CN103464690A - Manufacturing method of ceramic mold of monocrystal turbine blade - Google Patents
Manufacturing method of ceramic mold of monocrystal turbine blade Download PDFInfo
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- CN103464690A CN103464690A CN2013103767044A CN201310376704A CN103464690A CN 103464690 A CN103464690 A CN 103464690A CN 2013103767044 A CN2013103767044 A CN 2013103767044A CN 201310376704 A CN201310376704 A CN 201310376704A CN 103464690 A CN103464690 A CN 103464690A
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Abstract
The invention discloses a manufacturing method of a ceramic mold of a monocrystal turbine blade. The integral ceramic mold with a special spiral crystal selector is designed and manufactured according to grain orientation requirements of the monocrystal turbine blade. When orientated solidification is used for manufacturing the monocrystal blade, the thickness of a shell at an abrupt change in a section (such as a connecting part between a blade body and a marginal plate) is increased, and the heat transfer capacity is reduced, so that crystal defects such as stray crystals are caused easily. On the premise that the casting strength requirements are met, with the adoption of topological optimization and design of a heat transfer passage, the heat transfer capacity of the mold is improved, and a temperature gradient on the leading edge of a solid-liquid interface during the orientated solidification is increased, so that the whole blade can obtain a good monocrystal organization.
Description
Technical field
The invention belongs to the quick cast field, relate to a kind of manufacture method of single crystal turbine blade ceramic-mould.
Background technology
Single crystal blade is based on a kind of blade of eliminating crystal boundary texture along the blade direction fully that directional solidification technique develops.There is good high temperature and creep resistance, heat resistanceheat resistant mechanical fatigue, antioxidant anticorrosive performance and higher hold warm ability.In order to obtain high-quality metal single crystal, at first in metal bath, form a monocrystalline core.At present, in the manufacture of single crystal turbine blade, mainly adopt the spiral crystal selector to obtain monocrystalline core.The spiral crystal selector is the cavity arranged in the bottom of foundry goods body, and it is comprised of graining section and the brilliant section of screw selecting.While manufacturing single crystal blade by the model casting mode, for obtaining complete casting prototype, the wax-pattern of spiral crystal selector need be assembled on the blade wax-pattern in the past, expend time in, and precision is difficult to guarantee.So, develop a kind of resin mould of the single crystal turbine blade with spiral crystal selector integrated manufacturing method particularly important, can well solve in the past the model casting wax-pattern make in assembly precision low, long shortcoming expends time in.
In the tradition investment casting method, the method that the main employing of the manufacture of shell repeatedly is coated with, the shell profile of producing is uncontrollable, easily in abrupt change of cross-section place (blade and listrium junction), causes the thick large phenomenon of shell.Then reduce the heat-transfer capability at this place, cause the crystal defects such as stray crystal.In the past for improving the capacity of heat transmission of ceramic shell, adopt on blade shell tenon the graphitization layer and pasted the technology such as graphite heat conductor in thick cross section corner, the thermal conductivity of ceramic shell be can better improve, but difficulty and cost that shell is manufactured increased.So, utilize the Stereolithography technology, manufacture the resin formwork with topological heat transfer path, and then manufacture the casting mold with topological heat transfer path, can, under the prerequisite that does not increase Casting mold manufacturing difficulty and cost, well improve the heat-transfer capability of casting mold abrupt change of cross-section place.
Summary of the invention
The problem that the present invention solves is to provide a kind of manufacture method of single crystal turbine blade ceramic-mould, solve in traditional single crystal turbine blade Casting mold manufacturing that spiral crystal selector assembly precision is low, the unmanageable problem of grain form, improve quality and precision that single crystal turbine blade is manufactured.
The present invention is achieved through the following technical solutions:
A kind of method of removing monoblock type ceramic-mould resin die comprises the following steps:
1) according to the grain-oriented requirement of single crystal turbine blade, utilize the casting finite element software to design the spiral crystal selector be complementary, comprise the number of turn, the distance of adjacent spiral section and the size of nucleation machine of the brilliant section of screw selecting;
2) according to the initial casting mold of single crystal hollow Design Turbine Blade with the spiral crystal selector, it is imported in the casting finite element software, conducted heat and stress analysis; In the Stress calculation process, the concentrated zone for stress, change the shape of shell outer wall of casting mold to subdue stress; According to each thermal stress distribution situation constantly, select the wall thickness that meets calorific intensity, is subject to the stress minimum, take the uniform wall thickness of this wall thickness initial casting mold after subduing stress, obtain the secondary casting mold;
3) simulated environment that the secondary casting mold designed is placed in to directional solidification is carried out analysis of Heat Transfer, obtain HEAT TRANSFER LAW and the temperature gradient distribution of secondary casting mold, for abrupt change of cross-section place, using mould strength as the initial boundary condition, pass through topological optimization, the design heat transfer path, improve the heat-transfer capability of abrupt change of cross-section place, forms casting mold three times;
4) then three casting molds are repeated to analysis of Heat Transfer, stress analysis and directional solidification sunykatuib analysis, and modify until the thermograde requirement of the compound directional solidification in variable cross-section place, and can bear the stress be subject in directed crystals growth process, obtain the casting mold of finalizing the design;
5) casting mold designed is produced to the colophony prototype mould by Introduction To Stereolithography, utilize the method for gel injection-moulding to manufacture the single crystal turbine blade ceramic-mould.
The described resin mould of the turbo blade with the spiral crystal selector and initial casting mold design construction in UG software.
The integrated manufacture of the described resin mould of the turbo blade with the spiral crystal selector, the spiral crystal selector cad model designed is assembled on the blade cad model, the application modeling software is taken out shell to the threedimensional model of part and is processed, solid parts is taken out as hollow, taking out thickness of the shell is 0.6-3mm, then utilizes light-curing rapid forming equipment to produce the turbo blade colophony prototype with the spiral crystal selector.
The sharp parts that the form of subduing stress described step 2) is passivation shell outer wall, concentrate or reduce stress and concentrate until eliminate stress.
Described secondary casting mold is placed in the simulated environment of the directed crystals growth that ProCAST software provides and carries out the radiant heat transfer analysis, and following setting is arranged while in ProCAST software, setting up pre-thermal model:
5.1) coefficient of heat transfer that foundry goods and formwork be set is 0;
5.2) on the formwork surface, the heat transfer boundary condition being set, VIEW FACTOR is set is ON and set radiance;
5.3) foundry goods is set is EMPTY, it is FULL that the foundry goods state is set;
After completing preheating calculating by pre-thermal model, use the mould shell temperature distribution results, set up the computation model that radiant heat transfer is analyzed, comprise following setting:
5.4) temperature distribution state of extraction formwork in preheating is calculated;
5.5) change 0 coefficient of heat transfer of foundry goods and formwork;
5.6) remove formwork inner surface Transfer Boundary Condition, it is FULL that the foundry goods state is set;
Carry out the radiant heat transfer analysis on the computation model of radiant heat transfer analysis, when analyzing, the reckoning of the alloy material parameter of foundry goods adopts the Lever model, it is ON that VIEW FACTOR is set, the Radiation module be arranged in radiant heat transfer calculating of operational factor is set, and radiation button case and formwork are corresponding;
After completing the radiant heat transfer analysis, obtain Temperature Distribution and the HEAT TRANSFER LAW of formwork and foundry goods, i.e. the temperature field distribution map; Carry out thermograde calculating according to Temperature Distribution situation and model, obtain temperature gradient distribution figure; And, in conjunction with stress field distribution situation, temperature field distribution situation and temperature gradient distribution situation, carry out analysis-by-synthesis, instruct the casting mold design.
The rate travel of described radiation button case is set to the freezing rate of foundry goods with molten metal.
The initial ceramic-mould of described design, utilize finite element software to carry out heat transfer and the grain structure analysis in the directional solidification process, thick large for abrupt change of cross-section place ceramic shell, heat-transfer capability reduces, and easily causes crystal defect, usings mould strength as the initial boundary condition, pass through topological optimization, improve casting mold structure, the design heat transfer path, improve this place's heat-transfer capability.
Describedly produce the resinogen pattern by Introduction To Stereolithography and be:
The design of light-cured resin mould completes in UG software, based on the typing casting mold, according to function and the shape of parts, determines pouring position, design dead head; And increase curving of castings R0.5～1 according to GB/T6414-1999; The light-cured resin mould adds the cast shell, the thick 1～2mm of shell, and add the enhancing fin on shell;
Derive with the STL form after the light-cured resin Design of Dies completes, then stl file is imported in Magics software and takes out shell, interpolation support, derive the SLC file; The SLC file is loaded in Stereolithography machine RPbuild software, controls the Stereolithography machine and automatically prepare resin piece;
After having prepared, remove the resin piece supplemental support, with alcohol, clean the colophony prototype part 2～3 times, assurance residual liquid resin is cleaned out fully.
Described gel casting forming adopts following methods to carry out the preparation of ceramic size:
1) calculate the volume of deionized water according to the solid concentration of the volume of light-cured resin mould and ceramic powder particle, then add successively organic monomer, crosslinking agent and dispersant, stirring and dissolving, be 10～11 by the pH value of concentrated ammonia liquor regulator solution, obtains the premixed liquid that organic concentration is 20%;
2) ceramic powder is added in premixed liquid in batches, add the abrading-ball of 2～3 times of quality, about spheroidal graphite 1h, obtain viscosity and be less than the ceramic size that 1PaS, solid volume fraction are 58～63vol%;
Described ceramic powder mainly comprises that the coarse granule of granularity 40 μ m is alumina powder jointed, the fine grain alumina powder jointed and magnesia mineralizer of granularity 2～5 μ m.
The method of described gel injection-moulding prepares the single crystal turbine blade ceramic-mould and comprises:
1) successively catalyst and initator are added to ceramic size, and its Quick uniform is disperseed, then the colophony prototype mould is positioned in the vibrating grouting machine, vibration frequency is 30Hz～60Hz, injects ceramic size, obtains biscuit of ceramics; Then freeze drying under vacuum, make moisture in biscuit of ceramics from the solid-state gaseous state that directly changes into;
2) then biscuit of ceramics is sloughed to resin, slough presintering after resin, pre-sintering temperature<1250 ℃; There are certain ashes in ceramic-mould inside after presintering, with compressed air, the residual ashes in ceramic shell is cleared up, and compressed air pressure is less than 2Mpa;
3) finally carry out whole sintering, 1350 ℃～1550 ℃ of sintering temperatures, obtain ceramic-mould.
Compared with prior art, the present invention has following useful technique effect:
The manufacture method of single crystal turbine blade ceramic-mould provided by the invention, according to the grain orientation requirement of single crystal turbine blade, design and manufacture the integral ceramics casting mold with specific spiral crystal selector.While for directional solidification, manufacturing single crystal blade, abrupt change of cross-section place (as blade and listrium junction) shell enlarged in thickness, heat-transfer capability reduces, easily cause the phenomenon of the crystal defects such as stray crystal, under the requirement that meets casting intensity, pass through topological optimization, the design heat transfer path, improve the casting mold heat-transfer capability, and then the thermograde in solid-liquid interface forward position while improving directional solidification, make whole blade can obtain good single crystal organization.
The manufacture method of single crystal turbine blade ceramic-mould provided by the invention, adopted the integrated design of CAD-CAE technology, integrated while accomplishing to design; Can instruct by result of finite element the modification of three-dimensional modeling data, for example: during single crystal turbine blade directional solidification FEM calculation, find that casting mold abrupt change of cross-section place heat-transfer capability is low, easily cause the crystal grain defect, can be by the mode of design heat transfer path, revise model, improve the model heat transfer ability.
The manufacture method of single crystal turbine blade ceramic-mould provided by the invention, also solved traditional casting mold when directional solidification, the complicated uncontrollable problem of conducting heat, for example: during casting, abrupt change of cross-section place heat transfer property reduces, and causes this place the phenomenon of the crystal defects such as stray crystal easily to occur.
The manufacture method of single crystal turbine blade ceramic-mould provided by the invention, while also having avoided traditional shell to manufacture, the uncontrollable problem of shell profile, for example: the place that can't strengthen conducting heat at needs arranges heat transfer path, the place that can't strengthen investment shell intensity at needs arranges reinforcement, and the inventive method can be according to analyzing and experimental result be done adaptive improvement to casting mold.
In the ceramic molding of the Rapid casting process based on Stereolithography and gel injection-moulding, the inventive method has solved traditional investment casting method and has manufactured the low problem of assembly precision that single crystal turbine blade exists.For example: during wax-pattern is manufactured, there are deviation in spiral crystal selector wax-pattern and the assembling of blade wax-pattern.
The manufacture method of single crystal turbine blade ceramic-mould provided by the invention, shortened design and manufacture cycle of casting mold, promoted the performance of casting mold, greatly reduces production cost.
The accompanying drawing explanation
Fig. 1 is with spiral crystal selector single crystal turbine blade design process schematic diagram (from left to right: the spiral crystal selector designs, and the single crystal turbine blade schematic diagram, assembled rear model schematic diagram)
Fig. 2 is the schematic diagram as the blade of foundry goods;
The schematic diagram of the running gate system that Fig. 3 is foundry goods;
The three dimensional design schematic diagram that Fig. 4 is casting mold;
Fig. 5 is the time m-STRESS VARIATION of shell thermal stress with thickness, and abscissa is the time, and ordinate is stress;
Fig. 6 is the time m-thermal stress variation of shell thermal stress with thickness, and abscissa is the time, and ordinate is thermal stress;
Fig. 7 is foundry goods thermal physical property parameter (Ni based high-temperature alloy K4169) analysis chart, and wherein in each figure, abscissa is temperature, and ordinate is respectively solid rate, the coefficient of heat conduction, density and heat content;
The temperature field distribution map that Fig. 8 is the variable cross-section place and high-temperature region schematic diagram (from left to right: variable cross-section place temperature field cloud atlas, high-temperature region schematic rear view, high-temperature region front schematic view);
Fig. 9 is variable cross-section position schematic diagram;
Figure 10 heat transfer path distribution schematic diagram;
Variable cross-section place temperature field cloud charts after Figure 11 final optimization pass.
The specific embodiment
Below in conjunction with specific embodiment, the present invention is described in further detail, and the explanation of the invention is not limited.
A kind of manufacture method of single crystal turbine blade ceramic-mould comprises the following steps:
1) according to the grain-oriented requirement of single crystal turbine blade, in conjunction with calculating and the experiment of casting finite element software, design the spiral crystal selector, comprise the number of turn, the distance of adjacent spiral section and the size of nucleation machine of the brilliant section of screw selecting;
2) according to the initial casting mold of single crystal hollow Design Turbine Blade with the spiral crystal selector, it is imported in the casting finite element software, conducted heat and stress analysis; In the Stress calculation process, the concentrated zone for stress, change the shape of shell outer wall of casting mold to subdue stress; According to each thermal stress distribution situation constantly, select the wall thickness that meets calorific intensity, is subject to the stress minimum, take the uniform wall thickness of this wall thickness initial casting mold after subduing stress, obtain the secondary casting mold;
3) simulated environment that the secondary casting mold designed is placed in to directional solidification is carried out analysis of Heat Transfer, obtain HEAT TRANSFER LAW and the temperature gradient distribution of secondary casting mold, thick large for abrupt change of cross-section place (blade and listrium junction) ceramic shell, heat-transfer capability reduces, and easily causes the phenomenon of the crystal defects such as stray crystal, usings mould strength as the initial boundary condition, pass through topological optimization, the design heat transfer path, improve the heat-transfer capability of abrupt change of cross-section place, forms casting mold three times;
4) then three casting molds are repeated to analysis of Heat Transfer, stress analysis and solidified structure analysis, and modify until the thermograde requirement of the compound directional solidification in variable cross-section place, and can bear the stress be subject in directed crystals growth process, obtain the casting mold of finalizing the design;
5) casting mold designed is produced to the colophony prototype mould by Introduction To Stereolithography, utilize the final casting mold of method manufacture of gel injection-moulding.
Concrete, for the design of the turbo blade resin mould with the spiral crystal selector, below provided the design process of certain type single crystal turbine blade resin mould:
According to the grain-oriented requirement of single crystal turbine blade, in conjunction with calculating and the experiment of casting finite element software, design the spiral crystal selector, comprise the number of turn, the distance of adjacent spiral section and the size of nucleation machine of the brilliant section of screw selecting, utilize the 3 d modeling software modeling.
According to standard GB/T/T6414-1999 " dimensional tolerance of casting " requirement, the design transition section, be assembled to spiral crystal selector threedimensional model on the turbo blade of required manufacture.
Derive stl file, utilize Stereolithography technique to make the turbo blade resin mould with the spiral crystal selector, as the prototype of casting use.Certain type single crystal turbine blade resin mould design process as shown in Figure 1.
Concrete, with certain type turbo blade casting mold design process of topological heat transfer path:
According to the threedimensional model of the turbo blade shown in Fig. 2, the high about 192.5mm of blade, connect the about 80mm of falcon root, the about 166mm of falcon root the widest part.And in conjunction with the design of top pouring type pouring position, consider the thin-walled blade is arranged on to this principle of position away from dead head design running gate system as shown in Figure 3.Select top pouring type to be for following consideration: hollow turbine blade of combustion gas turbine is complex-shaped, and wall is thin and inhomogeneous, and irrational running gate system makes blade produce more defect.It is complete that bottom gating is difficult for that thin-wall construction is filled to type, so select the top pouring type pouring position.
In addition, by blade, being arranged on away from the dead head position is for following consideration: in the directional solidification process, casting mold first is preheated, then the molten metal through vacuum melting is full of casting mold fully, and the growth of directional crystal is carried out in the thermal treatment zone, adiabatic region and the cooling zone that then move to directional solidification furnace.The dead head position is set like this, makes the leaf quality of manufacture higher.
According to casting engineering teacher handbook, design cup upper end diameter 140mm, lower end diameter 80mm, cup height 50mm.Be that the Osann formula is checked the ingate area by the Gating Area method, and utilize modular approach to check dead head size, the actual cast of above-mentioned size conforms requirement.
Design casting mold according to Fig. 3, the casting mold graphics is shown in Fig. 4.The initial casting mold of design in three-dimensional software (as UG software), casting mold wall thickness now is uniform.Such as the shell of selecting 6mm, 9mm, 12mm and several uniform wall thickness of 15mm carries out thermal stress calculating.And carry out thermal stress calculating in ProCAST software stress analysis module.Note, thermal stress is herein calculated as common thermal field and stress field calculation, is not the calculating under the directional solidification condition, and reason is that the type that fills of molten metal completes entering the directional solidification stokehold.
The thermal-stress analysis that Fig. 5, Fig. 6 are different-thickness shell dead head place, as seen from the figure, when shell thickness is reduced to 9mm by 15mm, the thermal stress in arbitrary moment all reduces along with reducing of thickness, and when shell thickness is 6mm, the shell thermal stress significantly increases, even higher than the thermal stress of 15mm thickness shell.
Wherein, Fig. 5 is that thermal stress is schemed over time, and square means the thermal stress variation diagram that thickness is 6mm, for going up most a curve; Round dot means that thermal stress variation diagram that thickness is 9mm is for next curve; Upper triangle means the thermal stress variation diagram that thickness is 12mm, for from several second curves; Lower triangle means the thermal stress variation diagram that thickness is 15mm, for from several the 3rd curves, show the shell thermal stress minimum that shell thickness is 9mm.Can find out in Fig. 6 that the thermal stress that thickness is the 9mm shell is minimum at each constantly.
The simulated environment (as ProCAST software) that then initial casting mold is placed in to directed crystals growth is carried out thermal stress and radiant heat transfer analysis.Then initial casting mold is imported in cast software (as ProCAST software) and conducted heat and stress analysis, check each thermal stress distribution situation constantly, determine a kind of optimization shell wall thickness that meets the calorific intensity design.
Complete the radiant heat transfer analysis, need first to complete preheating and calculate in ProCAST software, set up pre-thermal model and should be noted that:
1) coefficient of heat transfer that foundry goods and formwork is set is 0;
2) on the formwork surface, the heat transfer boundary condition is set, VIEW FACTOR is set is ON and set radiance;
3) foundry goods being set is EMPTY.
After completing preheating calculating, use the mould shell temperature distribution results, set up the computation model that radiant heat transfer is analyzed, should be noted that in radiant heat transfer:
1) in calculating, preheating extracts the temperature distribution state of formwork;
2) change 0 coefficient of heat transfer of foundry goods and formwork;
3) remove formwork inner surface Transfer Boundary Condition.In the directional solidification process, the type that fills of molten metal completes in vacuum melting furnace, and only calculate and need to complete Calculation of Heat Transfer herein, so the foundry goods state is set, be FULL.
The main control point of simulation in Calculation of Heat Transfer:
1) high-temperature alloy material parameter.General hollow turbine vane high temperature alloy composition used is all very complicated, does not have ready-made material parameter figure to check.But can be calculated according to computation model.The computation model that the material parameter database is arranged in ProCAST software and calculated can complete the high-temperature alloy material coaptation.The reckoning of high-temperature alloy material parameter adopts the Lever model.
2) boundary condition.All VIEW FACTOR to be placed in to the ON state in first step preheating calculating and the calculating of second step radiant heat transfer.
3) set in the Radiation module (RUN PARAMETER) of operational factor in radiant heat transfer calculates, notice that radiation button case and formwork are corresponding.
Concrete, carry out the thermal field analysis on the uniform wall thickness shell that is 9mm at thickness.Thermal field is analyzed shell thermal physical property parameter used: thermal diffusion coefficient 1.513 ± 0.002mm2/s, and specific heat is 0.784 ± 0.017J/ (gK), thermal conductivity is 2.3580.004W/ (mK).Above thermal physical property parameter is measured by LFA447 flash of light conductometer.Thermal field is analyzed blade thermal physical property parameter used and can be calculated by ProCAST software material database, sees Fig. 7.
Above-mentioned thermal physical property parameter input ProCAST software is carried out to thermal field calculating.Primary condition is that blade metal liquid temperature is high 1600 ℃, and the shell temperature is 1550 ℃ of radiation heatings.Boundary condition is that the blade bottom applies 35 ℃ of aqueous cold plate borders, and the place, freezing interface applies 35 ℃ of condensation ring borders.
Check the zone that stress is concentrated in the process of Stress calculation, the concentrated existence of stress can make the high temperature alloy labyrinth in the directional solidification process, shell occurs that hot tearing or molten metal impact the generation that defects i.e.cracks occurs, the shell outer wall need to be subdued to stress for fear of the appearance of these defects and problem and process.The form of subduing stress is mainly the sharp parts of passivation shell outer wall.
It should be noted that in the directional solidification process, casting mold is radiation heating and heat radiation, will add radiation button case in ProCAST computational process.Button case rate travel is traditionally arranged to be the freezing rate of molten metal.
Complete after above-mentioned all calculating Temperature Distribution and the HEAT TRANSFER LAW that can obtain formwork and Blade roughcast, i.e. the temperature field distribution map; Carry out thermograde calculating (ProCAST temperature parameter computing method), i.e. temperature gradient distribution figure according to Temperature Distribution situation and model.In conjunction with the stress field distribution situation of Stress calculation, temperature field distribution situation and temperature gradient distribution situation, carry out analysis-by-synthesis, instructs the casting mold design.
Fig. 8 is that casting mold distributes in the temperature field of variable cross-section place (blade and listrium junction) while once designing, can find out that the variable cross-section place is because shell thickens suddenly, heat-transfer capability reduces, formed inhomogeneous temperature field in blade interior, main high-temperature region is positioned at around the exhaust limit (high-temperature area as shown in Figure 8).Inhomogeneous temperature field distribution easily causes the defects such as stray crystal at root of blade, and then reduces the performance (the variable cross-section position as shown in Figure 9) of integral blade.
The Temperature Distribution of casting mold, except outside the Pass the physical parameter with casting mold and foundry goods has, depends primarily on the shape of casting mold.Therefore distribute for making the variable cross-section place obtain comparatively average temperature field, be necessary the casting mold structure at this place is carried out to topological optimization.
According to the distribution law of temperature field of initial casting mold, for high-temperature area, carry out structural Topology Optimization.Heat transfer path by design perpendicular to the shell surface, reach the purpose that improves the shell heat-sinking capability, specific implementation method: according to the temperature field cloud charts, judge position, high-temperature area place, the design heat transfer path, the main regulation and control parameter of heat transfer path is: passage aperture R, channel depth D and interchannel spacing G.Heat radiation compare Man district, increase the passage aperture, and the degree of depth, reduce the interchannel spacing, and the very fast district of dispelling the heat, reduce the passage aperture, and the degree of depth increases the interchannel spacing, even can not design heat dissipation channel.Then compute repeatedly, revise the heat transfer path parameter, until whole section uniformity of temperature profile is revised Secondary Design, complete three designs.Above design must complete under the condition that meets the mould strength requirement; 2, the casting mold thickness of the minimum of a value of casting mold thickness for drawing according to Stress calculation.
Heat transfer path specific design method is:
Take out variable cross-section place temperature field cloud atlas and analyzed, as Fig. 8.The topology of observing leaf cross-section is long flat, and is growing to one side indent.In the heat radiation process, be positioned at the annex heat radiation of exhaust limit slower, in order to remain on temperature field in same cross section casting mold, be consistent, shell circumferentially and radially do not have a thermograde, the distribution results of calculating according to temperature field is carried out the design of topological heat transfer path.Carry out respectively the design of heat transfer path for each high-temperature area, and temperature field is distributed and checked, until whole section completes the heat transfer path design, finally form Secondary Design.
As shown in Figure 8, high-temperature area is position in black surround, and heat radiation is slower herein, need carry out the heat transfer path design, the Temperature Distribution calculated according to software is measured the layout of carrying out heat transfer path, the aperture R of design heat transfer path, depth D and spacing G, improve this regional heat-sinking capability.Heat transfer path after design distributes as shown in figure 10.And the casting mold that will revise imports in Procast software and carry out analysis of Heat Transfer, and be optimized calculating.
The shell heat transfer path method of topological optimization design that above-mentioned method for designing is a certain high-temperature area in variable cross-section place, as made satisfied temperature field distribution uniform requirement in whole variable cross-section place to complete the design in each zone according to above-mentioned design and analysis method, again the casting mold three-dimensional data is imported in Procast software and carries out radiant heat transfer calculating after having designed, if do not obtain desirable Temperature Distribution result, also need heat transfer path, repeat above-mentioned steps, until the requirement that satisfied temperature is evenly distributed.
After obtaining the casting mold thickness of optimizing, again in ProCAST software, carry out stress and general Calculation of Heat Transfer, check investment shell intensity.
Three casting mold designs:
After completing Secondary Design, will be placed in the casting mold of heat transfer path ProCAST software and carry out radiant heat transfer calculating.Thermal physical property parameter, primary condition, boundary condition etc. all do not change.Then carry out temperature field and check, the thermograde analysis, further revise the heat transfer path parameter, carries out three designs, is the section temperature field distribution after final optimization pass as shown in figure 11, and whole cross-section temperature field is evenly distributed, and blade interior is without obvious high-temperature region.
Then repeated stress is calculated and Calculation of Heat Transfer, revises design, until whole variable cross-section place uniform distribution of temperature field, and can bear the stress be subject in directed crystals growth process, and determine the casting mold three dimensional design, be the final design of shell.
After complete design, based on photocuring integrated molding technology, according to final casting mold design, sl prototype is carried out to detailed design, and add necessary auxiliary process structure, as pour into a mould shell etc., manufacture colophony prototype and cast shell, then utilize the method for gel injection-moulding to produce pottery (AL-system) casting mold that meets design, then in vacuum oriented stove (three Room of solidifying, comprise the vacuum melting chamber, moist closet and cooling chamber) in complete the directionally solidified superalloy, DS superalloy labyrinth, as the oriented growth of blade.
Concrete grammar is: use final formwork design, complete corresponding colophony prototype and the design of cast shell in UG software, then in the Stereolithography machine, produce colophony prototype and cast shell; Then the deployed Al-that meets intensity and performance requirement is ceramic size, utilizes colophony prototype and cast shell castable ceramic formwork, through steps such as overcuring, drying, presintering and whole sintering, obtains final ceramic-mould entity; Finally vacuum oriented, manufacture the single crystal turbine blade product in solidifying stove.
Major control point prepared by ceramic shell:
1) raw material and equipment.Prepare ceramic-mould raw material used and must leave in sealed package bag or sealed package bucket, preserve under the environment of drying, ventilation.The composition of raw material for preparing ceramic shell mainly comprises coarse granule (40 μ m) and fine grained (2～5 μ m or nanoscale) is alumina powder jointed, magnesia mineralizer, deionized water, acrylamide, methylene-bisacrylamide, Sodium Polyacrylate (concentration 18% left and right), polyethylene glycol, ammonium persulfate (concentration 30% left and right), 4-methyl hexamethylene diamine (concentration 25% left and right) and concentrated ammonia liquor etc.Equipment used mainly comprises photocureable rapid shaping machine (SPS450B), ball mill, gel injection-moulding shaping machine, vacuum freeze drier and vacuum pressure impregnation machine.
2) sl prototype design and preparation.The design of sl prototype completes in UG software, according to GB/T6414-1999, increases curving of castings R0.5～1.The three-dimensional modeling of based single crystal turbo blade, determine pouring position, design dead head according to function and the shape of parts.And then running gate system adds the cast shell outward, shell is for guaranteeing ceramic shell profile and thickness, for guarantee ceramic size fill type after whole colophony prototype there is enough intensity, thick 1～the 2mm of resin enclosure, and add and strengthen fin, thick 1mm, wide 3～5mm on the cast shell.Complete above-mentioned design in UG software after, by data, with the STL derivation of travelling, deriving the triangle tolerance is set is 0.05, and adjacent tolerance is 0.05, and normal generates automatically.Then stl file imported in Magics software and take out shell, add and support, derive the SLC file.The SLC file is loaded in Stereolithography machine RPbuild software, controls the Stereolithography machine and automatically prepare resin piece.After having prepared, remove the resin piece supplemental support, with industrial alcohol, clean the colophony prototype part 2～3 times, assurance residual liquid resin is cleaned out fully.Attention: paddle prototype is manufactured respectively with the cast shell, then is assembled together, and does like this and is convenient to clean colophony prototype, and be easy to post processing is carried out in the paddle prototype surface.
3) ceramic size allotment
At first this process completes the preparation of premixed liquid.Calculate the volume of deionized water according to the solid concentration of the volume of light-cured resin mould and ceramic powder particle, then add successively organic monomer (acrylamide or its substitute), crosslinking agent (methylene-bisacrylamide) and dispersant (Sodium Polyacrylate) etc., stirring and dissolving, pH value with the concentrated ammonia liquor regulator solution, remain in alkaline range (10～11), finally obtain the premixed liquid that organic concentration is 20%.Then prepare water base ceramic size.Ceramic powder is added in premixed liquid in batches, add the abrading-ball of 2～3 times of quality, more than spheroidal graphite 1.5h, obtain viscosity and be less than the ceramic size that 1PaS, solid volume fraction are 58～63vol%.
4) preparation of ceramic-mould
First complete the making of biscuit, successively catalyst (4-methyl hexamethylene diamine) and initator (ammonium persulfate) are added to ceramic size, and its Quick uniform is disperseed, then resin die is positioned in the vibrating grouting machine, vibration frequency is 30Hz～60Hz, inject ceramic size (this process must keep ceramic size to flow steadily and slowly, guarantee the smooth discharge of bubble in slurry), obtain biscuit of ceramics.Then freeze drying under vacuum.Carry out cryodesiccated purpose and be making moisture in biscuit from the solid-state gaseous state that directly changes into, can control like this shrinkage factor of ceramic-mould.Next step carries out degreasing and the presintering (sintering temperature<1250 ℃) of ceramic-mould.Then repeatedly flood (this step is nonessential, if the intensity of ceramic-mould is enough, this step can be omitted).Finally, carry out whole sintering (1350 ℃～1550 ℃ of sintering temperatures).Attention: there are certain ashes in the ceramic-mould inside after presintering, with compressed air, the residual ashes in ceramic shell is cleared up, and compressed air pressure is less than 2MPa.
Acquisition is placed on three chamber vacuum oriented solidifying in stove and carries out the single crystal turbine blade casting after meeting the ceramic-mould of directional solidification requirement.
Claims (10)
1. the manufacture method of a single crystal turbine blade ceramic-mould, is characterized in that, comprises the following steps:
1) according to the grain-oriented requirement of single crystal turbine blade, utilize the casting finite element software to design the spiral crystal selector be complementary, comprise the number of turn, the distance of adjacent spiral section and the size of nucleation machine of the brilliant section of screw selecting;
2) according to the initial casting mold of single crystal hollow Design Turbine Blade with the spiral crystal selector, it is imported in the casting finite element software, conducted heat and stress analysis; In the Stress calculation process, the concentrated zone for stress, change the shape of shell outer wall of casting mold to subdue stress; According to each thermal stress distribution situation constantly, select the wall thickness that meets calorific intensity, is subject to the stress minimum, take the uniform wall thickness of this wall thickness initial casting mold after subduing stress, obtain the secondary casting mold;
3) simulated environment that the secondary casting mold designed is placed in to directional solidification is carried out analysis of Heat Transfer, obtain HEAT TRANSFER LAW and the temperature gradient distribution of secondary casting mold, for abrupt change of cross-section place, using mould strength as the initial boundary condition, pass through topological optimization, the design heat transfer path, improve the heat-transfer capability of abrupt change of cross-section place, forms casting mold three times;
4) then three casting molds are repeated to analysis of Heat Transfer, stress analysis and directional solidification sunykatuib analysis, and modify until the thermograde requirement of the compound directional solidification in variable cross-section place, and can bear the stress be subject in directed crystals growth process, obtain the casting mold of finalizing the design;
5) casting mold designed is produced to the colophony prototype mould by Introduction To Stereolithography, utilize the method for gel injection-moulding to manufacture the single crystal turbine blade ceramic-mould.
2. the manufacture method of single crystal turbine blade ceramic-mould as claimed in claim 1, is characterized in that, the described resin mould of the turbo blade with the spiral crystal selector and initial casting mold design construction in UG software.
3. the manufacture method of single crystal turbine blade ceramic-mould as claimed in claim 1, it is characterized in that, the integrated manufacture of turbo blade resin mould with the spiral crystal selector, the spiral crystal selector cad model designed is assembled on the blade cad model, the application modeling software is taken out shell to the threedimensional model of part and is processed, solid parts is taken out as hollow, and taking out thickness of the shell is 0.6-3mm, then utilizes light-curing rapid forming equipment to produce the turbo blade colophony prototype with the spiral crystal selector.
4. the manufacture method of single crystal turbine blade ceramic-mould as claimed in claim 1, is characterized in that, described step 2) in subdue the sharp parts that the form of stress is passivation shell outer wall, concentrate or reduce stress and concentrate until eliminate stress.
5. the manufacture method of single crystal turbine blade ceramic-mould as claimed in claim 1, it is characterized in that, described secondary casting mold is placed in the simulated environment of the directed crystals growth that ProCAST software provides and carries out the radiant heat transfer analysis, and following setting is arranged while in ProCAST software, setting up pre-thermal model:
5.1) coefficient of heat transfer that foundry goods and formwork be set is 0;
5.2) on the formwork surface, the heat transfer boundary condition being set, VIEW FACTOR is set is ON and set radiance;
5.3) foundry goods is set is EMPTY, it is FULL that the foundry goods state is set;
After completing preheating calculating by pre-thermal model, use the mould shell temperature distribution results, set up the computation model that radiant heat transfer is analyzed, comprise following setting:
5.4) temperature distribution state of extraction formwork in preheating is calculated;
5.5) change 0 coefficient of heat transfer of foundry goods and formwork;
5.6) remove formwork inner surface Transfer Boundary Condition, it is FULL that the foundry goods state is set;
Carry out the radiant heat transfer analysis on the computation model of radiant heat transfer analysis, when analyzing, the reckoning of the alloy material parameter of foundry goods adopts the Lever model, it is ON that VIEW FACTOR is set, the Radiation module be arranged in radiant heat transfer calculating of operational factor is set, and radiation button case and formwork are corresponding;
After completing the radiant heat transfer analysis, obtain Temperature Distribution and the HEAT TRANSFER LAW of formwork and foundry goods, i.e. the temperature field distribution map; Carry out thermograde calculating according to Temperature Distribution situation and model, obtain temperature gradient distribution figure; And, in conjunction with stress field distribution situation, temperature field distribution situation and temperature gradient distribution situation, carry out analysis-by-synthesis, instruct the casting mold design.
6. the manufacture method of single crystal turbine blade ceramic-mould as claimed in claim 5, is characterized in that, the rate travel of described radiation button case is set to the freezing rate of foundry goods with molten metal.
7. the manufacture method of single crystal turbine blade ceramic-mould as claimed in claim 1, it is characterized in that, design initial ceramic-mould, utilize finite element software to carry out heat transfer and the grain structure analysis in the directional solidification process, thick large for abrupt change of cross-section place ceramic shell, heat-transfer capability reduces, and easily causes crystal defect, usings mould strength as the initial boundary condition, pass through topological optimization, improve casting mold structure, the design heat transfer path, improve this place's heat-transfer capability.
8. the manufacture method of single crystal turbine blade ceramic-mould as claimed in claim 1, is characterized in that, describedly produces the resinogen pattern by Introduction To Stereolithography and be:
The design of light-cured resin mould completes in UG software, based on the typing casting mold, according to function and the shape of parts, determines pouring position, design dead head; And increase curving of castings R0.5～1 according to GB/T6414-1999; The light-cured resin mould adds the cast shell, the thick 1～2mm of shell, and add the enhancing fin on shell;
Derive with the STL form after the light-cured resin Design of Dies completes, then stl file is imported in Magics software and takes out shell, interpolation support, derive the SLC file; The SLC file is loaded in Stereolithography machine RPbuild software, controls the Stereolithography machine and automatically prepare resin piece;
After having prepared, remove the resin piece supplemental support, with alcohol, clean the colophony prototype part 2～3 times, assurance residual liquid resin is cleaned out fully.
9. the manufacture method of single crystal turbine blade ceramic-mould as claimed in claim 1, is characterized in that, described gel casting forming adopts following methods to carry out the preparation of ceramic size:
1) calculate the volume of deionized water according to the solid concentration of the volume of light-cured resin mould and ceramic powder particle, then add successively organic monomer, crosslinking agent and dispersant, stirring and dissolving, be 10～11 by the pH value of concentrated ammonia liquor regulator solution, obtains the premixed liquid that organic concentration is 20%;
2) ceramic powder is added in premixed liquid in batches, add the abrading-ball of 2～3 times of quality, about spheroidal graphite 1h, obtain viscosity and be less than the ceramic size that 1PaS, solid volume fraction are 58～63vol%;
Described ceramic powder mainly comprises that the coarse granule of granularity 40 μ m is alumina powder jointed, the fine grain alumina powder jointed and magnesia mineralizer of granularity 2～5 μ m.
10. the manufacture method of single crystal turbine blade ceramic-mould as claimed in claim 1, is characterized in that, the method for described gel injection-moulding prepares the single crystal turbine blade ceramic-mould and comprises:
1) successively catalyst and initator are added to ceramic size, and its Quick uniform is disperseed, then the colophony prototype mould is positioned in the vibrating grouting machine, vibration frequency is 30Hz～60Hz, injects ceramic size, obtains biscuit of ceramics; Then freeze drying under vacuum, make moisture in biscuit of ceramics from the solid-state gaseous state that directly changes into;
2) then biscuit of ceramics is sloughed to resin, slough presintering after resin, pre-sintering temperature<1250 ℃; There are certain ashes in ceramic-mould inside after presintering, with compressed air, the residual ashes in ceramic shell is cleared up, and compressed air pressure is less than 2Mpa;
3) finally carry out whole sintering, 1350 ℃～1550 ℃ of sintering temperatures, obtain ceramic-mould.
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