netefatsa boleng ba Ra holim'a foil ea moea, metso le libaka tse tiisang.
• Tlhahlobo ea Metallurgical: Lekola sebopeho sa lijo-thollo ho netefatsa boleng ba lijo-thollo tsa equiaxed / directional solidified / single-crystal.

7. Lipotso Tse Botsoang Khafetsa

Q1: Na motsoako o tloaelehileng oa equiaxed alloy o ka nka sebaka sa mahare a kristale e le 'ngoe bakeng sa ts'ebeletso ea HPHT?
A: Che. Li-superalloys tse lekanang li na le meeli ea lijo-thollo tse fetohang lintlha tse fokolang tlas'a mocheso o phahameng le mojaro oa nako e telele. CMSX-4 e nang le kristale e le 'ngoe e felisa meeli ea lijo-thollo mme e boloka botsitso bo ka holimo ho 1000 ° C, e ke keng ea nkeloa sebaka bakeng sa likhaba tsa karolo ea pele e chesang.

Q2: Ke botenya bo bokae ba lebota bo ka behoang bakeng sa li-blade tsa turbine tse pholileng?
A: Ka li-cores tsa ceramic tsa alumina tse hloekileng haholo le ho tšeloa ha vacuum, bonyane botenya ba lebota bo ka lahloang ke 0.5 mm. Moeli ona o fapana le geometry ea lehare le khetho ea alloy. Mabota a masesaane a tla lebisa ho tlatsitsoeng ho sa fellang le litefiso tse phahameng tsa likhechana.

Q3: Ke chelete e kae ea machining e lokelang ho bolokoa bakeng sa likheo tsa matsete?
A: Kabelo ea motheo ea unilateral ke 0.3-1.5 mm. Eketsa tumello ka limilimithara tse 0.3–0.5 libakeng tse nang le bofokoli bo boholo ba ho lahlela joalo ka malebela a lehare le mapheo a morao ho qoba khaello ea thepa ea lehae nakong ea mochini.

Q4: Ke mokhoa ofe oa ho hlahloba o ka bonang thibelo ea ka hare ea litemana tse pholileng?
A: Ho hlahlojoa ha Indasteri ea CT ke mokhoa o tšepahalang ka ho fetisisa oa ho lekola ho koaloa ha kanale ea pholileng ka hare, masala a mantlha le botenya bo sa lekaneng ba lebota ntle le ho senya ho lahla. X-ray e khona ho bona litšitiso tse kholo feela, athe masala a manyane a mantlha a ka bonoa feela ka ho hlahlojoa ha CT.

8. Qetello & Mehato e Latelang

Ho etsa li-blade tsa turbine tse tšoanelehang ho hloka taolo e hokahaneng ea khetho ea thepa, ho lahlela ka nepo, ho bopa ha mantlha, ho etsa mochini oa 5-axis le tlhahlobo e felletseng ea NDT.

1. Bapisa limaraka tsa superalloy ka tieo le mocheso o sebetsang le mecha ea litaba e senyang; khetha Inconel 718 / 625 bakeng sa tikoloho e senyang ea mocheso o mahareng, le li-alloys tsa kristale / e le 'ngoe bakeng sa maemo a phahameng a mocheso a HPHT.
2. Adopt vacuum investment casting ka ho tiisetsoa ka tataiso le kalafo ea HIP ho fokotsa porosity ea kahare le deformation.
3. Rala li-cores tsa ceramic tse nang le katoloso e tlase ea mocheso le matla a lekaneng ho qoba ho robeha ha mantlha le ho netefatsa ho etsoa ka botlalo ha liteishene tsa pholileng tsa kahare.
4. Boloka chelete e loketseng ea machining ho latela deformation ea ho lahla; sebelisa 5-axis CNC le EDM ho laola mamello ea profil le likoti tsa filimi tse pholileng ka nepo.
5. Kenya ts'ebetsong tlhahlobo e felletseng ea RT, UT, PT le CT e sa senyeheng hammoho le tlhahlobo ea sebopeho sa CMM ho netefatsa boleng ba lehare.

Haeba u na le lits'oants'o tsa turbine blade 2D / 3D mme u hloka tlhahlobo ea lisebelisoa, moralo oa ts'ebetso ea ho lahla, tlhahlobo ea mamello ea mochini kapa mantsoe a qotsitsoeng bakeng sa li-blade tsa turbine tse nepahetseng, o ka fana ka lintlha tsa hau tsa tekheniki bakeng sa tlhahlobo e felletseng ea boenjiniere.