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:
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-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-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 |
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 |