CN101629289A - Laser anti-corrosion and wear-resistant process for trunnion of movable guide vanes of turbines - Google Patents
Laser anti-corrosion and wear-resistant process for trunnion of movable guide vanes of turbines Download PDFInfo
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- CN101629289A CN101629289A CN200910304634A CN200910304634A CN101629289A CN 101629289 A CN101629289 A CN 101629289A CN 200910304634 A CN200910304634 A CN 200910304634A CN 200910304634 A CN200910304634 A CN 200910304634A CN 101629289 A CN101629289 A CN 101629289A
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Abstract
The invention relates to a laser anti-corrosion and wear-resistant process for the trunnion of movable guide vanes of turbines. The process comprises the following steps: useing liquid penetrant test detection to detect the whole guide vane trunnion so as to determine cracks, air cavities and slag in the erosive wear area; and making balancing weights according to the shape and poise error of the guide vanes; removing the fatigue layer of the erosive wear area of the guide vanes; and carrying out cleaning technology treatment after clearing. A special powder feeding device is used to carry out laser cladding for special alloy materials which have good fusion property, high bonding strength and good anti-corrosion and wear-resistant properties. The specific parameters of the cladding process are as follows: the laser power is 3,200W, the spot diameter is 3.2 mm, the latus spots are used, the scanning speed of numerical control programming is 700 mm/min, the lapping rate is 25%, argon protection is used, and the alloy materials are delivered into the melting bath of laser cladding in an angle of 15 DEG by a special laser powder feeding device in a synchronous powder feeding way. All movable guide vanes to be repaired in the invention do not need sending to the manufacturer for treating, huge transport expenditure is not needed, and the whole repair period can be greatly shortened.
Description
Technical field
The present invention relates to laser melting and coating technique, provide a kind of laser melting and coating technique that utilizes especially hydropower station trunnion of movable guide vanes of turbines hybrid laser and anti-corrosive wearing layer new process.
Background technology
The most of large-scale water power of China stands in last century seven; the water wheels unit that the eighties comes into operation also accounts for sizable ratio; the water wheels unit is as one of power station nucleus equipment; movable guide vane is as the core key part of water wheels unit; its operation quality is directly brought serious consequence to unit operation; because each great river stream river sediment concentration is all higher relatively; caused badly damaged for each parts of water turbine; particularly each axle journal of movable guide vane brings corrosion and washes away; directly influencing the unit movable guide vane opens and closes not in place; leak in a large number when causing compressor emergency shutdown standby; and when unit is standby, can not withdraw from air lock, otherwise unit will be turned over automatically.Movable guide vane seriously leaks, and has both caused a large amount of valuable water resourcess of waste when standby, jeopardizes device security again.When maintenance recovers, increase many unnecessary work loads again, these disadvantageous effect factors are to hinder a great problem of the safety in production in each power station, and the Hydropower Unit of river basin is this type of problem of ubiquity all.And this part water wheels unit that comes into operation, be the product about the eighties, installed capacity according to the power station, are furnished with several to tens water wheels units, every water wheels unit is made up of movable guide vane 24-32 radical amount, every movable guide vane weight is at 6.5 tons, 7 meters long are not waited, be limited to structure, intensity, processing realizes and manufacturing cost is considered, can not select anti scuffing for use by integral unit, cavitation performance is good, expensive stainless steel is made, and select ZG20MnSi for use, 20MnSi body material does not possess corrosion resistance nature, and it is that the mode of 0.2-0.3mm hard chrome is carried out corrosion protection abrasion resistant that former designing for manufacturing is adopted at journal surface plating thickness.Chromium coating is subjected to the higher and non-metallurgical binding of parent of void content that technology is limit, coating is scratched by hard sand grains squeeze crack very easily in the water to come off, medium easily is immersed in coating and parent forms corrosion at the interface, corrosion causes again that chromium coating is large-area to come off, and the chromium coating that splits away off can cause stator to wear and tear in the process of motion again.So finally cause the unit movable guide vane to support axle journal repeatedly and serious corrosive wear occurs.Each power station solves the problem that the trunnion of movable guide vanes of turbines corrosion is washed away at present at home, and can only drop into a large amount of manpower and materials stator is handled every year, will arrange two unit maintenances every year by 7 units, hangs out stator, and it is multiple to return repair in shop.But often maintenance does not also circulate time a time, and above-mentioned situation appears again in the unit that begins to repair.This method takies lot of manpower and material resources, and the repair time prolongs, poor stability, and cost is high.
Summary of the invention
The objective of the invention is to be improved, a kind of laser anti-corrosion and wear-resistant process for trunnion of movable guide vanes of turbines is provided at shortcoming that exists in the background technology and problem.
The invention provides and solve trunnion of movable guide vanes of turbines laser anti-corrosion and wear-resistant new process, comprise following processing step:
1) at first movable guide vane prosthesis shaft cervical part of esophagus is carried out size detection and non-destructive test(ing)(NDT) detection, and determine repair coverage according to detected result;
2) damage location is cleared up and fatigue layer is handled, and carry out protection work, prevent to cause new damage not doing the reparation position;
3) make balancing weight according to the stator shape and the amount of laying particular stress on;
4) damage location to movable guide vane carries out the roughing processing, and fatigue layer or the monolateral car of former electrolytic coating are removed 0.8-1mm, and local corrosion point adopts polishing;
5) carrying out non-destructive test(ing)(NDT) detection and hardness after the roughing once more detects;
6) carry out the clean clean of at least two times acetone solvents to clearing up position to be processed, back;
7) carry out laser melting coating processing,, put in order the circle cladding then at first to the local dell subregion cladding of movable guide vane damage axle journal;
8) carry out the manual grinding cleaning after cladding first finishes, and carry out painted nondestructive flaw detection examination, carry out follow-up cladding behind the zero defect again;
9) laser melting coating is finished after mechanical roughing, precision work and carry out polished finish machine-shaping;
10) carry out tolerance of dimension, form and position tolerance, roughness, surface hardness, metallographic sampling, surface imperfection and nondestructiving inspecting test at last.
Advantage of the present invention and beneficial effect: do not do any processing with parts surface and compare, cladding layer and matrix all do not have thick tissue behind the laser melting coating, cladding layer and basic Interface Microstructure densification, and crystal grain is tiny, defective such as cladding organizes flawless, be mingled with; Cladding layer and matrix form metallurgical binding, do not come off; Low to the matrix thinning ratio, cladding layer size and position can accurately be controlled, and machining allowance is little after the cladding; In resizing, also promote the erosion resistance and the wearability at this axle journal position, be greatly improved, can improve work-ing life more than 3 times than original design manufacturing scheme serviceability; On-the-spot quick movable guide vane repair process to erosive wear, greatly shorten the turnaround, reduce the repair time greatly, the safety coefficient of raising equipment, reduce the cost of overhaul greatly, with scrap the acquisition cost that renews, simultaneously from having solved the technical bottleneck problem of this manufacturing process of components in essence.The inventive method can be extended to that new part manufacturing, discard laser are reproduced, the medium-and-large-sized on-the-spot repairing fast that can not the mechanically moving device product of the industries such as Steam Turbine macro-axis, metallurgy and chemical industry in fuel-burning power plant, for producer resumes production fast, the work-ing life of simultaneously great prolongation equipment.
Embodiment
Embodiment:
One, all movable guide vanes corrosion journal surface reparation of washing away all at the scene or off-line realize that laser melting coating and mechanical workout moulding handle.
Two, project implementation major equipment and required condition:
1, site work major equipment: 5KW CO2 laser generator; Frequency conversion constant temperature handpiece Water Chilling Units; The numerical control housing; Five numerically-controlled machines that tetrad is moving; The special-purpose powder feeder of laser processing; CW61180 * 8000 lathes; The workpiece support wheel of maximum support load 30T; Air compressor and some other utility appliance.
2, required field condition: needing provides a 150m of place in equipment factory building one side
2Field apparatus put the operational zone; The construction electrical source of power; Necessary security protection isolation facility and easy fire extinguishing appliance and off-set facility.
Three, early-stage preparations and workpiece pre-treatment
1, according to movable guide vane size and laser melting coating processing needs, design improvement laser processing rotary tooling bed body, stent holder.
2, apolegamy customization machine adds designing and producing of lathe and lathe base support steel platform.
3, the making of other attached frock.
4, to be processed original material analysis confirmed.
5, the preparation of laser melting coating special metals powder.
6, the design of laser melting coating working process parameter and process program.
7, test of sample piece and evaluation, technology is solidified.
8, possess execution conditions after, relevant complementary conditions are finished in the Installation and Debugging of laser apparatus and relevant suite of equipment simultaneously.
9, every movable guide vane is numbered registration.
10, each prosthesis shaft cervical part of esophagus of every movable guide vane is carried out size detection, the size neck can objectively respond out the ovality and the tapering of original shaft part to detecting with axial multiple spot during detection, and with picture and text form detail record check point position and detection data.
11, every movable guide vane is waited to repair the axle journal section and carry out the non-destructive test(ing)(NDT) detection, the detected result mug, and with picture and text form record.
12, every movable guide vane is waited to repair the axle journal section and carry out the hardness detection, must detect by multiple spot during detection, and by the numbering detail record.
13, the damage location repair coverage is determined:
(1) according to above size detection and nondestructive testing result, determines repair coverage.
(2) the reparation size range and the relative position of detail record damage location, and to every movable guide vane number record file.
14, damage location cleaning, fatigue layer are handled, before clean the processing, must repair the position and carry out protection work not doing, and prevent to cause new damage defect.
Four, mechanical workout scheme:
1, lathe selects installation and debugging with lathe for use
(1) select light-duty CW61180 * 8000 lathes for use, significant parameter:
The straight neck 1800mm maximum machining length 8000mm of maximum revolution
Top maximum processing weight: 18T knife rest (planker) is gone up maximum revolution straight neck: 1400mm
Lathe bed width: 1100mm master speed: the 1-125 that walks around
Main motor current: DC49 (frequency conversion) lathe weight: 32T
Machine overall dimension: 12.92 * 2.28 * 2.41
(2) installation of lathe and debugging
Consider that place, working-yard, power station can't lay foundation, and lathe (8 meters) lathe bed is generally two sections, so need to make the steel platform of (16 meters long according to practical situation) in advance.Platform is made of the Q345 material.Every about 13T amounts to 27T.
2, the counterweight of movable guide vane
(1), make balancing weight, balancing weight divides 5 groups according to stator shape and the amount of laying particular stress on;
(2) check stator two ends spindle nose centre hole, rust cleaning.Repair damaging serious centre hole.
3, the roughing of the movable guide vane that corrosion is washed away is handled
(1) at first adopts a card one top mode clamping, chuck-end design anti-channeling device; Behind the centering institute's working position is removed fatigue layer and former electrolytic coating, monolateral car according to circumstances removes 0.8-1mm.Local corrosion point can not done turning and handle, and adopts detail sanding, local cladding treatment process.In like manner, need working position fatigue layer car to remove the other end after tune is installed.
(2) to note the damage location two ends during turning damage location and not decrease the axle journal junction, form chamfering so that laser melting coating prevents stress concentration effect.
(3) after the damage location roughing, through non-destructive test(ing)(NDT) detection and hardness detect confirm no latent defect can, and detection record damage location finished size, mug.
(4), machine after, implement laser melting coating processing.
4, the precision work behind the laser melting coating is handled
(1) allowance for finish of 0.2-0.3mm is stayed by illustrated dimensions in machined into two end axles neck position on the movable guide vane after laser melting coating is finished after the roughing.
(2) the intact axle journal of roughing is carried out the surface and carry out the non-destructive test(ing)(NDT) detection, through confirming to change finishing step over to after the defectives such as flawless, slag inclusion.
(3) by the illustrated dimensions requirement, axle journal is carried out precision work and polished finish, counterweight is as previously mentioned during precision work.
Five, laser melting coating processing treatment:
1, the clean clean that position to be processed after clearing up is no less than two times acetone solvents determines that no any oil stain and residue can.
2, treat cladding area field surface fatigue layer removing situation and finally detect affirmation.
3,, implement cladding processing according to laser melting and coating process scheme and the parameter formulated.
4, movable guide vane is damaged axle journal and carry out cladding, earlier to whole circle cladding after the cladding of local dell subregion.
5, the intact back of the first layer cladding manual grinding cleaning, painted nondestructive flaw detection examination, behind the affirmation zero defect, the follow-up cladding work of being allowed for access.
6, laser melting coating thickness guarantees that there is the above process redundancy of 0.75-1mm on mechanical turning work sheet limit.
The chemical ingredients of the preparation of laser melting coating special metals powder of the present invention consists of: 1.0-1.3%C, 28-30%Cr, 3.00%Fe, 0.50%Mn, 1.00%Mo, 3.00%Ni, 1.55%Si, 5.5%W, other is Co.
Formulation laser cladding technological parameter of the present invention is: laser power is 2000-4000W; spot diameter is 3.0-4.0mm; adopt positive burnt hot spot; the numerical control programming sweep velocity is 600-1000mm/s; overlapping rate 20-30%; cladding material is corrosion-resistant and special metal powder wear resistance, argon shield, and alloy material uses the special-purpose powder feeder of laser material to be sent into the molten bath of sending into laser melting coating with 15-20 ° of angle with the synchronous powder feeding system mode.
Six, quality inspection: comprise that check tolerance of dimension, form and position tolerance, roughness, surface hardness, metallographic sampling, surface imperfection and non-destructive test(ing)(NDT) detect.Take pictures the detection data of every movable guide vane of detail record.
Solution trunnion of movable guide vanes of turbines laser anti-corrosion and wear-resistant new process provided by the invention, its laser melting coating adopts carbon dioxide gas laser, powder feeder synchronous powder feeding system and five four-linkage numerical control lathe array modes to carry out, metal powder and light beam and parts profile are synchronous, when metal powder arrives the parts profile, light beam arrives the parts profile simultaneously, metal powder is melted fully, and make matrix little molten the two combine.
Solution trunnion of movable guide vanes of turbines laser anti-corrosion and wear-resistant new process provided by the invention, the reparation of the journal surface that the corrosion of all movable guide vanes is washed away at the scene or off-line can realize that all Laser Cladding Treatment and mechanical workout moulding handle.
Solution trunnion of movable guide vanes of turbines laser anti-corrosion and wear-resistant new process provided by the invention, all movable guide vanes that will repair do not need return-to-factory to handle, and need not huge transportation expenditure, can greatly shorten the whole turnaround.
Embodiment of the present invention only is the description that preferred implementation of the present invention is carried out; be not that design of the present invention and scope are limited; do not breaking away under the preceding topic of design philosophy of the present invention; engineering technical personnel make technical scheme of the present invention in this area various modification and improvement; all should fall into protection scope of the present invention; the technology contents that the present invention asks for protection all is documented in claims.
Claims (3)
1. laser anti-corrosion and wear-resistant process for trunnion of movable guide vanes of turbines is characterized in that comprising following processing step:
1) at first movable guide vane prosthesis shaft cervical part of esophagus is carried out size detection and non-destructive test(ing)(NDT) detection, and determine repair coverage according to detected result;
2) damage location is cleared up and fatigue layer is handled, and carry out protection work, prevent to cause new damage not doing the reparation position;
3) make balancing weight according to the stator shape and the amount of laying particular stress on;
4) damage location to movable guide vane carries out the roughing processing, and fatigue layer or the monolateral car of former electrolytic coating are removed 0.8-1mm, and local corrosion point adopts polishing;
5) carrying out non-destructive test(ing)(NDT) detection and hardness after the roughing once more detects;
6) carry out the clean clean of at least two times acetone solvents to clearing up position to be processed, back;
7) carry out laser melting coating processing,, put in order the circle cladding then at first to the local dell subregion cladding of movable guide vane damage axle journal;
8) carry out the manual grinding cleaning after cladding first finishes, and carry out painted nondestructive flaw detection examination, carry out follow-up cladding behind the zero defect again;
9) laser melting coating is finished after mechanical roughing, precision work and carry out polished finish machine-shaping;
10) carry out tolerance of dimension, form and position tolerance, roughness, surface hardness, metallographic sampling, surface imperfection and nondestructiving inspecting test at last.
2. a kind of laser anti-corrosion and wear-resistant process for trunnion of movable guide vanes of turbines according to claim 1 is characterized in that the chemical ingredients of the preparation of described laser melting coating special metals powder consists of: 1.0-1.3%C, 28-30%Cr, 3.00%Fe, 0.50%Mn, 1.00%Mo, 3.00%Ni, 1.55%Si, 5.5%W, other is Co.
3. a kind of laser anti-corrosion and wear-resistant process for trunnion of movable guide vanes of turbines according to claim 1; it is characterized in that described formulation laser cladding technological parameter is: laser power is 2000-4000W; spot diameter is 3.0-4.0mm; adopt positive burnt hot spot; the numerical control programming sweep velocity is 600-1000mm/s; overlapping rate 20-30%; cladding material is corrosion-resistant and special metal powder wear resistance; argon shield, alloy material use the special-purpose powder feeder of laser material to be sent into the molten bath of sending into laser melting coating with 15-20 ° of angle with the synchronous powder feeding system mode.
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| CN200910304634A CN101629289A (en) | 2009-07-22 | 2009-07-22 | Laser anti-corrosion and wear-resistant process for trunnion of movable guide vanes of turbines |
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| CN200910304634A CN101629289A (en) | 2009-07-22 | 2009-07-22 | Laser anti-corrosion and wear-resistant process for trunnion of movable guide vanes of turbines |
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| WO2013079193A1 (en) * | 2011-12-02 | 2013-06-06 | Lufthansa Technik Ag | Method for repairing a variable guide vane and correspondingly repaired guide vane |
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| CN105420721A (en) * | 2015-10-27 | 2016-03-23 | 新疆汇翔激光科技有限公司 | Repairing method for steam turbine oil pump flywheel shaft through laser cladding |
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| CN108220955A (en) * | 2018-01-09 | 2018-06-29 | 中国长江电力股份有限公司 | A kind of material and renovation technique for the laser melting coating reparation of Rotator in Hydropower Station room |
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