汽轮机高温转子焊接技术简介.pdf

introduction on welding technology of elevated temperature rotor 汽轮机高温转子焊接技术简介汽轮机高温转子焊接技术简介 2013-09-04 contents 目录 background of elevated temperature welded rotor 高温焊接转子背景介绍高温焊接转子背景介绍 background of elevated temperature welded rotor 高温焊接转子背景介绍高温焊接转子背景介绍 01 construction design 结构设计结构设计 construction design 结构设计结构设计 02 welding technology development 焊接工艺技术开发焊接工艺技术开发 welding technology development 焊接工艺技术开发焊接工艺技术开发 03 conclusion 小结小结 conclusion 小结小结 04 05 usc dual-reheat steam turbine designed by stp 上汽自主设计的超超临界620二次再热汽轮机 1. background ip module of usc double-reheat steam turbine 超超临界二次再热汽轮机中压模块 1. background ip 620 rotor of usc double-reheat steam turbine 超超临界二次再热汽轮机620中压转子 1. background difficult to forge 锻造难度大锻造难度大 long period 锻造周期长锻造周期长 high price 大锻件价格高大锻件价格高 so welded rotor is an option 开发焊接转子是一个好选择 material/锻件材料：锻件材料：fb2 forging weight /锻件重量锻件重量 ：53t max od/最大外径最大外径：1180mm 2. construction design 1. material：dissimilar steels 异种钢材料对接，中间为fb2钢，两侧为crmov钢。 2. welds position 应力低,温度相对低-lower stress and temperature 焊接可达性-welding accessability 可检测性-detectability 2. construction design distribution of temperature 温度云图 distribution of mises stress 应力云图 3. welding technology development fb2 crmov technical challenges 1 difference in tempering temperature of the two materials 两种母材的性能热 处理回火温度不同 2 difference in chemical composition and mechanical properties 两种母材化学成分和 力学性能差异较大 3 carbon migration and segregation 两种材料由于cr含 量差异较大，会产 生碳迁移。 goal properties of weld joint meet the requirement of service condition .焊接接头性能满足服役条件。 weld metal can balance the requirement of two parent metals.选择合适焊缝金属匹配两侧母材。 3. welding technology development two solution were tested 分两种方案进行测试 1 weld fb2 to crmov directly fb2直接与crmov焊接 2 weld fb2 with buffer layer then weld buffer layer to crmov 在fb2上堆焊过渡层再与crmov焊接 the comparison test results show that weld joint without buffer layer has better mechanical properties 两个方案测试结果对比发现，无过渡层力学性能更优， 主要是过渡层焊缝经历两次焊后热处理，强度下降明显。 better 3. welding technology development elding processwelding process 焊接方法 mock-up 模拟件 outer diameter：900mm 圆环外径圆环外径 depth of weld：135mm 焊缝深度焊缝深度 tig 氩弧焊氩弧焊 saw 埋弧焊埋弧焊 + 3. welding technology development pwht 焊后热处理 no excessive heat affected zone hardness 焊接热影响区没有硬度过高点。 no unacceptable softening at the weld fusion lines 焊接熔合线附近没有软化层。 ndt 无损检测 ut：good detectability of weld and haz 焊缝和热影响区的超声波可探性较好。 ut&rt ：no unacceptable defect 超声波和射线检测均未发现超标缺陷。 3. welding technology development scope of testing 检测项目检测项目 long-term properties still ongoing 长时测试项目仍在进行 hardness 硬度 bend 弯曲 fatt50 韧脆转变温度 lcf 低周疲劳 creep 蠕变 da/dn 疲劳裂纹扩展速率 kth 疲劳裂纹扩展门槛值 macrostructure 宏观金相 creep-rupture 持久强度 microstructure 微观金相 j-integral j积分 hcf 高周疲劳 tensile 拉伸 charpy-v 冲击 rt 室温 rt&rt 室温和高温 3. welding technology development macrostructure 宏观金相 (1) cross section of weld 焊缝横截面 fb2 side fb2侧金相图 crmov side crmov侧金相图 3. welding technology development tensile 拉伸 (2) yield strength tensile strength 0 1 2 3 测试母材、焊接接头在室温和高温下的屈服强度和抗拉强度。 tensile tests on base metal and welding joint at rt and elevated temperature respectively 3. welding technology development charpy-v（rt）& fatt50 室温冲击和韧脆转变温度 (3) fb2-hazweldcrmov-haz akv/j 0 1 2 3 测试焊缝及两母材室温下的冲击功，焊缝的韧脆转变温度 impact energy and fracture appearance transition temperature 3. welding technology development hardness 硬度 (4) fb2fb2-hazweldcrmov-hazcrmov hv10/tig hv10/1 hv10/2 hv10/3 1 0 2 3 4 5 6 测试两母材、焊缝及两侧热影响区，氩弧焊和埋弧焊焊缝的硬度 hardness distributions across the joint in transverse and depth 无硬度过高区域也没有明显软化区域 neither excessive hardness nor softening area 1 2 3 ti g 3. welding technology development bend 弯曲 (5) 整个焊接接头区域无开裂 no open discontinuity across the joints 3. welding technology development creep-rupture 持久强度 (6) 3. welding technology development hcf 高周疲劳 (7) 焊接接头室温&470 weld joint rt&470 应力比r=-1， 循环次数n 5107 3. welding technology development creep 蠕变 (8) 分区悬臂梁小试样 cantilever beam 焊缝470测试结果 weld metal at 470 已经获得焊缝470本构方程 norton-bailey constitutive equations on weld metal at 470 is available 取样图中包括母材,焊缝和热影响区 base metal ,weld metal and haz 3. welding technology development creep 蠕变 (8) 全焊缝试样 full-penetration weld 接头小试样 weld joint 以上两种试样的蠕变 测试正在进行。 test ongoing 4. conclusion 1.weld fb2 to crmov without buffer layer is a feasible solution. 不用过渡层，直接将fb2与crmov钢焊接起来是可行的。 from test data we got： 2.weld joint that meets the requirement of service condition can be acquired with appropriate weld metal、welding process