Maternal and infrastructure industries in any country are dependent on rotating equipment and heavy machinery, at the heart of which are turbines. Turbines play a vital role as power generators in power plants, refineries and aviation industries. The technical and engineering complexity in manufacturing turbine parts is so high that only limited countries and highly specialized workshops have the ability to produce and repair them. In the meantime, the turbine disk, as one of the most sensitive rotating components, requires metallurgical knowledge and micron dimensional accuracy. Sajjadi turning workshop is known as one of the specialized hubs in the field of machining and manufacturing of these strategic parts by using modern technical knowledge and advanced devices.
In this article, we intend to examine the complex production processes, special materials and technical challenges in the way of manufacturing turbine parts and especially turbine discs and explain the key role of Sajjadi turning workshop in localization and providing superior industrial services.
The strategic importance of making turbine parts in the industry
Turbines are machines that convert fluid energy (such as gas, steam, or water) into mechanical work. These equipments work in very harsh environmental conditions. High temperature, high pressure and dizzying rotation speed are the factors that threaten the life of the parts. Therefore, manufacturing turbine parts is not a process that can be done with conventional turning methods. Each part, from blades to shaft and shell, requires precise engineering and the use of superalloys.
In Iran, due to sanctions and high import costs, the need for domestic production is felt more than ever. Understanding this national need, Sajjadi Turning Workshop has focused on reverse engineering and producing parts that were previously only supplied through imports. The ability to manufacture turbine parts with global standards has made this group a reliable partner for the power plant and oil and gas industries.
turbine disk; The beating heart and the main axis of stress tolerance
Among all the components of a turbine, Turbine Disc (Turbine Disc) plays a vital and pivotal role. The turbine disc is the part on which the moving blades are mounted and transmits the force resulting from the collision of the fluid with the blades to the main shaft. This part is affected by the strongest centrifugal forces. If there is the slightest flaw in the material structure or dimensions of the turbine disk, it will lead to the explosion of the turbine and irreparable damages at high speeds.
The production process of turbine disc in Saat Tarash Sajjadi workshop is carried out with great obsession. From the selection of raw materials, which are usually nickel or titanium base alloys, to the final machining steps, everything is under strict control. The blade retaining grooves (which are often fir-tree-shaped) must be machined with a precision of a few microns so that the blades sit firmly on the disc without slack. Our expertise in manufacturing turbine components allows us to produce the most complex disc geometries with quality assurance.
Metallurgical challenges and material selection in turbine parts manufacturing
One of the most important differences between making turbine parts and other industrial parts is the type of materials that are used in them. Conventional steels melt or deform at temperatures above 1000°C, which are common in gas turbines. Therefore, superalloys are used in the production of these parts.
Characteristics of superalloys in turbine parts
- Creep Resistance: Parts such as turbine discs and blades at high temperature and pressure should not change length over time.
- Fatigue Strength: Turbines are constantly turned on and off and experience many stress cycles.
- Resistance to corrosion and oxidation: Hot exhaust gases They can be very corrosive.
Working with these alloys (such as Inconel, Hostaluge and Titanium) is very difficult. They are extremely hard and slow down turning tools. Sajjadi Lathe Industry Workshop has overcome this challenge by using advanced ceramic and carbide cutting tools and using modern machining techniques. We have enough knowledge to choose the best machining method for each specific type of alloy in the process of manufacturing turbine parts.
The process of reverse engineering of the turbine disc in the Sajjadi turning industry workshop
Many of the existing turbines in the country are old models whose construction plans are not available. This is where the art of reverse engineering comes into play. In Sajjadi turning workshop, the process of producing a new turbine disc from a used or damaged sample is carried out through the following steps:
- 3D scanning and digitizing: Using CMM devices and precise laser scanners, the cloud points of the part are removed.
- Material analysis: A sample of the disc material is sent to the metallurgical laboratory for accurate determination of the alloy and heat treatment.
- Computer modeling: Engineering team with advanced CAD software, 3D model of the disc Redesign the turbine and apply the necessary modifications. Preparation of construction drawings: Executive drawings with exact geometric tolerances (GD&T) are extracted. Preparation of the construction process: Machining, heat treatment and stress relief steps are planned.
This scientific approach has led to manufacturing of turbine parts in this collection with the same or even better quality than the original foreign sample.
CNC machining technology in the production of precision parts
The beating heart of the production line in Sajjadi Lathe Workshop is advanced CNC machines. Manual machines cannot be used to carve complex shapes on the turbine disk or the precise holes in the cooling system of the blades. Multi-axis CNC milling and turning machines allow the tool to approach the workpiece at different angles.
In making turbine parts, surface finish is of vital importance. Any scratches on the surface of the turbine disc can become the starting point for fatigue cracks. Our experienced operators create a flawless, polished surface by fine-tuning cutting parameters such as spindle speed, feed rate and load depth. In addition, the use of high pressure coolants during the machining of superalloys prevents thermal deformation of the part.
Importance of dynamic and static balance in turbine disc
After finishing the machining steps in the process of Sa Digitizing: using CMM devices and precise laser scanners, the cloud points of the part are removed.
- Material analysis: A sample of the disc material is sent to the metallurgy laboratory for accurate determination of the alloy and heat treatment.
- Computer modeling: The engineering team, with advanced CAD software, redesigns the 3D model of the turbine disc and applies the necessary corrections. (GD&T) are extracted.
- Development of manufacturing process: Machining, heat treatment and stress relief steps are planned.
This scientific approach has led to manufacturing of turbine parts in this collection with the same or even better quality than the original foreign sample.
CNC machining technology in the production of precision parts
The beating heart of the production line in Sajjadi Lathe Workshop is advanced CNC machines. Manual machines cannot be used to carve complex shapes on the turbine disk or the precise holes in the cooling system of the blades. Multi-axis CNC milling and turning machines allow the tool to approach the workpiece at different angles.
In making turbine parts, surface finish is of vital importance. Any scratches on the surface of the turbine disc can become the starting point for fatigue cracks. Our experienced operators create a flawless, polished surface by fine-tuning cutting parameters such as spindle speed, feed rate and load depth. In addition, the use of high pressure coolants during the machining of superalloys prevents thermal deformation of the part.
Importance of dynamic and static balance in turbine disc
After finishing the machining steps in the process of manufacturing turbine parts, it is time for one of the most sensitive steps, i.e. balance. The turbine disc rotates at very high speeds (sometimes up to 30,000 rpm in small turbines). The slightest mass imbalance causes violent vibrations. These vibrations not only destroy the bearings, but can also cause the main shaft to break.
Dynamic and static balance services are performed with calibrated devices at Sajjadi Turning Workshop. We ensure that the center of mass of the turbine disc is exactly aligned with the axis of rotation. It is the attention to detail that distinguishes a normal part from a standard turbine part.
Quality control and non-destructive testing (NDT)
Our commitment to quality in manufacturing turbine parts is not just a slogan, but a documented and implemented process. No piece leaves Sajjadi turning workshop unless it has passed quality control tests. For sensitive parts such as turbine discs, the following non-destructive tests are required:
This level of quality control ensures that our customers can safely install manufactured components in their expensive turbines. Manufacturing turbine parts without a powerful quality control system is considered a big risk for the employer's capital.
Types of turbines and services of Sajjadi turning industry
Our expertise in manufacturing turbine parts is not limited to one specific type. We have the ability to provide services for all types of turbines:
1. Gas Turbines
These turbines are used in combined cycle power plants and gas pressure boosting stations. Their working temperature is very high and the turbine disc in them must have an extraordinary thermal resistance. Sajjadi Turning Workshop has a lot of experience in rebuilding and making hot sections of these turbines.
2. Steam Turbines
They are used in steam power plants and petrochemical industries. The main problem in these turbines is corrosion and erosion caused by water droplets. We increase the life of these turbine parts by using resistant coatings and special stainless steel materials.
3. Water and wind turbines
Although they have different mechanisms, the precision in making shafts and their connections is also within our expertise.
Major repairs and rebuilding of the turbine disk
It is not always necessary to make a new part. Sometimes the turbine disc suffers minor damage that can be repaired with specialized methods. Sajjadi Turning Workshop also provides restoration services. These services include specialized laser or argon welding for edge repair, recoating and final machining to bring the part back to standard dimensions. Repair and reconstruction greatly reduces the costs of the employer compared to the construction of turbine parts in a new way and minimizes the downtime of the device.
Why choose Sajjadi turning workshop?
In today's competitive market, choosing the right contractor for manufacturing turbine parts is a big challenge. The reasons that major industries of the country trust Sajjadi turning workshop are:
- Experience and brilliant history: Years of activity in the field of turning heavy and complex parts.
- Modern equipment: Access to precise CNC machines and advanced measuring tools.
- Expert technical team: Employing expert mechanical and metallurgical engineers along with experienced technicians.
- Commitment to delivery time: We understand that every hour the turbine stops How expensive it is, so good promises are our priority.
- Competitive price: Providing global quality at a much more reasonable price than foreign samples.
- Quality assurance: Guaranteed performance of parts made, especially turbine disc.
We at Sajjadi Turning Workshop believe that the country's industry deserves the best. When it comes to manufacturing turbine parts, there is no room for error and we take this heavy responsibility with pride.
A look at the future of the turbine manufacturing industry in Iran
Due to technological advances, the new generation of turbines have higher efficiency and more complex dimensions. Manufacturing turbine parts for this new generation requires constant updating of knowledge and equipment. Sajjadi Group is continuously researching and developing in order to be able to meet the future needs of the country's industries in line with the modern technology of the world. The localization of advanced single crystal turbine disks and the use of additive manufacturing methods along with machining are our long-term goals.
Ordering process and technical advice
If you also operate in the power plant, oil, gas or petrochemical industries and need to make turbine parts, overhaul or supply turbine discs, our experts are ready for free consultation. We can suggest the best technical and economic solution by checking the condition of your equipment. The work process is started by sending a drawing or a piece sample, and after estimating the cost and time, the project is placed in the production line of Sajjadi turning workshop.
The satisfaction of our customers in major national projects is a proof of our ability. Our goal is to cut off the country's dependence on foreign countries by providing superior services in the field of manufacturing turbine parts and make the wheels of the industry turn with more power.
Summary
Turbines are complex and sensitive machines whose correct operation guarantees the continuity of production in parent industries. Manufacturing turbine parts and especially turbine discs, requires a combination of engineering knowledge, advanced metallurgy and precision machining. Any negligence in this process can lead to disaster.
Sajjadi Turning Workshop, relying on years of experience and using modern technologies, is ready to meet all your needs in the field of design, reverse engineering and manufacturing of rotating and fixed turbine parts. We have put quality, precision and speed at the top of our work so that you can produce and develop with confidence. Trusting internal experts in Sajjadi Group is an investment in the quality and safety of your equipment. To order manufacture of turbine parts and receive expert advice, contact us today.
