For hydro power generation- ESRC wicket gate for Three Gorges Power Station.
Material: ASTM A743 Gr CA6NM, ZG0Cr13Ni4Mo (ZG0Cr13Ni5Mo ZG0Cr16Ni5Mo etc.) stainless steel
Production method：AOD refining+ electro-slag remelting casting
Individual net weight: 150~30000 kg
Delivery state: as cast, semi-machined, machined
More than 1000 wicked gates are produced annually at SRIF, including more than 200 for export. Total weight of annual output is about 2500 tons. Our products are used in world renowned hydraulic power generation endeavors, such as Three Gorges, Baihetan, Xiluodu, Xiangjiaba, Wudongde, etc.
Working principle of ESRC
The ESRC process completes electro-slag remelting, refining and casting at the same time, so the castings produced by ESRC boast not only good inner quality, but also good material properties.
At the beginning of the ESRC process, a pool of molten slag with the depth of 100-200mm is formed at the bottom of a crucible. When the consumable electrode connected to a power source is submerged into the molten slag, strong electric current passes through the slag pool, producing heat to increase the temperature of slag.
When the temperature of slag exceeds the melting point of the consumable electrode, the electrode melts to form steel droplets on the surface which then fall through the slag pool due to gravity. In this process, the harmful elements and the impurities in the consumable electrode are lowered.
The molten steel forms a metal pool under the slag pool. Cooled by circulating water, the molten steel gradually solidifies and eventually forms a casting.
In the ESRC process, the melting of the consumable electrode, the refining of molten steel, the filling of the crucible and the solidification continuously proceed in turn until the crucible is fully filled and a casting thus made from bottom to top.
Advantages of ESRC
1. Progressive solidification and self padding: the density of final products is much higher than that of sand mold castings.
2. Slag refining: the sulfur content and other impurities are reduced and the toughness, fatigue resistance and welding ability is higher than those of sand mold castings.
3. The result of ultrasonic tests proves to meet the requirement of CCH70-3 and the highest level of ASTM A609, 1-2 levels higher than the result of sand mold castings.
4. Cavitation resistance is increased by 30% compared with sand mold castings.
5. Metal mold casting process creates less environmental pollution.
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