Posted Date: 31/05/2018
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Heavy-duty gas turbine blades: core technology China is subject to people

Heavy-duty gas turbines (hereinafter referred to as re-ignition) are truly big powers. As the power machinery with the highest heat/power conversion efficiency so far, it is widely used in mechanical drives (such as ships and trains) and large-scale power plants. China now has the capability of autonomy of light-type combustion engines (with a power of 50,000 kilowatts or less); however, re-ignition (with a power of more than 50,000 kilowatts) still relies on introduction. It is reported that the reburning generating unit currently accounts for about 3% of the total installed power generation in the country. Although not a large piece, it is an indispensable part - a gas turbine unit with quick startup and shutdown, higher thermal efficiency, and less pollution. The best choice for peaking capacity of large power grids plays an irreplaceable role in the overall national energy security. Without autonomy, it means that China's energy security is an important link and it is still subject to human beings. There is a risk of being stuck.

Extreme Technology: The pursuit of near-perverted quality and performance

The molten liquid metal is poured into the mold, waiting for it to solidify; under the microscope to see the metallographic, it will appear like "dry farmland" gap, the technical term is called "grain boundary"

"The grain boundary is a weak link in the metal," said the person in charge of the technology for heavy gas turbines, a major national science and technology project. In order to increase the strength of metal materials at high temperatures, we must find ways to eliminate grain boundaries.

This is an extremely complex and lengthy process, including precise temperature control, as well as precision casting and oriented/pulled single crystal processes. The blanks of its core components are "from abroad"; the core equipment single crystal furnaces must also be imported from abroad.

The person in charge of the technology explained that as a rotary-boiler heat engine, the turbine blade is one of the most important core components. It needs to work stably for a long time at a high temperature of 1400°C-1600°C. At present, no metal can do it. How to do?

Extreme working conditions give birth to the ultimate technology, a madness to near-perverted pursuit of quality and performance. In addition to eliminating grain boundaries and increasing the strength of the materials used, "only by cooling": the blades are hollow to allow cooling of the air; the surface has a ceramic coating, a cooling film, which isolates it from the hot gases, and so on.

More importantly, at any stage of the above complex process, there is no deviation in any of the technical parameters. "This is the biggest difference from the conventional manufacturing process." He emphasized that there is also a safety factor in conventional manufacturing, that is, a certain tolerance for fault tolerance; and “the ultimate manufacturing is completely another concept”: the blades are hollow and thin, and in addition to precision casting, there are currently no other technological means to do it. It is unclear whether future 3D printing can be solved. In the casting process, slag, cracks, looseness, porosity, and deformation of the material will affect the strength and performance of the blade. Because "it is impossible on its own, relying on a lot of extreme means to make it possible", all technologies must be done to the extreme. Therefore, one is one, two is two, and the deviation cannot be tolerated or allowed.

Therefore, one is one, two is two, and the deviation cannot be tolerated or allowed.


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