In the grand picture of modern industry, gas turbine as the core of efficient energy conversion device, its complex structure not only shows the beauty of engineering technology, but also reflects the spirit of human pursuit of extreme performance. Behind all this, it is inseparable from the support of precision casting technology. Precision casting molds, as a key link in this process, are not only the basis for the manufacture of high-quality gas turbine components, but also the bridge between the design idea and the actual product. Through highly accurate design and manufacturing processes, these molds ensure that each casting can meet extremely strict dimensional tolerances and surface quality requirements, so that the final assembled gas turbine can operate efficiently and stably, playing an irreplaceable role in many fields such as power generation and aviation.
Moulds are used to form the inner cavity and shape of high-temperature turbine blades. They are divided into wax moulds and ceramic core moulds, which play a crucial role in blade size control. At present, the processing accuracy of the mold can be guaranteed by a good machine tool, but the good mold is still very few, the mold’s processability and operability are not good, which will lead to the mold being difficult to use, and the workers are not willing to use it, or the use is not good, which will directly cause the deformation of the blade.
The ceramic core mold belongs to the static blade core, the exhaust side is equipped with many spoiler columns and reinforcement plates, close to the intake side channel, because the core is relatively thick and large, 3 hollow channels are provided, and the channels are realized by metal pins. Considering the uniformity of the filling of the core, the runner enters from the middle of the core and distributes synchronously to the left and right, so as to ensure that the exhaust side is filled as soon as possible, and prevent the exhaust side from being full and the inlet side from maintaining insufficient pressure.
The mold is also a ceramic core mold for the guide blade, and there are 3 cylindrical holes in the core near the intake edge for forming a metal convex and rib structure for the installation of the plug-in. The core head also has a waist lock structure, which is used to fix the core and the shell.
Pictured above is a typical ceramic core multi-section calibration tool for the calibration of oversized ceramic core blank. The ceramic core length is between 600mm and 800mm. Each section can be rotated and moved up and down to correct the bending and torsional deformation of the core. Using round steel rods in series between different sections can improve the efficiency of tooling closure. Reduce the reference drift caused by the difference in the closing sequence of different sections of the tool.
Above is a typical solid moving blade wax mold. The mold cavity is divided into two parts, the left part is a cold wax core, and there are notches on the side of the inlet side of the leaf and the inlet side respectively, which are used for positioning in the right mold after pressing, and there is a matching convex table in the right mold cavity. This set of mold adopts double channel design, forming one cold wax core and one blade at a time. However, the author believes that this design is not good, because the design of the double runner can not evenly distribute the wax liquid, which may lead to the filling of the cold core and the wax mold, especially the pressure preservation is insufficient. At the same time, the cold wax core is not sufficiently cold, and it is immediately used for the pressing of the blade wax mold, which is easy to expose the cold core due to insufficient strength. Therefore, it is recommended that the cold wax core mold be opened separately and pressed separately.
Above is a typical cold wax core mold. There are many stripes on the cold wax core mold, which is used to form the rough surface of the cold wax core, so as to enhance the binding force between the cold wax core and the wax mold, and avoid local detachment from the stratification. The cold wax core has a number of conical convex, which is used for positioning the cold core in the mold when pressing the wax.
In short, precision casting molds are not only an indispensable technical support for the production of gas turbines, they are also pieces of art in their own right, demonstrating the exquisite combination of human wisdom and natural laws. From the initial concept sketch to the final product, every step is the culmination of the engineers’ blood and sweat. With the progress of material science and the continuous innovation of technical means, in the future, we have reason to believe that more advanced and efficient gas turbines will continue to be born in these carefully built molds, contributing more to the development of human society. This is not only a recognition of existing achievements, but also a beautiful vision of the infinite possibilities of the future.
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