The "Super Titanium Factory" is officially put into operation. The "Super Titanium Factory" is officially put into operation, helping to forge important weapons of great powers. Helping to forge important weapons of great powers.
A new project called the "Super Titanium Factory" has been launched in Changde, Hunan. This project has a construction area of 46,000 square meters and an annual output of 5,000 tons. The maximum weight of the embedded parts inside is 3.5 tons. During the installation process, the allowable error range is only 4 millimeters. How difficult is this construction task.
Project put into production
By 2026, the advanced titanium alloy industrialization project for high-end equipment in Changde, Hunan, will be officially put into production. The total construction area of this project is 46,000 square meters. It mainly focuses on high-end equipment fields such as aircraft engines, deep-sea submersibles, advanced ships, and weapons. It is one of the single titanium alloy processing bases with the largest production capacity in this direction in China.
The production line's designed annual production capacity has reached the level of 5,000 tons. It covers a complete processing chain starting from titanium sponge raw materials, through the intermediate melting and casting links, to the forging and rolling processes, and finally to the final formed materials.
After the construction of this production line was completed and put into production, Hunan Province has successfully made up for the existing problem of insufficient production capacity in the field of high-end titanium and titanium alloy processing materials, so that the region is no longer in a state of being completely dependent on external supply to meet demand.
strategic value
Titanium alloy is the core material of the turbine disk of aeroengine, deep-sea pressure shell and ship load-bearing structure. The strength of this material is very high, and the corrosion resistance is also very good. Judging from the current situation, some grades of titanium alloy still need to be obtained from imports. The improvement of production capacity and quality control directly determine whether high-end equipment manufacturing can achieve the goal of independence. This is a link, and there is a "stuck neck" problem in this link. There is no way around the solution to this problem.
After the Changde project was launched, Hunan has extended its industry from the downstream titanium use link to the upstream titanium manufacturing link. This will provide nearby and stable material supply for aero-engine factories and shipyards across the country, reducing the trouble of long-distance transportation logistics and the risk of supply chain interruption. This strategic significance is not limited to Hunan.
Embedded parts accuracy challenge
Under the roof of the factory, it is necessary to place more than 20 types of giant equipment, with the number reaching more than 30 units, and the shapes and sizes of these equipment are all different. At the same time, we have to correspond to the basic locations for building more than 30 large-scale equipment.
The site involved a total of more than 7,800 embedded parts, with a total weight of more than 570 tons, and the peak weight of one of them alone reached 3.5 tons. What needs special explanation here is that if any of the embedded parts is slightly deviated, then the key equipment that needs to be installed with particularly high precision requirements will definitely not be installed normally.
The design requirements are very rigid, that is, when all embedded parts are installed, their positioning deviation cannot exceed 4 mm.
Because it involves the concrete pouring process, the operation of equipment hoisting, and the cross-working of multiple types of work, so as long as there is a little hand shaking or instability in any link, the deviation is very likely to exceed the 5 mm limit. Once this happens, the entire foundation must be smashed and remade. The economic losses caused are calculated in millions of yuan.
BIM plus three-level review
The construction team did not rely on the personal experience of the older masters to act recklessly, but actually created a control system from beginning to end of "BIM model, dedicated personnel to review, and then conduct cross-examination."
Before the official start of construction, BIM technology was used to create a three-dimensional model of all basic parts of the equipment involving all majors and elements. Then, in the virtual space, possible collision areas were picked out in advance, and the installation of all equipment was rehearsed in advance.
Three-level measurement work was performed on site, and dedicated personnel were assigned to conduct initial and re-testing, technical review, and final cross-acceptance. A total station was used to track the whole process, and each embedded part was calibrated after it was placed, and then inspected again after it was completed. In this way, all the 570 tons of embedded parts were controlled within a circle with a precision of 4 mm, basically achieving zero rework.
Solve the dilemma through interspersed construction
The current civil construction work has not yet ended, and large equipment must be brought into the site for hoisting work. There is a deep intersection between these two lines in time, resulting in extremely limited site resources and time arrangements. The project department set the smooth installation of the equipment as the only ultimate goal, arranged the construction period backwards through reverse deduction, and redeployed on-site personnel and mechanical equipment resources.
By arranging the work more scientifically and accurately planning the site, we turned the processes that could only be done one after another into a situation where they could be done at the same time. This is called parallel work, and then the soil construction work and the installation work were rushed forward together. The final result was that there was not even a day's delay due to the need for cross-construction, and all the large equipment accurately arrived at the designated location according to the set date.
Full process automation
After being put into production, the processes from titanium sponge smelting, forging, rolling to final forming are all carried out under the operation of the automated production line, which greatly reduces the need for manual intervention. At the same time, the consistency between batches is much more stable than that achieved by traditional manual operations, and the performance fluctuations of the material become smaller.
For those downstream aero-engine factories and shipyards, the supply of materials is already stable, and the cycle of research and development and verification has been significantly shortened. There is no need to rely on imported materials to rely on luck. The high-end equipment manufacturing supply chain in Hunan and even the country has an independent and controllable support channel.
With an accuracy level of 4 mm, do you think it is more reliable to rely on the manual skills of experienced masters, or do you think it is more trustworthy to use a combination of BIM systems and total stations in terms of technology?
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