World of Metallurgy ERZMETALL 68 2015 No 3128 Economics Technology and Science it is ideally suited for aircraft engines The material provides the potential to reduce the weight of turbine blades for aircraft engines by up to 50 which also goes along with a significant re duction of the centrifugal forces The lighter design of the engines made possible with the new components will contribute decisively to reduced fuel consumption Intermetallic tita nium aluminide was considered as not forgeable for a long time Compared to casting forging generates a special re crystallization structure which is ne cessary for safety reasons for the rot ating engine parts In addition the pro cess stability during forging is higher than during casting and consequently the turbine blades meet the extremely high quality requirements of the air craft industry Leistritz has developed a new process where the blanks can be formed without cracks under ca refully defined conditions at tempe ratures between 1150 and 1300 C The high forming temperature and the long dwell time of the forgings in the die due to forming speeds of less than 0 1 mm s require heating the tools to forging temperature The extremely low press speeds re quire the hydraulic drive control to be especially accurate and uniform Special guide and sealing systems as sure uniform compression and thus avoid the undesired stick slip effect The symmetrical press design with a cross thread guide located on the out side allows for high precision forging Because the guide elements are isola ted from the heat source there is no thermal influence on the guide The large distance between the guidance elements and the high rigidity of the press frame also contribute to preci sely opposite aligned upper and lower dies during the forging process Leis tritz has been operating a Siempel kamp 50 MN isothermal forging press since 1984 Due to the positive expe riences and Siempelkamp s expertise in the technologically sophisticated isothermal forging process Leistritz contacted Siempelkamp early on and discussed different concepts In No vember 2014 Leistritz commissioned Siempelkamp with the development and production of two manufacturing plants for the series production of tur bine blades Since the molybdenum contained inside the dies sublimates in the open air at temperatures over 600 C oxygen has to be prevented from entering the dies Therefore the entire plant is enclosed which allows the complete automatic process start ing with the inserting of the blank at room temperature to the unloading of the forged turbine blades to take pla ce in an inert gas atmosphere Figure 10 Siempelkamp supplies both pres ses from a single source The scope of supply for both presses includes a rotary hearth furnace a loading mani pulator the forging press the tool hea ting system the hydraulic drive system and the complete electrical system The process control monitors and do cuments the process parameters ac cording to the certification standards in the aircraft industry The first press will start series production in March 2016 the second press one year later Press Release March 27 2015 200 MN Open Die Press PAHNKE outperforms own world record After a long tendering phase Wepuko PAHN KE succeeded in winning the bidding against worldwide competition for a project in China The contract includes the entire press system for the world s prospectively largest top floor open die forging press TFP with a press force of 200 MN generated by a hy draulic drive system with an installed power of 12 000 kW Figure 11 In the modern energy efficient PAHN KE Modified Sinusoidal Direct drive PMSD 20 advanced and durable ra dial piston pumps of the type RX 500 will be put in action With this project Wepuko PAHNKE WP enters new dimensions regarding pressure press force and dimensional press daylight and is breaking its own world record Fig 10 The complete plant forging press left loading unloading device in center in front of it the rotary hearth furnace is enclosed and operates under an inert gas atmosphere Picture Siempelkamp Previously in 2011 a structurally simi lar TFP with a press force of 185MN was delivered to Citic Heavy Machi ne Corporation Figure 1 The main field of operation of this new instal lation will be the production of ring segments and discs for manufacturing pressure vessels for the nuclear power plant industry Thus the buyer broa dens his product portfolio and tabs into a rapidly expanding market Chi na s goal is to increase the overall nuc lear power generation from 18 GW to 40 GW by 2020 Furthermore multiple nuclear power plants with significantly higher outputs than what is common today are being projected The safety requirements in this industry are very stringent This implies facing unique challenges for the press system With this press homogeneous parts for high pressure vessels with diameters of up to 9 5 m will be forged to highest qua lity and precision standards The main characteristic of this press is besides forging the ring segments the abili ty to also forge the large arced vessel bottoms in one piece Forging those large parts the press must offer an ex ceptional eccentric loading capacity This is also required for an additional manufacturing step punching the flan ge connection ports into the vessel s main body or the vessel bottoms Visi tors of the METEC 2015 trade fair in Düsseldorf will have the opportunity to receive first hand information ab out solutions and products by Wepuko PAHNKE The booth C03 is located in hall 05 Press Release April 27 2015 Fig 11 185 MN PAHNKE open die press at Citic HMC in China

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