IiBladi zeTurbine: Izinto zokuphosa, ukunyamezela kunye neeMfuno zoMatshini ezichanekileyo 

Iibhleyidi ze-turbine zisebenza phantsi kobushushu obuphezulu bokuhamba kwerhasi, uxinzelelo lwebhayisikile ye-thermal, kunye nemithombo yeendaba eyonakalisayo, ibenza ibe yenye yezona zinto zingumngeni wokuphosa ngokuchanekileyo kwishishini lamandla. Uninzi lwamaqela okuthenga kunye nobunjineli ajongene nemingeni yemveliso engaguqukiyo xa kufunwa amagqabi einjini yomoya: iifoyile zomoya ezinodonga olucekethekileyo zinengxaki yokucutheka kunye noguquko, amajelo okupholisa angaphakathi antsonkothileyo akhokelela ekwaphukeni okungundoqo, kwaye imathiriyeli ye-superalloy idala ukuqina komatshini kunye nemingeni yolawulo lonyamezelo olungqongqo.

Esi sikhokelo sibandakanya ukukhethwa kwezinto ze-alloy, ulawulo lwenkqubo yotyalo-mali, ukupholisa imida yesakhiwo setshaneli, imigangatho yokunyamezela i-dimensional, iindlela ezichanekileyo ze-machining, kunye nemithetho yokuhlola epheleleyo ye-NDT yee-blades ze-turbine. Ijolise ekwenzeni umzobo osekelwe kwi-blade, kukunceda unciphise ukulahlwa kwenkunkuma, ukulawula isibonelelo somatshini, kwaye unqande ukuphinda kusetyenzwe ngeendleko eziphezulu kwiindawo ezinobushushu obuphezulu kunye neendawo ezikwaziyo ukubola.

1. IiMeko zokuSebenza kunye neMiceli mngeni yoMveliso yeeBladi zeTurbine

Iibhleyidi ze-iturbine zihamba phantsi kobushushu obungapheliyo, ukukhwela ibhayisekile ngokushushu, kunye ne-sulfide corrosion. Iiblayidi zeinjini yegesi yenqanaba lokuqala zinokugcina inkonzo yexesha elide ngaphezulu kwe-900°C. Ukwandiswa okuphindaphindiweyo kwe-thermal kunye nokucutha kudala i-deformation ye-creep kunye ne-thermal fatigue cracks.

Ubunzima bejometri buphakamisa ngokukhawuleza ubunzima bokwenza:

• Ubukhulu bodonga lwe-airfoil ebhityileyo (kaninzi ngaphantsi kwe-1 mm) ibangela ukugcwala okulambathayo kwe-alloy etyhidiweyo kunye nokuqiniswa okungalinganiyo.
• Iipaseji zokupholisa zangaphakathi ezintsonkothileyo zifuna i-ceramic cores edibeneyo, eguquka ngokulula okanye iqhekeza ngexesha lokugalela.
• Imiphezulu egobileyo enefomu ekhululekileyo ayinakuveliswa kukugalelwa kwesanti eqhelekileyo. Kuphela ukugaywa okuchanekileyo okufunxayo kunokuzisa izikhewu zokuphosa ezikufutshane ne-net-shape.
• I-nickel-based superalloys ibonisa umsebenzi obandayo oqinileyo. Oku kukhawulezisa ukunxitywa kwesixhobo kunye nokunciphisa ukuchaneka komda ngexesha lomatshini we-CNC.

Amanqaku aphambili okuvelisa iintlungu abandakanya ukuphosa i-porosity, i-core offset, ukuphazamiseka kweprofayili ye-blade, i-machining deformation, kunye nemingxuma yefilimu yokupholisa engafanelekanga ukuchaneka kwe-dimensional.

2. UKhetho lweMathiriyeli ye-Alloy ye-High-Temperature yeeBlades ze-Cast Turbine

Ukukhetha i-superalloy efanelekileyo sisiseko sobomi benkonzo ye-blade ende. Umgangatho wezinto eziphathekayo kufuneka uhambelane nobushushu bokusebenza, indawo engcolisayo, kunye neemfuno zokuxhathisa izinambuzane. Eli candelo lijolise kwi-nickel-based superalloys esetyenziswa ngokubanzi phosa amaphiko einjini.

2.1 AMabanga eSuperalloy aPhambili kwiiBladi zeTurbine

• I-Inconel 718 (UNS N07718)
  Ubushushu benkonzo eqhubekayo ukuya kuthi ga kwi-700°C, ngamandla agqwesileyo okuqina kunye nokusebenza okuphakathi kokurhubuluza. Isetyenziswa kakhulu kwiiblayidi zeinjini yobushushu obuphantsi naphakathi kunye nee-compressor blades, ezinikezela ukuxhathisa okulungileyo kwigesi emuncu kunye nomhlwa omanzi.
• I-Inconel 625 (UNS N06625)
  Ukuchasana okunamandla kwi-pitting kunye ne-crevice corrosion, ehambelana ne-NACE MR0175 imigangatho yenkonzo emuncu. Isebenza ngokuthe ngcembe ukuya kuthi ga kwi-650°C kwaye ilungele iincakuba ezivezwe kwiimeko zerhasi enomhlwa.
• Rene 80
  I-common equiaxed cast superalloy enamandla obushushu obuphezulu kunye nokumelana ne-oxidation, eyilelwe iincakuba zeinjini ye-injini ezisebenza ngaphantsi kwe-950°C.
• I-CMSX-4 (Ingxubevange yeCrystal enye)
  Inqanaba eliphezulu elixhathisayo kwi-HPHT yamagqabi enqanaba lokuqala. Inkonzo eqhubekayo inokufikelela kwi-1150 ° C ngaphandle kokuphumla okucacileyo kwe-creep. Ukuqiniswa kolwalathiso kuphelisa imida yeenkozo ukuphucula ukuzinza kobushushu obuphezulu.

2.2 IMithetho yoKhetho lweMathiriyeli esekwe kubume beNkonzo

1. Irhasi emuncu emanzi kunye neemeko zokubola kwamanzi olwandle: Khetha i-Inconel 625 ukuze uxhathise umhlwa (iindawo ezikwaziyo ukuginya).
2. Amagqabi ombane wokuvelisa amandla obushushu aphakathi (≤700 ° C): I-Inconel 718 lukhetho olungabizi kakhulu olunokulungelelanisa kunye nokusebenza koomatshini.
3. Ubushushu obuphezulu be-injini yerhasi amagqabi amacandelo ashushu (950–1150 ° C): Yamkela i-Rene 80 equiaxed casting okanye i-CMSX-4 enye-crystal directional directional solidification casting for anti-creep performance.
4. Kuphephe ukucaciswa ngokugqithisileyo kwebakala: Ingxubevange yekristale enye izisa iindleko zokuphosa eziphezulu kakhulu; zisebenzise kuphela kwezona ndawo ziphezulu zobushushu beblade.

Ukuqinisekiswa okulindileyo: Imigangatho yempahla ye-ASTM echanekileyo, ibakala le-NACE corrosion kunye nedatha ye-creep rupture yexesha elide kwibakala ngalinye le-alloy.

3. IziLawuli zoTyalo-mali oluchanekileyo kwiiBladi ze-Turbine

Ukuphosa ngokuchanekileyo (ukuphosa utyalo-mali / ukulahlwa kwewax elahlekileyo) kuphela kwetekhnoloji yetekhnoloji esele ikhulile ekuveliseni iincakuba zeinjini yeinjini enomgongxo ezinamatshaneli okupholisa angaphakathi. Ukulawulwa kwenkqubo engalunganga kuya kukhokelela ekuncipheni kwe-porosity, ukufuduka okungundoqo, kunye nokuphazamiseka kweprofayili ye-blade.

3.1 Ubunzima obuphambili kwiBlade Investment Casting

1. Ukuzaliswa kodonga olubhityileyo: I-superalloy enyibilikisiweyo iqina ngokukhawuleza. Amacandelwana efoyile yomoya obhityileyo athande ukwenza ukuvaleka okubandayo kunye nokungagcwaliswa okungaphelelanga.
2. Uzinzo lwe-Ceramic core: I-cores edibeneyo iqhekeza okanye i-shift phantsi kwempembelelo yetsimbi yobushushu obuphezulu, okukhokelela ekuvinjweni okanye kwiipaseji zokupholisa.
3. Ukuqina kokuqina: Ukupholisa okungalinganiyo kubangela ukutenxa kubukhulu obukhulu kunye ne-porosity yangaphakathi yokuncipha.
4. Ulawulo lwesakhiwo sokutya okuziinkozo: Iinkozo ezilinganayo zenza lula ngaphandle kokuqina, ukunciphisa ubushushu obuphezulu bokuphila.

3.2 Izilawuli zeNkqubo yokuSasa ngeMilo ekufutshane ne-Net-Shape

• Ukunyibilika kwevacuum kunye nokugalela: Nyibilikisa i-nickel superalloys phantsi kwe-vacuum ephezulu yokunciphisa umxholo we-oksijini kwaye ugweme iziphene zokufakwa kwe-oxide. Preheat i-ceramic shell mold ukuya kwi-900-1100 ° C ukuphucula ukunyibilika kwesinyithi.
• Ulawulo lokuqinisa umkhombandlela: Misela i-gradient epholileyo elawulwayo (i-10-50 ° C / min izinga lokupholisa) ukwenza iinkozo zekholomu okanye izakhiwo ze-crystal eyodwa, eziphucula kakhulu ukuchasana nokunyuka kweqondo lokushisa.
• I-HIP eshushu isostatic icinezela: Phatha i-blank blanks nge-HIP ukuvala i-micro-pores yangaphakathi kunye ne-shrinkage cavities, ukuphucula ukuxinana kwangaphakathi kunye nokusebenza kokukhathala.
• Imbuyekezo yokuncipha kwepateni yewax: Ukuseta kwangaphambili isantya sokuncipha kwesikhunta (malunga ne-1.6% -1.7% yesalathiso sobude) ukuphelisa ukuchithwa kwe-casting kunye nokulawula ukuphambuka kwe-dimensional jikelele.

3.3 Isiseko soNyamezelo lokuSasa kwiiBleyi zeTurbine

Ukuphosa ukunyamezela okungenanto kulandela i-ISO 8062 kunye nemigangatho ye-VDG P690. Ngotyalo-mali-i-injini yokuphosa izikhewu zokuphosa izikhewu:

• Iprofayile yomoya etenxileyo: ±0.30 mm emva kwembuyekezo yokuncipha.
• Isibonelelo esicetyiswayo somatshini we-unilateral: 0.3-1.5 mm; Isibonelelo esityebileyo esibekelwe kwincam yencakuba ekhubazekileyo kunye neendawo zomphetho.
• Ukunyamezelana kobunzima bodonga lweencakuba ezikroliweyo: ±0.15 mm kumacandelo anodonga olucekethekileyo.

Ukuqinisekiswa okulindileyo: I-VDG epheleleyo ye-P690 amabakala okunyamezela kunye namaxabiso achanekileyo esibonelelo somatshini kwiisayizi ezahlukeneyo ze-blade.

4. IiMfuno zokuSasa kwiBlade yaNgaphakathi yokuPholisa iZakhiwo

Iibhleyidi zeinjini zomgongxo zixhomekeke kwiitshaneli zokupholisa zangaphakathi ukunciphisa ubushushu bencakuba. Umgangatho wepaseji zokupholisa umisela ngokuthe ngqo ukusebenza kakuhle kwe-injini ye-thermal, kwaye ukuveliswa okungundoqo kugqiba ukuba isakhiwo sangaphakathi sinokubunjwa ngokupheleleyo.

4.1 Uyilo oluQhelekileyo lweSitishi sokuPholisa kunye neMida yokuVelisa

Izakhiwo zokupholisa eziqhelekileyo ziquka i-serpentine multi-pass channels, i-front-edge edge inmpingement cavities, i-trailing-edge emxinwa, kunye ne-pin-fin turbulence structures.

Unyino olungundoqo:

• Ubuncinci obunobunzima bodonga olunokukhutywa kunye ne-ceramic cores kunye nokugalelwa kwevacuum: 0.5 mm. Eli xabiso lixhomekeke kubukhulu be-blade kunye nohlobo lwe-alloy.
• Ubuncinci beempawu ezingundoqo: i-0.5 mm ububanzi kwii-cores ezincinci zefilimu zokupholisa; Iicores ezibhityileyo kakhulu ziya kwaphuka ngexesha lokugalelwa.
• Iipaseji ze-slit ezinqamlekileyo zifuna amandla aphezulu aphezulu kunye nokwandiswa kwe-thermal ephantsi ukukhusela i-deformation phantsi kobushushu obuphezulu.

4.2 Ukwenziwa kweNqanaba eliPhambili kunye naManyathelo okuChasekisa ukwaphuka

I-alumina-isekwe kwi-ceramic cores lolona khetho luphambili kwi-turbine blade investment casting. Iimfuno zokusebenza eziphambili:

1. I-refractoriness ephezulu: Ukuxhathisa amaqondo okushisa angaphezu kwe-1500 ° C ngaphandle kokuthambisa ngexesha lokugalela i-alloy.
2. I-coefficient yokwandisa i-thermal ephantsi (ngaphantsi kwe-4×10⁻⁶/K) ukunqanda ukuqhekeka koxinzelelo lwe-thermal kunye ne-dimensional drift.
3. Amandla aphakathi kwe-flexural (> 15 MPa) kunye nokuvuza okulungileyo ekususweni kweekhemikhali emva kokuphosa.

Izisombululo eziphambili zokunqanda ukwaphuka:

• Yongeza iimbambo ezixhasayo kumacandelo amade kunye namancinci angundoqo ukumelana nefuthe lokuhamba kwesinyithi.
• Tshatisa umlinganiso wokwandiswa kwe-thermal phakathi kondoqo we-ceramic kunye ne-superalloy ukunqanda ukuchaneka kokwanda kwe-thermal.
• Lawula i-core sintering shrinkage engaphantsi kwe-5% ukugcina uzinzo lwe-channel dimensional yangaphakathi.

5. UkuNyamezelwa koMachining okuchanekileyo kunye neNkqubo yokuLungisa

Nokuba kufutshane-netha-imilo yokuphosa utyalo-mali ezingenanto zifuna i-5-axis CNC echanekileyo machining ukuhlangabezana neprofayili ye-aerodynamic kunye neemfuno zokunyamezela indibano. Umatshini weSuperalloy unobunzima bokuqina komsebenzi, ekufuneka kulawulwe ngeparameters zokusika eziphuculweyo.

5.1 IiMfuno zoNyamezelo oluBalulekileyo kwiiMpawu eziPhambili

1. Umphezulu ogobileyo womoya: Ukunyamezela iprofayili ye-GD&T ±0.02~0.05 mm; uburhabaxa bomphezulu iRa 0.8–1.6 μm ukunciphisa ilahleko yokungqubana komoya.
2. Ingcambu yomthi wefir-blade: Ukunyamezela indibano ye-tensile ± 0.015 mm; umphezulu ukugqiba i-Ra 0.2-0.8 μm ukuphepha ukudinwa koqhagamshelwano phantsi komthwalo we-cyclic.
3. Umphezulu wokutywina weqonga: Ukunyamezela kwe-Flatness ngaphakathi kwe-0.02 mm; ulawulo olungqongqo lwe-flatness luthintela ukuvuza kwerhasi phakathi kwemiqolo yeencakuba.
4. Ukupholisa imingxuma yefilimu: Ukunyamezela isikhundla ± 0.03 mm; ukunyamezela kwedayamitha yomngxuma ± 0.02 mm, ubukhulu becala icutshungulwa yi-EDM yokukhupha umbane.

5.2 Indlela yoMatshini kunye noKhetho lweZixhobo

Ukusetyenzwa okusemgangathweni kweeblade zeinjini yomoya:

1. Unyango lwasemva kokuphoswa: Ukususwa kweqokobhe, ukutyhefa okungundoqo, ukudutyulwa kokudubula, kunye nokuxinana kwe-HIP.
2. Umatshini orhabaxa: Susa uninzi lwezibonelelo zokugalela ngee-carbide cutters ezigqunyiweyo, gcina i-0.2-0.4 mm ye-semi-finishing margin.
3. Semi-finishing: 5-axis linkage milling of airfoil curved surfaces, lawula ukuguqulwa komatshini okubangelwa kukusika ubushushu.
4. Ukugqiba: Ukugaya ngesantya esiphezulu okanye ukugaya umphezulu ukufikelela ukunyamezela iprofayili yokugqibela kunye noburhabaxa bomphezulu.
5. Umatshini wesibini: I-EDM yomba imingxunya emincinci yefilimu epholisayo kwincakuba ekhokelayo kunye neencam ezisemva.

Iingcebiso ngoMatshini kwi-superalloys:

• Sebenzisa isantya esisezantsi sokusika ukunciphisa ukuqina komsebenzi; gcina izinga lokutya liphezulu ngokufanelekileyo ukusika umaleko womphezulu oqinileyo.
• Kuphephe ukuphinda-phinda ukugqiba okungenzulu okudlulayo okupholisha kuphela ulusu oluqinileyo kunye nokukhawulezisa ukunxiba kwesixhobo.

5.3 Ulawulo lwezibonelelo zokunciphisa iRate ye-Scrap

I-deformation yokuphosa ayinakuthintelwa, ngoko ke isibonelelo esingalinganiyo somatshini kufuneka siqwalaselwe xa kumiselwa ubungakanani obungenanto:

• Ukwandisa isibonelelo somatshini nge-0.3-0.5 mm kwincam ye-blade, i-trailing edge kunye neendawo ezinodonga oluncinci kunye ne-shrinkage deformation enkulu.
• Sebenzisa ukuskena okuluhlaza okwesibhakabhaka kwe-3D ukulinganisa eyona nguquko yokuphosa phambi komatshini, emva koko ulungelelanise inkqubo ye-CNC ukubuyisela ukutenxa komgangatho wendawo.

6. I-NDT kunye neMigangatho yokuHlola uMgangatho weeBlades ze-Cast Turbine

Inkqubo yokuhlola epheleleyo ibandakanya ukuqinisekiswa kwezinto, umlinganiselo wobukhulu, uvavanyo olungonakalisi, kunye nokujonga umgangatho womphezulu, osisinyanzelo kwiindawo ezinobushushu obuphezulu obusetyenziswa kwiiinjini zegesi.

6.1 Izinto zoVavanyo olungangonakalisi (NDT).

1. Uvavanyo lweRadiographic (RT / uhlolo lweX-reyi): Ukuhlolwa kwe-100% ukufumana i-porosity yangaphakathi ye-shrinkage, inclusions kunye neziphene ezivaliweyo ezibandayo ngaphakathi kwe-blade airfoil kunye neengcambu.
2. Uvavanyo lweUltrasonic (UT): Qwalasela amacandelo ashinyeneyo engca yencakuba ukuze ufumane iziphene ezinzulu zangaphakathi ezingenako ukubonwa yiX-reyi.
3. Uvavanyo olungeneyo (PT): Jonga yonke imiphezulu yeblade ukubona iintanda ezincinci, ngakumbi kwimiphetho ye-airfoil kunye neengcambu zeengcambu.
4. Ukuskena kwe-CT yoshishino: Qinisekisa ukunyaniseka kweepaseji zokupholisa zangaphakathi, fumana i-residu engundoqo kunye nemigodi evaliweyo yefilimu yokupholisa engenakubonwa ngezinye iindlela ze-NDT.

Ukuqinisekiswa okulindileyo: imigangatho ye-NADCAP ye-aerospace ye-NDT kunye nesiphene sokwamkelwa kwamabanga okujulwa kweeblade ze-turbine.

6.2 Ukuhlolwa koMda kunye noMphezulu

• CMM (Lungelelanisa uMshini wokuMisa): Umlinganiselo ogcweleyo we-3D weprofayili ye-airfoil, ubungakanani bengcambu yeblade kunye nendawo yokupholisa ifilimu yomngxuma kunye nokuchaneka komlinganiselo ukuya ku-± 0.002 mm.
• I-Optical laser scanning: Thelekisa eyona milo yeblade kunye nemodeli ye-CAD ukulinganisa ukutenxa kwiprofayili iyonke.
• Uvavanyo loburhabaxa bomphezulu: Qinisekisa ixabiso le-Ra kwi-airfoil, ingcambu kunye neendawo zokutywina.
• Ukuhlolwa kweMetallurgical: Jonga ulwakhiwo lweenkozo ukuqinisekisa i-equiaxed / directional solidified / single-crystal grain quality.

7. Imibuzo Ebuzwa Rhoqo

I-Q1: Ngaba i-alloy eqhelekileyo ene-equiaxed ingathatha indawo ye-crystal blades enye yenkonzo ye-HPHT?
A: Hayi. I-equiaxed superalloys inemida yengqolowa eba ngamanqaku abuthathaka phantsi kobushushu obuphezulu kunye nomthwalo wexesha elide. I-CMSX-4 ye-crystal eyodwa isusa imida yeenkozo kwaye igcina ukuzinza kwe-creep ngaphezu kwe-1000 ° C, engenakuphinda ithathelwe indawo yamagqabi ashushu akwinqanaba lokuqala.

I-Q2: Bubuphi ubungqingqwa bodonga obuncinane obunokuphoswa kwiiblade ze-injini ye-injini yokupholisa?
A: Ngococeko oluphezulu lwe-alumina ye-ceramic cores kunye nokugalelwa kwe-vacuum, ubuncinci bodonga olunokulahlwa yi-0.5 mm. Lo mda uyahluka kunye nejometri ye-blade kunye nokukhethwa kwe-alloy. Iindonga ezincinci ziya kukhokelela ekuzalisweni okungaphelelanga kunye namazinga aphezulu e-scrap.

Q3: Singakanani isibonelelo somatshini ekufuneka sigcinelwe iindawo ezingenanto zotyalo-mali?
A: Isibonelelo esisisiseko se-unilateral yi-0.3-1.5 mm. Ukwandisa isibonelelo nge-0.3-0.5 mm kwiindawo ezine-deformation enkulu yokuphosa njengeengcebiso ze-blade kunye nemiphetho elandelwayo ukuphepha ukunqongophala kwezinto zendawo ngexesha lomatshini.

I-Q4: Yiyiphi indlela yokuhlola enokubona ukuvaleka kwangaphakathi kweepaseji zokupholisa?
A: I-Industrial CT scanning yeyona ndlela ithembekileyo yokuhlola ukuvaleka kweshaneli yokupholisa yangaphakathi, intsalela engundoqo kunye nobukhulu bodonga olungalinganiyo ngaphandle kokonakalisa ukuphosa. I-X-reyi inokubona kuphela izithintelo ezinkulu, ngelixa iintsalela ezingundoqo ezincinci zingachongwa kuphela nge-CT scanning.

8. Isiphelo & Amanyathelo Alandelayo

Ukuvelisa ii-blades ze-injini ye-turbine elungelelanisiweyo kufuna ulawulo olulungelelanisiweyo lokukhethwa kwezinto, ukuphosa ngokuchanekileyo, ukubumba okungundoqo okupholisa, i-5-axis machining kunye nokuhlolwa okupheleleyo kwe-NDT.

1. Tshatisa amabakala e-superalloy ngokungqongqo kunye nobushushu bokusebenza kunye nemidiya eyonakalisayo; khetha i-Inconel 718 / 625 yeendawo ezinobushushu obuphakathi, kunye ne-alloys ye-directional / enye-crystal kwiimeko eziphezulu ze-HPHT.
2. I-Adopt vacuum investment casting kunye nokuqina kolwalathiso kunye nonyango lwe-HIP ukunciphisa i-porosity yangaphakathi kunye ne-casting deformation.
3. Yila i-ceramic cores kunye nokwandiswa kwe-thermal ephantsi kunye namandla okwaneleyo ukuphepha ukuphuka okungundoqo kunye nokuqinisekisa ukubunjwa okupheleleyo kweetshaneli zokupholisa zangaphakathi.
4. gcina isibonelelo esifanelekileyo somatshini ngokwenkqubo yokuphosa; sebenzisa i-5-axis CNC kunye ne-EDM ukulawula ukunyamezela kweprofayili kunye nokupholisa imingxuma yefilimu ngokuchanekileyo.
5. Ukuphumeza uvavanyo olupheleleyo lwe-RT, i-UT, i-PT kunye ne-CT engonakalisi kunye nokuhlolwa kobukhulu be-CMM ukuqinisekisa umgangatho we-blade.

Ukuba une-turbine blade ye-2D / 3D imizobo kwaye ufuna ukuvavanywa kwezinto eziphathekayo, ukucwangciswa kwenkqubo yokuphosa, ukuhlalutya ukunyamezela komatshini okanye ukucaphuna okuqhelekileyo kwii-blade ze-injini ye-injini yokuphosa ngokuchanekileyo, ungangenisa iinkcukacha zakho zobugcisa kuphononongo olupheleleyo lobunjineli.