A successful forging of the third generation nuclear power evaporator cone

China has recently utilized its 15,000-ton hydraulic press to forge a "flare-shaped" cone cylinder, showcasing a remarkable hands-on technique. This process allows for the precise forging of both the "straight section" and "oblique section" of the third-generation nuclear power evaporator connected to the "meter-shaped" cone cylinder, a rare and highly specialized skill. A few days ago, China successfully completed the forging of the third-generation nuclear power evaporator cone. From forging a "trumpet shape" to producing a "meter bucket" cone cylinder, this represents a significant leap in high-hard forging technology. It demonstrates that China has mastered the critical manufacturing techniques for third-generation nuclear power components, marking a major milestone in advancing the localization of nuclear power equipment production. Currently, the AP1000 third-generation nuclear power technology developed by Westinghouse in the U.S. offers clear advantages over second-generation standards, including fewer welds, better safety, and higher operational efficiency. It is considered the most advanced and safe commercial nuclear power technology in the global market. South Korea’s Doosan Heavy Industries also utilizes third-generation nuclear power technology for its equipment manufacturing. In November 2007, China was entrusted with two major forgings—pressure vessels and four evaporators for units No. 1 and No. 2 at Doosan in South Korea. These components are technically challenging and complex to manufacture. The key parts of third-generation nuclear power products pose significant challenges for those aiming to achieve the AP1000 localization strategy. The newly forged AP1000 evaporator cone resembles a "meter bucket," standing 2 meters tall and 4 meters wide. The straight section of the cone is the most technically demanding part of the forging process. Traditionally, the cylindrical body was first shaped into a "flare shape," followed by extensive post-processing to meet the technical requirements of both the oblique and straight sections. This method often required nearly 300 tons of steel ingots, leading to significant waste and increased costs. Breaking through this labor-intensive, time-consuming, and costly traditional approach is crucial for manufacturing 70% of the cone-shaped cylinders. More importantly, achieving the localization of key components like the AP1000 evaporator cone requires skilled engineers to develop new forging technologies. Wang Baozhong, president of a heavy metal casting and forging company, led a team from a heavy metallurgical research institute to tackle these challenges. Collaborating with Tsinghua University, they conducted extensive computer simulations on the 10,000-ton hydraulic press technology, calculated the technical parameters for each forging process, and invented 11 types of auxiliary tools specifically for large hydraulic press forging operations. These 11 tools act as "hands-on" extensions, enabling the 10,000-ton hydraulic press to handle the forging of cone-shaped cylinders with precision and ease. They allow for angle adjustments and accurate shaping, significantly improving forging efficiency while reducing manufacturing costs. Today, Yizhong has become the only company in China capable of forging third-generation nuclear power evaporator cones and related components. The AP1000 key component, the pressure vessel top cover, demands even higher manufacturing standards. It must be formed without any weld seams in one single operation to enhance safety. There are 37 types of such difficult forgings, expected to be delivered by 2009. Wu Shengfu, the company's general manager, emphasized that a large-scale cast-forged steel base and a technical transformation project for localized casting and forging have been approved by the National Development and Reform Commission. The preparatory work is complete, with plans to begin production in 2010. Once this technological upgrade is completed, the facility will reach the world-class manufacturing goal known as "7654": 700 tons of molten steel, 600-ton maximum steel ingots, 500-ton maximum castings, and 400-ton maximum forgings. At that point, it will be capable of producing 150 300–1000MW high, medium, and low-voltage rotors and generator rotors annually. Additionally, it will be able to produce five sets of large hydropower units per year, meeting national needs for power station castings and forgings and gaining international competitive strength.

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