The process flow for the forging of a large thermal power generator rotor consists of several steps. It begins with smelting and casting ingots, followed by heating the steel ingots to the appropriate temperature. The heated ingots are then forged into the desired shape using a 125MN hydraulic press, with the forging temperature ranging from 750 to 1270°C. A forging ratio of 6.7 is maintained during this process, and multiple fire cycles are performed to achieve the desired results.
To ensure the production of high-quality forgings, suitable deformation techniques need to be applied based on the requirements of the forging structure. This involves selecting the right tool structure, improving operational methods, and utilizing uneven temperature and stress fields in defective materials. By doing so, it becomes possible to fully forge defective parts, weld internal voids and defects, and enhance the overall quality and mechanical properties of the forgings.
After the forging process is complete, the gating and risers are removed before proceeding to post-forging heat treatment. The purpose of this heat treatment is primarily to prevent white spots and hydrogen embrittlement, eliminate internal stress, reduce hardness, refine the internal structure of the forgings, and prepare them for the final heat treatment.
For the performance heat treatment, specific process parameters must comply with relevant specifications. The values obtained from the performance testing of the large rotor forgings require customer approval. Only when the physical and chemical performance analysis results meet the technical requirements specified by the customer can the products be considered ready for delivery.
In summary, the process of forging a large thermal power generator rotor involves various stages, including smelting and casting, heating, forging, post-forging heat treatment, rough machining, non-destructive testing, performance heat treatment, performance testing, and final machining delivery. Each step is crucial for producing high-quality forgings that meet the customer's requirements.
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