CN102218638A - Process method for repairing gas turbine vanes by micro-arc deposition coating - Google Patents
Process method for repairing gas turbine vanes by micro-arc deposition coating Download PDFInfo
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Abstract
The invention relates to the maintenance field of gas turbines, in particular to a process method for repairing gas turbine vanes by a micro-arc deposition coating. The invention relates to a process method that adopts the micro-arc deposition coating to repair the local damage area of a geometrical component or a surface coating caused during the service process of air compressor vanes of a heavy gas turbine, turbine rotor vanes and guider vanes/nozzles. The method can carry out micro-arc deposition coating restoration on the gas turbine vanes. The micro-arc deposition coating process is defined into a metallurgical process as follows: an electrode rod is used as an anode; a workpiece is used as a cathode; the high-frequency direct-current pulse micro-arc discharge is carried out between the electrode rod and a workpiece surface; and the material of the electrode rod is self-consumed and transferred to the contact area of the workpiece surface; and the environment during the transferring and depositing process of material is inert gas or vacuum or insulating oil. The process method can solve the problems that in the prior art, the restoration process is complex, the deformation occurs easily, the cost is high, and the restoration can not be done reliably and timely.
Description
Technical field
The present invention relates to gas turbine maintenance field, be specially a kind of gas turbine blades differential of the arc deposited coatings repair process, especially the compressor blade of heavy duty gas turbine, turbine rotor blade and stator blade/nozzle member adopt a kind of process of differential of the arc deposited coatings reparation through the local damage district of caused geometrical configuration of military service use and face coat.
Background technology
Gas turbine is the turbine turbogenerator that fuel oil, combustion gas, biogas, coal tar gasification etc. can be converted into Mechanical Driven power, possesses heat-machine transformation efficiency energy conversion device higher, that clean, be widely used on the industrial production drive units such as Aeronautics and Astronautics, aircraft, naval vessels, locomotive, metallurgy, oil, chemical industry, especially gas turbine-generator for electricity generation system and gas turbine-steam turbine-generator combined cycle generating system then extensively adopts especially on the ground electrical power device.Along with the energy-conservation and demand that improves constantly environmental protection, as heavy oil and blast furnace gas, coke furnace reformed gas, pyrolysis furnace flue gas, iron-smelting furnace tail gas, flue gas of refuse burning or the like impurity content oil and gas high, the component complexity, also be to be converted into mechanical energy and electric energy is utilized at present by gas turbine.For minimizing discharging effectively, improve efficiency, powerful heavy duty gas turbine is increasingly extensive with application in China's development at present.
Blade comprises that compressor rotor blade, turbine rotor blade and guider blades/nozzle are the important critical components of gas turbine.Compressor rotor blade and outer casing are united gas in the environment is pressed into and reaches certain high pressure and are entered the combustion chamber, and turbine nozzle vane will be imported by the gases at high pressure rectification of coming out in the combustion chamber to turbine rotor blade, the work done of rotor blade drive rotor motion.In this process, the relative sealed motion of rotor blade with outer casing.Because processes such as rotor oscillation, blade thermal expansion, centrifugal action elongation, startup and shutdown thermal cycle can cause the wearing and tearing and the fatigue damage of blade tip, particularly turbine rotor blade also can be subjected to the caused creep of high temperature action, cold cycling fatigue, high-temperature oxydation and the sedimental molten salt hot corrosion of combustion gas that contains impurity such as S, Cl, C, Ca, P; Under this external overload/overheat condition, stator blade/nozzle also can be subjected to the thermal shock and the ablation of high-temperature fuel gas.Along with the increase of gas turbine power output, this wearing and tearing of blade, corrosion and the damage of ablating were lost efficacy more serious.At present, mostly China is import at the heavily loaded gas turbine of operation, and homogeneous phase goes on into the overhaul phase so that overhaul state repeatedly, and blade comprises that the reparation production domesticization of nozzle is particularly important.This is because blade/nozzle member costliness, external import with repair expense height especially.
Summary of the invention
The object of the present invention is to provide a kind of gas turbine blades differential of the arc deposited coatings repair process, solve the renovation technique complexity that exists in the prior art, yielding, cost is high, problem such as can not in time reliably repair.
Technical scheme of the present invention is:
A kind of gas turbine blades differential of the arc deposited coatings repair process, gas turbine blades is carried out the reparation of differential of the arc deposited coatings, differential of the arc deposited coatings process is meant: be that positive pole, workpiece are negative pole with the electrode bar, high-frequency DC pulse micro-arc discharge between electrode bar and surface of the work, and the metallurgical process that electrode bar material consumable is transferred to the surface of the work contact area takes place, the environment of material transfer deposition process is inert gas or vacuum or insulating oil; Pulse micro-arc discharge frequency is 70Hz～5000Hz, pulsewidth 10
-3～10
-5S, differential of the arc source power output is 50W～5000W; Electrode bar is cylindrical or block, and the electrode bar motion mode is rotation or vibration, and electrode bar is operating as hand-held machine.
Among the present invention, differential of the arc deposited coatings process can be twice, carries out repair welding for the mode that adopts differential of the arc deposited coatings for the first time, prepares surface protecting layer for the mode that adopts differential of the arc deposited coatings for the second time.
Described gas turbine blades differential of the arc deposited coatings repair process, the gas turbine blower blade is steel blade or high-temperature alloy blades or titanium alloy blade, after the gas turbine blower blade is shortened with outer casing friction leaf tip, adopt differential of the arc deposited coatings spreading repair process, the spreading repair materials is with body material or the nickel-base alloy or the cobalt-base alloys of blade, the height of spreading reparation is 0.05mm～2.0mm, and spreading reparation formation blade tip hardness is HV250～HV550.
Described gas turbine blades differential of the arc deposited coatings repair process, short differential of the arc deposited coatings spreading repair process is adopted in the blade tip wearing and tearing of gas turbine turbine rotor blade, and the spreading repair materials is a MM ' CrAlY alloy, and M is Ni or Co; Perhaps, the spreading repair materials is nickel-base alloy or cobalt-base alloys; The spreading reparation highly is 0.05mm～5.0mm, and microhardness is HV450～HV600.
Described gas turbine blades differential of the arc deposited coatings repair process, the anti-air-flow of the corrosion protection of gas turbine blower blade washes away localized delamination, the spot corrosion of coating or hits the hole, the process that adopts differential of the arc deposited coatings to repair, filling up repair materials is stainless steel or nickel-base alloy or cobalt-base alloys, and microhardness is HV350～HV450.
Described gas turbine blades differential of the arc deposited coatings repair process, surface corrosion hole, fire check or the protective coating of gas turbine turbine nozzle vane nozzle peel off the district, adopt differential of the arc deposited coatings repair process, repair materials is nickel-base alloy, cobalt-base alloys or MM ' CrAlY alloy, M and M ' are Ni or Co, and microhardness is HV350～HV500.
Described gas turbine blades differential of the arc deposited coatings repair process is repaired the blade tip spreading, and the reparation of blade surface crackle, etch pit or blade surface protective coating peel off district's coating reparation, and the technology characteristics of its repair process is:
Damage floor → X-ray infiltration and the micro-tracking polishing of magnetic Non-Destructive Testing → original position removal of defects → repair type cleaning → differential of the arc deposited coatings → vacuum heat or mechanical force processing → shaping processing → surface finishing → mechanical force processing are removed in the polishing of blade cleaningization processing → to be repaired district.
Among the present invention, by weight percentage, the composition of nickel-base alloy can be as follows:
| Ni | Cr | W | Mo | Ti | Al | Y |
| Surplus | 18～22 | 6～10 | 6～10 | 1～5 | 0.1～1.5 | 0～0.8 |
Among the present invention, by weight percentage, the composition of Co base alloy can be as follows:
| Co | Cr | Ni | W | Mn | Mo | Si | B | O 2 |
| Surplus | 10～30 | 5～15 | 5～10 | ＜0.50 | 5～15 | 0.1～1.2 | ≤0.01 | ≤0.03 |
Among the present invention, by weight percentage, the composition of MM ' CrAlY alloy can be as follows:
| M | M′ | Cr | Al | Y | C | W or Mo | Ta | Si |
| Surplus | 0～30 | 12～30 | 3～12 | 0.1～1.0 | 0.02～0.45 | 0～8 | 0～8 | 0～5 |
When M was Ni, then M ' was Co, otherwise opposite.
The invention has the beneficial effects as follows:
The reparation of gas turbine blades/especially heavily loaded gas turbine blades/nozzle of nozzle reparation should comprise following three aspect contents: the recovery of the recovery of microscopic structure, the recovery of geometry and face coat usually.Obviously, mainly be the recovery of geometrical configuration and face coat for the wearing and tearing under most of non-overheat condition, burn into oxidation and the compressor blade of fatigue damage inefficacy and the reparation of turbo blade and nozzle.Adopt gas turbine blades differential of the arc deposited coatings process of the present invention, the geometrical configuration of heavily loaded gas turbine blades/nozzle that the damage that can realize being on active service was lost efficacy and the reparation of face coat and reconstruction and possess following characteristics:
(1) blades is indeformable.
(2) blades matrix, especially turbo blade/nozzle matrix of being made by the high strength high temperature alloy of difficulty weldering does not produce tangible heat affected area and thermo-responsive crackle.
(3) coating and blade matrix are firm, uniform metallurgical binding, the thermal barrier coating anti-strip of preparation.
(4) coating hardness height and quality are good.
(5) process is simple, and is easy to operate.
The specific embodiment
Embodiment 1
Certain oil field combustion gas conveying device adopts MS5001PG type gas turbine as driving force.Overhaul at the beginning of 2006 is broken the pit that the blade generation that has is differed in size so find the blade tip that this combustion turbine first order turbine rotor blade (for hollow-core construction) has in the inspection process.Most blade surface coating generation localized delamination.The material of blade is the GTD111 nickel based super alloy, because of containing＞8wt% (Al+Ti) amount.Crackle during melting welding can not the wlding material, is difficult to adopt reparations such as laser cladding weldering and argon arc welding.The damage of this grade blade is that the strike that is subjected to external rotor causes according to one's analysis.Test through carry out differential of the arc deposited coatings IMR-N800 nickel base superalloy on GTD 111 nickel based super alloy pieces shows, equal flawless on base material and sedimentary deposit and the combination interface thereof, but repair welding.
Crack repair technology is on the blade tip:
Crackle → finishing polishing gap → IMR-N800 nickel base superalloy differential of the arc deposited coatings soldering gap → shock treatment → soldering district surface shaping processing → x-ray flaw detection+penetrant inspection → surface by micro-arc deposition MM ' CrAlY coating is removed in the ultrasonic alkali cleaning of blade → x-ray flaw detection → fluorescent+infiltration+dye penetrant inspection → polishing.
In the present embodiment, the composition of IMR-N800 nickel base superalloy following (wt%):
| Ni | Cr | W | Mo | Ti | Al | Y |
| Surplus | 20 | 8 | 8 | 3 | 0.5 | 0.5 |
The machined parameters of IMR-N800 nickel base superalloy differential of the arc deposited coatings soldering gap is:
Diameter is
Long 60～the 100mm of IMR-N800 nickel base superalloy electrode bar, power 3000W, pulse frequency 2000Hz, pulsewidth 10
-5Under S, the Ar gas shiled, handheld operation.
In the present embodiment, the composition following (wt%) of MM ' CrAlY alloy:
| Ni | Cr | Al | Y | Co | C |
| Surplus | 22 | 10 | 1.0 | 0.1 | 0.03 |
The machined parameters of surface by micro-arc deposition MM ' CrAlY coating is:
Ni CrAlY alloy electrode rod diameter is
Length is 60～100mm, and power is 2500W, pulse frequency 700～1000Hz, and pulsewidth is 10
-4S, Ar gas shiled, handheld operation.
After five vanes said methods that the blade tip crack fault arranged were repaired, it is normal that installation uses at present operation always, and crackle repair welding district is intact.
Embodiment 2
The tail gas that certain coal coke-oven plant adopts whirlpool axle type gas turbine that coal one burnt reburner is produced utilizations of generating electricity solved the atmosphere pollution serious problems of this tail gas emptying effectively, also is the higher net profit of factory's acquisition simultaneously.But owing to contain impurity such as very high S, Cl, C (different and different) in the tail gas that coal-Jiao transforms according to ature of coal; make the primary rotor blade (hollow-core construction, K403 nickel base superalloy) of gas turbine produce serious heat erosion with one-level guide vane (hollow-core construction, K403 nickel base superalloy); so that falling hat less than 4000 hours interim moving vanes that will take place of being on active service; stator blade Durchgangshohle etc.; and stopping production is shut down in falling hat and falling piece with secondary and three grade blades of very high-speed bump back and make its destruction of a grade blade thus.Adopt differential of the arc deposited coatings technology to corrosion takes place but do not fall hat as yet, the one-level movable vane and the stator blade that fall piece repair, and obtained safe operation life-span more than 8000 hours so far, the at present equal operational excellence of five engines of reparation.
Differential of the arc deposited coatings renovation technique flow process is as follows:
Blade sandblast → alkali cleaning → x-ray flaw detection+penetrant inspection → mechanical removal corrosion damage layer → finishing → cleaning processing →
Deposited coatings → the heat treatment of → micromachine finishing → X-ray infiltration → IMR-N801 alloy the differential of the arc;
In the present embodiment, the composition of nickel-base alloy (IMR-N800) following (wt%):
| Ni | Cr | W | Mo | Ti | Al | Y |
| Surplus | 20 | 8 | 8 | 3 | 0.5 | 0.5 |
The machined parameters of nickel-base alloy differential of the arc coating (to the one-level movable vane) is:
Diameter is
Long 60～the 100mm of IMR-N800 nickel-base alloy electrode bar, power 3000W, pulse frequency 2000Hz, pulsewidth 10
-5Under S, the Ar gas shiled, handheld operation.
In the present embodiment, the composition of cobalt-base alloys following (wt%):
| Co | Cr | Ni | W | Mn | Mo | Si | B | O 2 |
| Surplus | 15 | 10 | 5 | 0.30 | 5 | 0.2 | 0.004 | 0.02 |
The machined parameters of cobalt-base alloys differential of the arc deposited coatings (to the one-level stator) is:
Diameter is
Long 60～the 100mm of cobalt-base alloys electrode bar, power 3000W, pulse frequency 2000Hz, pulsewidth 10
-5Under S, the Ar gas shiled, handheld operation.
In the present embodiment, the composition of IMR-N801 alloy following (wt%):
| Ni | Co | Cr | Al | Ta | Y |
| Surplus | 20 | 24 | 6.0 | 4.0 | 0.4 |
The technological parameter of IMR-N801 alloy differential of the arc deposited coatings is as follows:
Differential of the arc source power output 2000W～3000W, micro-arc discharge frequency 3000Hz～4000Hz, electrode bar
Rotatablely move He gas shiled, handheld operation.
Embodiment 3
Gas turbine-steam turbine-cycle generating system that power plant, Shenzhen adopts GE company to produce.The main damage failure mode of this gas turbine blades is that the leaf tip wearing and tearing of one-level turbine rotor blade shorten, and makes the power benefit of gas turbine reduce.Because this one-level movable vane inside is the hollow air cooling structure of labyrinth-like, is again that the high-temperature nickel base superalloy is manufactured, blade surface has inoxidzable coating again, costs an arm and a leg, and external import not only difficulty is purchased, and is also restricted simultaneously.Employing differential of the arc deposited coatings technology is carried out the reparation of Co base alloy spreading to the blade tip of blade, has not only solved urgent need, and the blade of also having lengthened the life re-uses the life-span, has reduced overhaul cost exponentially.
Blade tip differential of the arc deposited coatings spreading technical process is:
Blade tip abrasive damage stratification or machinery removes → repairs → use frock clamp with vanes fixed on the X-Y workbench → the auxiliary control of CAD/CNC X-Y workbench makes blade tip do motion → IMR-C802 alloy differential of the arc deposited coatings → machine finish → X-ray infiltration detection with respect to electrode bar.
In the present embodiment, the composition of IMR-C802 alloy cobalt-base alloys following (wt%):
| Co | Cr | Ni | W | Mn | Mo | Si | B | O 2 |
| Surplus | 10 | 10 | 8 | 0.2 | 15 | 8 | 0.005 | 0.01 |
The technological parameter of IMR-C802 alloy differential of the arc deposited coatings is:
Differential of the arc source power output 4000w～5000w; Micro-arc discharge frequency 2000Hz～2500Hz; Pulsewidth 10
-5S; Electrode bar
Electrode bar motion mode: rotate or vibration the Ar gas shiled.
Claims (7)
1. gas turbine blades differential of the arc deposited coatings repair process, it is characterized in that: gas turbine blades is carried out the reparation of differential of the arc deposited coatings, differential of the arc deposited coatings process is meant: be that positive pole, workpiece are negative pole with the electrode bar, high-frequency DC pulse micro-arc discharge between electrode bar and surface of the work, and the metallurgical process that electrode bar material consumable is transferred to the surface of the work contact area takes place; The environment of material transfer deposition process is inert gas or vacuum or insulating oil; Pulse micro-arc discharge frequency is 70Hz～5000Hz, pulsewidth 10
-3～10
-5S, differential of the arc source power output is 50W～5000W; Electrode bar is cylindrical or block, and the electrode bar motion mode is rotation or vibration, and electrode bar is operating as hand-held machine.
2. according to the described gas turbine blades differential of the arc of claim 1 deposited coatings repair process, it is characterized in that: differential of the arc deposited coatings process is twice, carry out repair welding for the mode that adopts differential of the arc deposited coatings for the first time, prepare surface protecting layer for the mode that adopts differential of the arc deposited coatings for the second time.
3. according to the described gas turbine blades differential of the arc of claim 1 deposited coatings repair process, it is characterized in that: the gas turbine blower blade is steel blade or high-temperature alloy blades or titanium alloy blade, after the gas turbine blower blade is shortened with outer casing friction leaf tip, adopt differential of the arc deposited coatings spreading repair process, the spreading repair materials is with body material or the nickel-base alloy or the cobalt-base alloys of blade, the height of spreading reparation is 0.05mm～2.0mm, and spreading reparation formation blade tip hardness is HV250～HV550.
4. according to the described gas turbine blades differential of the arc of claim 1 deposited coatings repair process, it is characterized in that: the blade tip wearing and tearing of gas turbine turbine rotor blade, adopt short differential of the arc deposited coatings spreading repair process, the spreading repair materials is a MM ' CrAlY alloy, and M and M ' are Ni or Co; Perhaps, the spreading repair materials is Superalloy Substrate+MM ' CrAlY alloy surface cover layer; Perhaps, the spreading repair materials is cobalt-base alloys matrix+MM ' CrAlY alloy surface cover layer; The spreading reparation highly is 0.05mm～5.0mm, and microhardness is HV450～HV600.
5. according to the described gas turbine blades differential of the arc of claim 1 deposited coatings repair process, it is characterized in that: the anti-air-flow of the corrosion protection of gas turbine blower blade washes away localized delamination, the spot corrosion of coating or hits the hole, the process that adopts differential of the arc deposited coatings to repair, filling up repair materials is stainless steel or nickel-base alloy or cobalt-base alloys, and microhardness is HV 350～HV450.
6. according to the described gas turbine blades differential of the arc of claim 1 deposited coatings repair process, it is characterized in that: surface corrosion hole, fire check or the protective coating of gas turbine turbine nozzle vane nozzle peel off the district, adopt differential of the arc deposited coatings repair process to repair, repair materials is nickel-base alloy, cobalt-base alloys or MM ' CrAlY alloy, M and M ' are Ni or Co, and microhardness is HV350～HV500.
7. according to the described gas turbine blades differential of the arc of claim 1 deposited coatings repair process, it is characterized in that, the blade tip spreading is repaired, and the reparation of blade surface crackle, etch pit or blade surface protective coating peel off district's coating reparation, and its repair process is:
Damage floor → X-ray infiltration and the micro-tracking polishing of magnetic Non-Destructive Testing → original position removal of defects → repair type cleaning → differential of the arc deposited coatings → vacuum heat or mechanical force processing → shaping processing → surface finishing → mechanical force processing are removed in the polishing of blade cleaningization processing → to be repaired district.
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