manufacturing technology
Complex energy components such as this blisk benefi t from a range of technologies that includes cutting tool strategies, cladding and wear protection options.
ing a broad range of Stellite alloys and composite materials commonly used on wear bands, stabilizers and reamers. Kennametal’s broad portfolio of hardfacing consumables is available in various forms such as wire, tube rods, composite rods and powders. Kennametal also offers JetKote HVOF and Starweld PTA systems for customers who are looking for a complete package for applying coatings in their facilities.
Turbine Blade Machining Whether powered by fossil fuels, hydro or nuclear power, almost all electrical power on earth is generated by a turbine of some type. Producing, managing and maintaining these critical components are vital to keeping the power fl owing. This puts a lot of pressure on manufacturers to continu- ally update their machining strategies. Many factors affect this: are large numbers of similar blades required or small volumes of different blade designs? Are multiple setups and machining centers involved or single multiaxis multitasking machines? What is the CAD/CAM system in use and what is the expertise of the operators? And, of course, what are the best tooling choices for the machining operations? Recent test results involving the new Kennametal KYS40 solid-ceramic end mill are insightful. First of all, the KYS40 Beyond grade ceramic in both the
four-fl ute and six-fl ute versions features an enlarged core design that improves tool rigidity and reduces defl ection at
high cutting speeds. Optimized end geometry and a 40° helix angle increase shearing action and chip evacuation. In roughing the profi le of a small turbine blade made of Inconel 718, machined dry, the EADE four-fl ute end mill was run at 645 m/min, fed at 0.03 mm/z (0.0012 IPT). Depth of cut (ap) was 0.5 mm and width of cut (ae) was 11.4 mm. Compared with a conventional solution, the EADE four-fl ute mill lasted three times longer doing the roughing in less time. This application re- sulted in three times more parts being produced per mill. The six-fl ute EADE solid-ce- ramic end mill was tested profi l- ing a blisk (blade integrated disk) made of Inconel 718 and run with compressed air for chip
evacuation. Unlike conventional carbide tooling, roughing to near net shape creates chips closer to dust than traditional curled chips, requiring only compressed air to blow them out of the cut. Test conditions were cutting speed of 679 m/ min, feed of 0.03 mm/z and the depth of cut varied up to 0.5 mm. The results were two blisk segments machined with one tool at a 12-minute machining time per segment, which test personnel deemed “unprecedented.”
Cladding Popcorn Screens in Coal Plants Popcorn screens are vital components in protecting selec- tive catalytic reduction (SCR) systems, essential equipment for reducing nitrogen oxide (NOx) emissions in coal-fi red power plants. Flue gas has to pass through so the SCR system can do its job. Highly abrasive and corrosive popcorn ash, though, can foul and “blind” the system, greatly reduc- ing or eliminating system effectiveness. Popcorn screens act as barriers, but like any other fi lters, performance life may be limited. And if an SCR system isn’t doing its job, not only are they extremely expensive to clean and repair, the power plant may fi nd itself running afoul of new EPA regulations mandating stricter control of NOx emissions. Tungsten carbide cladding from Kennametal Conforma Clad has been shown in fi eld tests to extend the life of pop- corn screens more than eight times compared with common-
84 — Energy Manufacturing 2015
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66 |
Page 67 |
Page 68 |
Page 69 |
Page 70 |
Page 71 |
Page 72 |
Page 73 |
Page 74 |
Page 75 |
Page 76 |
Page 77 |
Page 78 |
Page 79 |
Page 80 |
Page 81 |
Page 82 |
Page 83 |
Page 84 |
Page 85 |
Page 86 |
Page 87 |
Page 88 |
Page 89 |
Page 90 |
Page 91 |
Page 92 |
Page 93 |
Page 94 |
Page 95 |
Page 96 |
Page 97 |
Page 98 |
Page 99 |
Page 100 |
Page 101 |
Page 102 |
Page 103 |
Page 104 |
Page 105 |
Page 106 |
Page 107 |
Page 108 |
Page 109 |
Page 110 |
Page 111 |
Page 112 |
Page 113 |
Page 114 |
Page 115 |
Page 116 |
Page 117 |
Page 118 |
Page 119 |
Page 120 |
Page 121 |
Page 122 |
Page 123 |
Page 124 |
Page 125 |
Page 126 |
Page 127 |
Page 128 |
Page 129 |
Page 130 |
Page 131 |
Page 132 |
Page 133 |
Page 134 |
Page 135 |
Page 136 |
Page 137 |
Page 138 |
Page 139 |
Page 140 |
Page 141 |
Page 142 |
Page 143 |
Page 144 |
Page 145 |
Page 146 |
Page 147 |
Page 148 |
Page 149 |
Page 150 |
Page 151 |
Page 152 |
Page 153 |
Page 154 |
Page 155 |
Page 156 |
Page 157 |
Page 158 |
Page 159 |
Page 160 |
Page 161 |
Page 162 |
Page 163 |
Page 164 |
Page 165 |
Page 166 |
Page 167 |
Page 168 |
Page 169 |
Page 170 |
Page 171 |
Page 172 |
Page 173 |
Page 174 |
Page 175 |
Page 176 |
Page 177 |
Page 178 |
Page 179 |
Page 180 |
Page 181 |
Page 182 |
Page 183 |
Page 184 |
Page 185 |
Page 186 |
Page 187 |
Page 188 |
Page 189 |
Page 190 |
Page 191 |
Page 192 |
Page 193 |
Page 194 |
Page 195 |
Page 196 |
Page 197 |
Page 198 |
Page 199 |
Page 200 |
Page 201 |
Page 202 |
Page 203 |
Page 204 |
Page 205 |
Page 206 |
Page 207 |
Page 208 |
Page 209 |
Page 210 |
Page 211 |
Page 212 |
Page 213 |
Page 214 |
Page 215 |
Page 216 |
Page 217 |
Page 218 |
Page 219 |
Page 220 |
Page 221 |
Page 222 |
Page 223 |
Page 224