As an important component in thermal power generation equipment, the quality and performance of thermal power forging directly affect the safety and efficiency of thermal power generation equipment. However, in the production process of thermal power forgings, cracks often become the main factor affecting product quality. The generation of cracks will not only lead to the scrapping of forgings, but also may cause safety accidents during use. Therefore, it is of great significance to study the crack generation mechanism and control measures in thermal power forging production. In this paper, the mechanism of crack generation is discussed from the aspects of production process, raw material properties and forging technology, and corresponding control measures are proposed.
Crack generation mechanism
Production process factor
The production process of thermal power forgings includes raw material procurement, forging, heat treatment, machining and other links. In the production process, any part of the mistake may lead to cracks. For example, there are defects such as inclusions and pores in raw materials, improper temperature control during forging, insufficient forging ratio, and too fast cooling speed during heat treatment may cause cracks.
Material performance factor
Alloy steel is the main raw material of thermal power forgings, and its chemical composition, structure and mechanical properties have important effects on the generation of cracks. For example, too much carbon will cause the toughness of the material to decline, and it is easy to crack; Improper selection of alloying elements may lead to microstructure stress during heat treatment, and then crack.
Forging process factor
Forging process is the key link that affects the quality of thermal power forging. The temperature control, deformation rate and forging ratio in forging process may affect the crack formation. For example, too high temperature will lead to over-burning of the material, and too low temperature may lead to cracking of the material; Too fast a deformation rate may lead to stress concentration within the material, leading to cracks.
Control measure
Optimize production process
In order to reduce the occurrence of cracks, the production process of thermal power forgings should be optimized. First of all, it is necessary to strengthen the quality control of raw materials to ensure that there are no defects such as inclusions and pores in raw materials. Secondly, parameters such as temperature, deformation speed and forging ratio should be strictly controlled in the forging process to avoid over-burning and cracking of materials. In addition, the cooling rate should be reasonably controlled during the heat treatment process to prevent cracks caused by excessive organizational stress.
Reasonable selection of raw materials
According to the special requirements of thermal power forgings, raw materials should be selected reasonably. First of all, it is necessary to ensure that the chemical composition of the raw material meets the design requirements to avoid cracks caused by too high carbon content or improper selection of alloying elements. Secondly, it is necessary to ensure that the organizational structure and mechanical properties of raw materials meet the requirements to avoid cracks caused by insufficient toughness of the material or excessive organizational stress.
Improve forging process
In order to reduce the occurrence of cracks, the forging process should be improved. First of all, parameters such as temperature, deformation speed and forging ratio in the forging process should be reasonably controlled to avoid the occurrence of cracks caused by improper parameters. Secondly, advanced forging technology and equipment, such as precision forging and isothermal forging, should be used to improve the density of the material and reduce the internal stress concentration. In addition, the forging process can be simulated and optimized by numerical simulation to further reduce the occurrence of cracks.
In this paper, the mechanism of crack generation in thermal power forging is discussed from the aspects of production flow, raw material properties and forging technology, and the corresponding control measures are put forward. By optimizing the production process, selecting the raw materials reasonably and improving the forging process, the crack generation in the production of thermal power forgings can be effectively reduced, and the product quality and safety performance can be improved. In the actual production process, enterprises should take targeted control measures according to their actual conditions to ensure that product quality meets the requirements.
