Manufacturing of automated complexes for production of GTE cast intricate-shaped parts with directional and single-crystal structures
For realization of promising technological processes VIAM has developed and manufactures vacuum melting-pouring units with principally new thermal assemblies meeting the requirements of modern technological processes and equipped with automated computer control systems.
Units for high-gradient directional solidification provide:
- cooling efficiency of castings is 2.5-5 times higher than that implemented in foreign units by Bridgemen method;
- obtaining of homogeneous fine-dendritic structure in castings;
- 10-20% increase of strength and fatigue characteristics of alloys;
- increase of yield in terms of blades macrostructure.
The following units are applied for serial production of blades with directional and single-crystal structures under condition of temperature gradient G ? 100 degree/cm: UVNK-9A – for blade casting up to 300 mm;
Technical data of UVNK-9A unit
|
Power consumption, kW
|
250
|
|
Operating environment: vacuum, Pa | mm Hg
|
6,65·10-1 | 5 - 10-3
|
|
Mass of metal in crucible, kg
|
10 – 15
|
|
Metal temperature in crucible, °С
|
1700
|
|
Mould preheating furnace temperature, °С
|
1700
|
|
Capacity of crystallizer with liquid aluminum, kg
|
80
|
|
Temperature of liquid-metal cooler, °С
|
750-800
|
|
Vertical movement velocity, mm/min
|
0,1 – 10, 1,4 – 170
|
|
Mould dimensions, mm
|
130х260х350
|
|
Maximum temperature gradient, °С/cm
|
60 – 80
|
|
Productivity, moulds/working cycle
|
2
|
|
Occupied area, m2
|
47
|
UVNK-9 unit
UVNK-10 – for casting of large-sized (up to 800 mm) blades, flaps and spacers of jet nozzle with thrust vector control, intricate-shaped billets for isothermal forging of small-sized engine disks.
Technical data of UVNK-10 unit
|
Power consumption, kW
|
450
|
|
Operating environment:: vacuum, Pa | mm Hg
|
6,67·10-1 | 5 - 10-3
|
|
Mass of metal in crucible, kg
|
60 or 80
|
|
Metal temperature in crucible, °С
|
1700
|
|
Mould preheating furnace temperature, °С
|
1700
|
|
Capacity of crystallizer with liquid aluminum, kg
|
260
|
|
Temperature of liquid-metal cooler, °С
|
700-800
|
|
Vertical movement velocity, mm/min
|
2 - 120
|
|
Maximum working dimensions of moulds preheating furnace, mm
|
250х700х800
|
|
Maximum temperature gradient, °С/cm
|
50 – 60
|
|
Productivity, pcs. blades/24 hours
|
1-3
|
|
Occupied area, m2
|
65
|
UVNK-10 unit
UVNK-15 – for casting of large-sized (up to 600 mm) blades with directional and single-crystal structure for aviation GTE and power GTU.
Technical data of UVNK-15 unit
|
Power consumption, kW
|
430
|
|
Operating environment: vacuum, Pa | mm Hg
|
6,65·10-1 | 5 - 10-3
|
|
Mass of metal in crucible, kg
|
15-25
|
|
Metal temperature in crucible, °С
|
1700
|
|
Mould preheating furnace temperature, °С
|
1700
|
|
Vertical movement velocity, mm/min
|
2 – 100
|
|
Maximum dimensions of casting, mm
|
600
|
|
Maximum temperature gradient, °С/cm
|
60 – 80
|
|
Productivity, pcs/24 hours
|
3–12
|
|
Occupied area, m2
|
50
|
UVNK-15 unit
UVNS-6 – commercial high-gradient unit (gradient up to 200 °С/cm) with sluice chamber for casting of hot duct parts of GTE with directional and single-crystal structure (length up to 200 mm).
The unit is equipped with movable heat shields that separate the heating zone from the cooling zone (liquid-metal cooler - tin). The unit is equipped with an industrial computer based system to control main parameters of the production process.
Technical data of UVNS-6 unit
|
Power consumption, kW
|
200
|
|
Operating environment: vacuum, Pa | mm Hg
|
6,65·10-1 | 5 - 10-3
|
|
Weight of metal in crucible, kg
|
8-15
|
|
Metal temperature in crucible, °С
|
1700
|
|
Mould preheating furnace temperature, °С
|
1700
|
|
Vertical movement velocity, mm/min
|
1 – 170
|
|
Working dimensions of moulds preheating furnace, mm
|
140 х 360 х 400
|
|
Maximum temperature gradient, °С/cm
|
150-200
|
|
Crystallizer capacity with liquid tin, kg
|
150
|
|
Temperature of liquid-metal cooler, °С
|
300
|
|
Productivity, moulds/working cycle
|
2
|
|
Occupied area, m2
|
40
|
Industrial high-gradient UVNS-6 unit
