重型燃机定向结晶空心叶片凝固过程的实验与模拟

doi:10.11868/j.issn.1001-4381.2015.001320

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摘要

采用ProCAST软件系统研究HRS(High Rate Solidification)与LMC(Liquid Metal Cooling)工艺下, 不同工艺参数对重型燃机用大型定向结晶空心叶片凝固过程的影响。结果表明:与HRS工艺相比, LMC工艺下叶片的糊状区宽度更小, 固/液界面形状更加平直。LMC工艺下叶片的纵向温度梯度约为HRS工艺下的3倍; 利用LMC工艺制备该燃机叶片时冷却速率为0.3~2.00℃/s, 远高于HRS工艺时的冷却速率(0.05~0.16℃/s); LMC工艺下, 采用低的保温炉温度仍可保证叶片获得高的温度梯度和冷却速率; 而为避免缘板处杂晶对原始晶粒的阻碍, HRS工艺应当采用高的保温炉温度与更低的抽拉速率。实验与模拟结果均表明:与HRS工艺相比, 利用LMC工艺制备的燃机叶片, 枝晶组织显著细化。

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关键词 ：定向凝固, 工艺优化, 数值模拟, 燃机叶片

Abstract：

The effect of different process parameters on solidification of industrial gas turbine hollow blades via HRS(High Rate Solidification) and LMC(Liquid Metal Cooling) was studied by ProCAST software.The results show that the paste zone via LMC process is much narrower than that by HRS process and the shape of the S/L(solid/liquid) interface is more flat.The axial thermal gradient of the blade by LMC process is about three times higher than that by HRS process.The cooling rate of the blade is 0.3-2.00℃/s by LMC process, which is far higher than that by HRS process(0.05-0.16℃/s).In LMC process, low holding temperature can still ensure high temperature gradient and cooling rate of the blade; while in order to avoid blocking of stray grains to the initial grains at the platform of the blade, HRS process should adopt high holding temperature and lower withdrawal rate.The calculated and the measured results show that compared with the blade prepared by HRS process, the PDAS(primary dendrite arm spacing) is much finer in the blade prepared by LMC process.

Key words： directional solidification process optimization numerical simulation IGT blade

收稿日期: 2015-10-31 出版日期: 2018-01-18

中图分类号:

TG132

基金资助:国家重大科学仪器设备开发专项资助项目(2012YQ22023304);国家自然科学基金(51631008)

通讯作者: 卢玉章 E-mail: yzlu@imr.ac.cn

作者简介: 卢玉章(1984-), 男, 博士, 助理研究员, 主要研究方向为LMC定向凝固过程工艺优化, 联系地址:沈阳市沈河区文化路72号(110016), E-mail:yzlu@imr.ac.cn

引用本文:

卢玉章, 熊英, 彭建强, 申健, 郑伟, 张功, 谢光. 重型燃机定向结晶空心叶片凝固过程的实验与模拟[J]. 材料工程, 2018, 46(1): 8-15.
Yu-zhang LU, Ying XIONG, Jian-qiang PENG, Jian SHEN, Wei ZHENG, Gong ZHANG, Guang XIE. Simulation and Experiment of Solidification Process for Directionally Solidified Industrial Gas Turbine Hollow Blades. Journal of Materials Engineering, 2018, 46(1): 8-15.

链接本文:

http://jme.biam.ac.cn/CN/10.11868/j.issn.1001-4381.2015.001320 或 http://jme.biam.ac.cn/CN/Y2018/V46/I1/8

Table 1 模拟所用的工艺参数

Fig.1 HRS工艺下, 不同抽拉速率时, 叶片110mm(1), 180mm(2), 240mm(3)和280mm(4)位置处的固/液界面形态
(a) 3mm/min; (b) 5mm/min

Fig.2 LMC工艺下, 不同抽拉速率时, 叶片110mm(1), 180mm(2), 240mm(3)和280mm(4)处的固/液界面形态
(a)5mm/min; (b)10mm/min; (c)12mm/min

Fig.3 不同工艺下叶片的纵向温度梯度

Fig.4 HRS工艺下抽拉速率对叶片冷却速率的影响

Fig.5 不同工艺下, 保温炉温度为1480℃(1), 1500℃(2)和1520℃(3)时固/液界面的形状
(a) HRS; (b) LMC

Fig.6 LMC以及HRS工艺下保温炉温度对纵向温度梯度的影响

Table 2 保温炉温度对冷却速率的影响

Fig.7 模拟(a)以及实验(b)所得到的叶片缘板处的晶粒组织

Fig.8 不同工艺下叶身(1)榫头(2)的典型枝晶组织 (a)HRS; (b)LMC

Fig.9 叶片PDAS的LMC工艺模拟(LMC-M)、实验结果(LMC-E)与HRS工艺实验结果的对比

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