The film describes the high-tech process of manufacturing large ingots as a basis for further production of solid forged rotors - the basis of modern turbines and generators. Joint development of specialists from the Izhora Metallurgical Plant and NPO TsNIITMASH.
Photos of energy facilities.
Turbine parts for generating 1,000,000 kW of energy.
Alternating shots from the production of such large units.
Rotor shafts are the most important part of turbines and generators.
A cartoon explaining the principle of creating rotors in the recent past.
Turbines in a plant workshop.
Rotor shafts, created using the assembly method from different elements, were highly labor-intensive, had a long manufacturing cycle, but most importantly, a limited shelf life.
Installation of turbine blades.
One-piece forged rotor.
Production of such rotors from large and high-quality ingots.
This problem was undertaken to be solved at the Izhora Metallurgical Plant together with NPO TsNIITMASH. The building of the institute.
Having its own laboratory base, an important component of which is a 1-ton capacity unit, the institute's scientists have the opportunity to model and study complex processes of ingot formation.
Pouring liquid metal into molds.
Scientific and practical studies have shown that an increase in the mass of liquid metal leads to a deterioration in the quality of steel during its smelting and solidification.
Processes develop that lead to physical and chemical heterogeneity of the metal.
These defects are clearly visible on sulfur prints taken from templates - axial sections of ingots.
Alternating frames with ingot defects.
In the manufacture of small ingots, shrinkage defects can be eliminated by forging on powerful presses.
Another way to remove defects is to drill an axial channel in the workpiece.
However, it reduces the ultimate strength of the product and is unacceptable for the manufacture of rotors of powerful turbines.
In the process of studying the crystallization of the metal, several factors influencing the formation of ingots were identified.
A cartoon showing one of the factors, the choice of geometric parameters.
A cartoon explaining the correct parameters of the ingot profit.
A cartoon showing the growth of ingot volume as the theory and practice of producing large castings is studied.
Optimum parameters were found for super-large ingots.
A cartoon showing ingot deformations with optimal parameters.
Photos with defective ingots.
The reason is the low quality of steel obtained from scrap metal.
When smelting rotor steels, Izhora metallurgists, in addition to the usual alloying additives, use a significant amount of original iron.
Open-hearth shop.
Metallurgical furnaces.
Taking a sample for rapid express analysis of steel.
Analysis of the chemical composition of metal in the Izhora laboratory.
Various metal samples.
Laboratory equipment.
The analysis data is entered into the computer and displayed at the steelmaker's workplace.
Such efficiency allows adjusting the percentage of impurities directly during smelting.
Steelmaker at the furnace.
But even steel obtained from good raw materials is called a semi-finished product by metallurgists.
An out-of-furnace vacuumizing and refining unit, where the final processing of metal is performed.
Unit control panel.
Processing liquid steel in two ladles, with a capacity of 150 tons each.
The ladle installed in the stator of the magnetic mixer is fed by a trolley to the heating position.
Here, ordinary open-hearth steel is brought to the condition of electric steel.
Based on the results of the express analysis, the chemical composition is adjusted.
The exact amount of additives is fed into the ladle.
Steel is cleaned of gas impurities.
A deep vacuum is created in the ladle using ejector pumps.
The process is intensified by mixing the metal with a powerful induction field, and the steel is also blown with argon.
In this case, oxygen, hydrogen, nitrogen and other gases are removed from the thickness of the metal.
Metallurgy, Metal smelting
Leningrad
Izhora Metallurgical Plant. Scientific and Production Association TsNIITMASH.
Kramatorsk Plant Energomashspetsstal.
Circulation vacuum unit.
The unit is designed for extra-furnace processing of metal obtained in electric arc furnaces.
The technological process differs from the Izhora one.
A cartoon showing the metal improvement technology used at the Kramatorsk Plant.
A steelmaker at the unit's control panel.
The chemical composition is adjusted during the process.
The steelmaker types a program on the unit's control panel, according to which the automation will dispense the required amount of ferroalloys and deoxidizers into the ladle.
A cartoon explaining this process.
Steel preparation is the most critical operation in the technology of manufacturing a large ingot.
Blast furnace shop.
The closer to steel casting, the more often samples are analyzed.
The steelmaker takes a steel sample.
The plant's laboratory.
Equipment at the Izhora Plant laboratory.
Open-hearth shop.
Metal casting.
Footage of the production of the first ingot weighing 420 tons.
All work is carried out according to a pre-agreed schedule.
The steelmaker marks the completion of the stages.
An operator at the control panel of the after-furnace vacuum treatment and refining unit.
A diagram of the liquid steel collection is being filled in.
A cartoon explaining the casting work schedule.
A cartoon showing the preparation of the vacuum chamber in which the mold is assembled for melting.
A deep vacuum is created in the chamber.
The ladle from the after-furnace vacuum treatment and refining unit is the first to be fed for pouring.
A rotary stand operating on the rocker principle ensures the continuity of the pouring process.
While the first ladle is in the pouring position, the next ladle is installed on the second arm of the rotary stand.
As soon as the first ladle is released, the stand rotates 180 degrees.
Pouring of steel from the second ladle begins.
These operations are repeated sequentially until all units have produced the metal prepared for a given ingot.
Upon completion of pouring, the chamber is depressurized, and the ingot remains in it until the metal has completely solidified.
Special tooling and equipment were manufactured for the manufacture of the ingot.
Shots with tooling after casting an ingot.
The equipment withstood the technological process.
Extracting the ingot from the mold and transporting it.
The hydraulic tilter places the ingot in a horizontal position.
Side grip of the ingot for loading and unloading operations.
Ingot conveyor.
The final operation of manufacturing an extra-large ingot is the forging process.
After heating, the ingot is sent for forging.
For this purpose, the Izhora Plant uses a modernized press, working in conjunction with robotic manipulators.
Press control panel.
Alternating shots with solid-forged rotors.
Photos of energy facilities.
Metallurgy, Super Large Bars
Leningrad
Izhora Metallurgical Plant. Kramatorsk Plant Energomashspetsstal.