China Has Made Significant Breakthroughs In High-End Large Forgings

China has made significant breakthroughs in high-end large forgings

Core Tip: Recently, the world's largest single machine capacity of 500MW, high head and large capacity impulse turbine, developed by China National Machinery Heavy Industry Corporation and Dongfang Electric Machinery Co., Ltd., has successfully passed the ultrasonic testing before quenching and tempering.

Recently, the world's largest single machine capacity of 500MW high head and large capacity impulse turbine ultra large wheel center body forging developed by China National Machinery Heavy Industry Corporation and Dongfang Electric Machinery Co., Ltd. has successfully passed the ultrasonic inspection before quenching and tempering, marking a major breakthrough in the engineering application of pure purification smelting of molten steel, imitation forging of thick and large cake shaped parts, and coordinated control of forging process organization and shape in the field of ultra large martensitic stainless steel forgings for hydropower use by China National Machinery Heavy Industry Corporation. This is another major scientific research breakthrough after achieving the first breakthrough in the localization of FB2 rotors and nuclear welding rotors last year.

This forging is a key core component of the high head and large capacity impulse turbine and will be used in the construction of Zala Hydropower Station, the first hydropower station project with an installed capacity of over one million kilowatts in Xizang. Zhala Hydropower Station is the core power station of the integrated clean energy base in southeastern Tibet. It is currently the only hydropower project in China that can carry out the research and application demonstration of 500MW high head and large capacity impulse units. It is of great significance for achieving national energy security and the development strategy of "Tibetan electricity transmission".

The secondary equipment under the State Machinery Heavy Industry Group has made joint research and development with upstream units in the industry chain, focusing on the technical conditions for building large impact turbines for high head and large capacity impact units in high-altitude areas. Through systematic material basic characteristics and manufacturing process technology research, continuous breakthroughs have been made in forging smelting, forging, and flaw detection, contributing to the construction of a new "national heavy equipment" through heavy equipment.

Recently, the last set of M701J gas turbine cylinders successfully developed by China National Machinery Heavy Duty Truck Group Co., Ltd. passed the joint inspection and was sent to the user's site. So far, all 8 sets of products developed by China National Machinery Heavy Duty Truck Group Co., Ltd. have been delivered, becoming the first enterprise in China to successfully master the manufacturing technology of high-end heavy-duty gas turbine castings covering E-class, F-class, and H/J-class stages and achieve mass production, making important contributions to the world's advanced localization of H/J-class gas turbines.

Heavy duty gas turbines are the core equipment in the fields of power generation and drive, reflecting a country's industrial level. They are known as the "crown jewel" of equipment manufacturing and are widely used in power generation, aviation, shipbuilding, petrochemicals, and other fields.

The research and development team of China National Heavy Duty Truck Group's secondary equipment fully utilized numerical simulation technology and lean management tools to carry out multi field coupled simulation calculations of filling, solidification, and stress, as well as full process value stream analysis. They have overcome key manufacturing technologies such as high-quality H/J grade heavy-duty gas turbine thin-walled complex cast steel parts, providing important support for the localization of heavy-duty gas turbines in China and ensuring energy security.