Støbning af stort støbegods i ferritisk - SG jern - FMV
Støbning af stort støbegods i ferritisk - SG jern - FMV
Støbning af stort støbegods i ferritisk - SG jern - FMV
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<strong>Støbning</strong> <strong>af</strong> <strong>stort</strong><br />
<strong>støbegods</strong> i <strong>ferritisk</strong> <strong>SG</strong><strong>jern</strong><br />
Karl Martin Pedersen<br />
Siemens Wind Power A/S<br />
<strong>FMV</strong> Temadag om støbeprocesser i Slagelse,<br />
27. januar 2011<br />
Page 1<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
Outline<br />
Hvorfor <strong>SG</strong> <strong>jern</strong><br />
Støbeprocessen<br />
Metallurgi<br />
Form <strong>af</strong> gr<strong>af</strong>it<br />
Kimdannelse<br />
Chunky gr<strong>af</strong>it<br />
Indvirkning <strong>af</strong> defekter<br />
FeVIND projekt<br />
Test<br />
Page 2<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
1
Answers provided by 15 Divisions<br />
in three Sectors<br />
Sectors<br />
Healthcare Energy Industry<br />
Divisions<br />
Industry Automation<br />
Drive Technologies<br />
Building Technologies<br />
Oil & Gas<br />
Fossil Power<br />
Generation<br />
Renewable Energy<br />
Imaging & IT<br />
Workflow & Solutions<br />
Diagnostics<br />
Osram<br />
Industry Solutions<br />
Mobility<br />
Energy Service<br />
Power Transmission<br />
Power Distribution<br />
Siemens Wind Power, tidligere BONUS<br />
Page 3<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
Siemens Wind Power<br />
Facts at a glance<br />
One of the world’s leading suppliers of wind power solutions<br />
Deliveries: 2,900 MW in FY 2010<br />
Installed Base: > 9,000 turbines with > 11,000 MW capacity<br />
7,000 employees globally<br />
Record order backlog of roughly € 10 billion<br />
No. 1 in offshore wind power installations<br />
Target: To become Top 3 supplier in 2012<br />
Page 4<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
2
Store støbte emner i vindmøller<br />
Nav Lejehus Aksel Bundramme<br />
Page 5<br />
27-01-2011 Karl Martin Pedersen<br />
Materiale: EN-GJS-400-18LT<br />
Vægt: 3 til 25 tons<br />
Tykkelser: 30 to 200 mm<br />
Størrelse: Op til 4 m<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
Hvorfor <strong>SG</strong> <strong>jern</strong><br />
Ved størkning<br />
Metaller svinder (=porøsiteter i<br />
centrum <strong>af</strong> emnet)<br />
Kulstof udvider sig ved dannelse <strong>af</strong><br />
gr<strong>af</strong>it<br />
Kulstof sænker størkne-temperaturen<br />
ca. 350°C i forhold til stål<br />
Gråt støbe<strong>jern</strong><br />
Gr<strong>af</strong>it-kugler i stedet for gr<strong>af</strong>it-flager<br />
Højere styrke og sejhed<br />
Processen<br />
Stor geometrisk frihed<br />
Page 6<br />
27-01-2011 Karl Martin Pedersen<br />
<strong>SG</strong> <strong>jern</strong><br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
3
Støbeproces – Forme<br />
Top<br />
Støbes i sandforme.<br />
Jernramme rundt om<br />
sandformene<br />
Bund<br />
Kerne<br />
Page 7<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
Støbeproces<br />
Stål plader<br />
MgFeSi<br />
Ovn<br />
Behandlingsske<br />
Afgratte og slibe<br />
Page 8<br />
27-01-2011 Karl Martin Pedersen<br />
Undersøge kvalitet (mikrostruktur,<br />
ultralyd, opmåling…)<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
4
Støbeproces<br />
Film om støbeprocessen. Se den på:<br />
http://www.eisengiesserei-torgelow.de/<br />
Page 9<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
Mikrostruktur – Stort <strong>støbegods</strong><br />
Magnesium – Vigtigt for formen <strong>af</strong> gr<strong>af</strong>itten<br />
Koger ved 1091°C<br />
<strong>SG</strong> <strong>jern</strong> størkner ved ca. 1150°C<br />
Lang størkne tid -> Fordampning <strong>af</strong> magnesium -> Dårlig form <strong>af</strong> gr<strong>af</strong>it<br />
Kimdannelse <strong>af</strong> gr<strong>af</strong>it<br />
Sker på µm store partikler<br />
Lang størknetid -> Færre partikler -> Dårlig kimdannelse -> Porøsiteter<br />
Tilsætter forskellige elementer som Cerium og sjældne jordarter (RE)<br />
Chunky gr<strong>af</strong>it<br />
Dårlig gr<strong>af</strong>it form -> Ødelægger mekaniske egenskaber <strong>af</strong> emnet.<br />
Fremmes <strong>af</strong> bl.a. Cerium og sjældne jordarter<br />
Modvirkes <strong>af</strong> bl.a. Antimon (Sb)<br />
Page 10<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
5
Mikrostruktur – Gr<strong>af</strong>it form<br />
Formen <strong>af</strong> gr<strong>af</strong>it sammenlignes med<br />
billeder fra standard: ISO 945-1<br />
Form VI: Typisk for i <strong>SG</strong> <strong>jern</strong><br />
Form V: Typisk for tyk-vægget <strong>SG</strong> <strong>jern</strong><br />
Area of acceptable graphite<br />
Nodularity =<br />
×100%<br />
Total graphite area<br />
Størrelsen <strong>af</strong> gr<strong>af</strong>itten er også væsentlig.<br />
Page 11<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
Mikrostruktur – Gr<strong>af</strong>it form<br />
Page 12<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
6
Mikrostruktur – Gr<strong>af</strong>it form<br />
God gr<strong>af</strong>it form<br />
Dårlig gr<strong>af</strong>it form<br />
Begge billeder kommer fra samme emne – få mm<br />
<strong>af</strong>stand mellem billeder.<br />
Evaluer aldrig mikrostruktur ud fra et enkelt billede!!<br />
Page 13<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
Mikrostruktur – Chunky gr<strong>af</strong>it<br />
500 µm<br />
Page 14<br />
27-01-2011 Karl Martin Pedersen<br />
500 µm<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
7
Mikrostruktur – Chunky gr<strong>af</strong>it<br />
Page 15<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
FeVIND project<br />
The principal objective is to give the project partners knowledge, ability and<br />
methodology that make them best world wide when it comes to delivery of services<br />
linked to production of cast iron wind turbine components, including:<br />
Consistent quality<br />
Competitive price<br />
Intelligent design with documented fatigue properties<br />
Fatigue<br />
properties<br />
Base-line<br />
material<br />
Vestas<br />
castings<br />
Defected<br />
material<br />
Rejected<br />
Siemens hub<br />
Page 16<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
8
Base-line material<br />
Ø21 mm<br />
Ø50 mm<br />
Ved ∆σ = 190 MPa<br />
~ ±160 tons<br />
140 X 120 mm<br />
M. Shirani, G. Harkegard: Fatigue life distribution<br />
and size effect in ductile cast iron for wind turbine<br />
components, Engineering Failure Analysis, Vol.<br />
18, Issue 1, 2011, Pages 12-24<br />
Page 17<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
Defected material<br />
Page 18<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
9
3D X-ray computer tomography (CT skanner)<br />
Kendt fra hospitaler<br />
Ø21 mm test bar.<br />
Fejl > 0,2 mm kan findes<br />
Anvendt en CT skanner<br />
placeret i Aachen, Tyskland<br />
Page 19<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
3D X-ray computer tomography – Beregne levetid<br />
Udvælg mest kritiske<br />
Beregn levetid<br />
Defect Number<br />
Number of<br />
cycles to failure<br />
241 91 175<br />
215 52 330<br />
263 160 303<br />
218 168 664<br />
280 134 167<br />
251 136 877<br />
227 163 326<br />
247 253 064<br />
481 331 816<br />
224 152 027<br />
204 191 412<br />
380 489 488<br />
245 409 777<br />
192 339 951<br />
196 512 117<br />
432 641 859<br />
Page 20<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
10
Modellering i P-FAT – Beregning <strong>af</strong> levetid<br />
Virkelighed<br />
Model<br />
Page 21<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
Internal defects<br />
Page 22<br />
27-01-2011 Karl Martin Pedersen<br />
Kilde: Fatigue Fract. Engng. Mater. Struct. 22, 289-300<br />
Revnevækst hastighed 5 – 20<br />
gange højere i luft end i vakuum<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
11
Undgå porøsiteter ved overflade<br />
Migration of hotspot towards surface<br />
Machining into internal porosities<br />
Page 23<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
Mg – Inclusions<br />
Page 24<br />
Same effect as porosities<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
12
Cross section of fracture surface<br />
Page 25<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
Striation<br />
SEM images at different distance<br />
from initiation point<br />
Magnification: 10 000<br />
Detection limit: 0,20 to 0,25 µm<br />
Laminar spacing for pearlite<br />
structure: > 0,5 µm<br />
Variation in direction of striations!<br />
Page 26<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
13
Striation, 5 mm from edge<br />
Page 27<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
Graphite content on fracture surface<br />
17 mm from edge<br />
3 mm from edge<br />
Page 28<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
14
Tak for jeres opmærksomhed<br />
Page 29<br />
27-01-2011 Karl Martin Pedersen<br />
© Siemens AG 2011<br />
Siemens Wind Power A/S<br />
15
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