X6.6D - Dongqi Big Girl Makeup Ready

On December 5, 2018, the first piece of Dongqi (Dongfang Turbine Co., Ltd.) grooved stress relief rotor, drawing No. X6.6D-211100A01QF, undertaken by Hangzhou Automobile Casting and Forging Co., Ltd., was coated with golden antirust oil and ready for shipment.

With the expansion of external orders undertaken by casting and forging companies, especially for small and medium-sized steam turbines and generator rotors with a capacity of less than 25 tons, their product quality and reputation for delivery cycles have gradually emerged in the domestic market. In the middle of 2017, the marketing, quality assurance, materials, and process departments of Dongqi Motor Co., Ltd. sent personnel to the casting and forging company for qualification review of qualified suppliers. We know that Dongqi Motor Co., Ltd. is a large state-owned backbone enterprise engaged in the development and manufacturing of power plant power equipment and new energy fields in China, and is also one of the largest power generation equipment manufacturing enterprises in China. It is one of the top 100 mechanical industry enterprises in China, Our forging products can only reach a certain level to gain their favor. Their team of six experts conducted a document review and on-site management review of the key processes of rotor forging production, including ingot quality, forging process, and heat treatment process, in accordance with the six elements of quality management: personnel, machinery, materials, methods, environment, and measurement. The review results met the expectations of the expert team. After returning, they underwent strict review and tracking of software and hardware data for nearly half a year, Finally, at the end of 2017, it was officially approved to add Hangzhou Automobile Casting and Forging to their qualified supplier team.

In August of this year, the order for the first X6.6D-211100A01QF steam turbine rotor product from Dongqi arrived late and was cast and forged. Upon receiving the order from Dongqi, the company attached great importance to marketing, technology, quality assurance, and production. After analyzing the technical requirements related to the product drawings, it was found that the technical requirements for the first product of Dongqi were particularly high. The acceptance was conducted according to its own internal control standards and the requirements of the Japanese inspection plan. The internal control procurement standards originated from Japan and were higher than Japanese standards. According to foreign standards, all performance requirements include testing both 0.2% yield strength and 0.02% yield strength indicators, and ensuring that the discrete value of radial yield strength is less than 41MPa. Secondly, the internal quality of materials requires particularly strict ultrasonic testing requirements. Various specifications of longitudinal wave angle probes should be used for flaw detection according to American standards (originally, we only conducted transverse wave straight probe flaw detection according to industry standards), which takes a long time and uses many probes, Meet the requirements of gas turbine rotor forgings. After the improvement of flaw detection requirements, the requirements for the quality of steel ingots, forging, and heat treatment of products have greatly improved; Thirdly, there are many items required for product acceptance. In addition to the above required testing items, there are also four grain size and inclusion tests for the two shaft ends of the forging and the two ends of the shaft, as well as finished product uniformity analysis for the two end surfaces of the shaft, FATT50 curve analysis for both ends of the shaft, upper platform performance testing, and hardness uniformity analysis for each section of the shaft. In addition, users also require a particularly large number of test pieces when returning to the factory. A total of 24 test pieces are required for the longitudinal direction of the shaft end and the radial direction of the shaft body. The rotor slotting process is also a difficult problem. For the first time, we came into contact with an order where the machining surface at the bottom of the impeller groove is an inclined surface.

Facing the high requirements of the first rotor of Dongqi. The early stage technology development department will immediately prepare the first product process control quality plan MQP according to the contract cycle, and feedback it to Dongqi Materials, Technology, and Quality Assurance for countersigning. MQP includes all detailed technical documents, processes, and acceptance requirements for the first rotor. Due to the large number of countersignature departments and strict requirements of Dongqi, and the product delivery date is only three months. To ensure the product delivery date, we have analyzed our own capabilities and started work ahead of schedule. By the time the document is officially approved by Dongqi two months later, our products have already been produced in half, so that each process is tracked and responsible by a dedicated person. After nearly three months of joint efforts by all the company's marketing, technology, production, and quality assurance personnel, the acceptance indicators of the first X6.6D-211100A01QF rotor fully meet the high standards of Dongqi. Today, the entire makeup is ready for delivery.

The successful production of Dongqi's first X6.6D-211100A01QF rotor marks another milestone in the forging production of the casting and forging company, with the ability to undertake and produce high-end steam turbine and gas turbine rotors! Praise the casting and forging company!