Research On Manufacturing Process Of The Microporous Superalloy Honeycomb Semi-hexagonal Corrugated Structure

Turbine is a kind of rotary power machine which converted steam energy into mechanical power, and has been widely used in the aviation, marine, nuclear,thermal power and other fields. Tightness of turbine is closely related with utilization of high temperature steam and product safety, the traditional comb-sealing method which can not meet the work requirements of a modern steam turbine for some corrupt practices, has been replied by the metallic honeycomb structure which perfect excellent sealing performance in recent years.Due to the poor quality of domestic manufacturing seals honeycomb, product supply and technical support subjected to foreign countries always restricts turbine industry.This dissertation focus on exploring the forming process of corrugated foil and assembly method of the porous sealing honeycomb while using nickel-based superalloy GH536 as honeycomb foil substrate. On the basis of explicit material characteristics, basic requirements of honeycomb applications and quality, and according to the metal forming principle and mechanical analysis of the forming process, some key parameters have been selected for theoretical simulation process, combining finite element analysis with experimental method, got the optimized geometry parameters of forming roll by simulating, which is the key component of roll forming process, then designed experimental equipment with the parameters. Improved the developed forming apparatus through roll forming experiments, the results show that, different sides of the semi-hexagonal corrugated honeycomb structure foil have different forces during foil forming by roll forming method, the formed foil presented as local bending and single flank size asymmetry, which are difficult to assemble a qualified honeycomb.On the basis of defects analysis of roll forming process, then studied the corrugated foil stamping process, got optimized structure and preliminary design parameters of punch and die through finite element analysis, and as a basis for the design of stamping die, then press-forming test, and optimized the mold according to the experimental results. The results show that honeycomb semi-hexagonal corrugated structure which manufactured by stamping presented as overall flat, symmetrical single tooth and adjacent side clip angle close to the ideal value, which meet the requirements of design. On the basis of the experimental procedure and results, a multifaceted contrast has been done between the two forming methods, and pointed out both advantages anddisadvantages of them and the effect on production quality, and the microporous metallic honeycomb forming process was optimized. Finally, a welding method was also used for attempting to overcome honeycomb assembly process, which conducted a preliminary further clarify of the requirements for forming quality of corrugated foil and manufactured a honeycomb about 20 mm length.