Analysis And Solution Routes Of Slag Inclusion Defect To Wind Turbine Castings

With the global energy development towards to low-carbon,pollution-free,safe,low carbon dioxide emissions,affordable and maintain the sustainable development of the ecological environment,wind power casting enterprises can develop rapidly.Wind power casting enterprises have different castings quality due to different materials used in the manufacturing process,different process attention,different management level,different technical level,different equipment use degree and operation ability,different quality culture and weak overall profitability.Among all kinds of quality defects,slag inclusion defect is relatively high,which is also the direction that many enterprises continue to study,to solve slag inclusion defect,improve product quality level,so as to provide enterprises with comprehensive competitiveness and profitability in the market.This paper takes the base,hub and bearing housing of V112 series products as the research object,and analyzes the slag inclusion problems found in the molding process,melting process and machining process of the series products.Through analysis,it is found that slag inclusion defects mainly exist in casting edge,casting surface,casting groove,casting load bearing place,casting interior,etc.The reasons that affect the formation of these defects include sand compaction,selection of ceramic tube,personnel verification,process parameter ratio of resin,coating,curing agent and sealing condition of ceramic tube.Control of raw material composition in smelting process,control of spheroidizing process time,control of furnace temperature,control of melting pouring temperature,selection of pouring position,selection of gate basin diameter,design of pouring system,filter piece,etc.This paper by using eight steps corrective action report(8 d analysis),high risk event analysis(HIPO)analysis,fishbone diagram and five why analysis(5)according to the specific analysis of these defects,and adjust the production process of the above parameters,through experimental verification,to improve product quality,improve enterprise’s competitiveness and profitability.Through to the coating baume degree,the perpendicularity of the ceramic tube,the strength of sand,sand compactness,reinforcement is placed,melt temperature,pouring temperature,spheroidization time,gate basin size,pouring position,pouring system design of comprehensive optimization,our V112 series products of slag defects from improving reduced to improved 4.2% and 18.8% before improvement to achieve the desired goal,to improve the customer satisfaction.Moreover,the improvement ideas described in this paper can be applied to many other similar products in the company.It is believed that through such improvement actions,the slag defect rate of wind power castings in our company will be continuously reduced,which will bring better competitiveness and cost benefit to wind power complete machine enterprises.There are 58 figures,21 tables and 63 references in this paper.