MANUFACTURE

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