CN102642121A - Cast steel stator pressing ring repair welding process - Google Patents
Cast steel stator pressing ring repair welding process Download PDFInfo
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- CN102642121A CN102642121A CN2012101363982A CN201210136398A CN102642121A CN 102642121 A CN102642121 A CN 102642121A CN 2012101363982 A CN2012101363982 A CN 2012101363982A CN 201210136398 A CN201210136398 A CN 201210136398A CN 102642121 A CN102642121 A CN 102642121A
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Abstract
The invention relates to an economic and effective repair welding process for finding defects of a cast steel stator pressing ring. The repair welding process sequentially comprises the following steps that: (1) the defect checking on the rough processing surface of the cast steel stator pressing ring is carried out, and marks are made in defect positions; (2) the defects are dug and removed according to the positions and the depths of the defects; (3) the repair welding is carried out; (4) the cast steel pressing ring is processed to the size according to part draws; (5) the cast steel stator pressing ring is assembled and welded into a stator machine seat; and (6) the stator machine seat is mechanically processed to the final size. In the defect checking on the rough processing surface of the cast steel stator pressing ring, firstly, a 4MHz phase array inclined probe is used for finding the defects, in addition, marks are made in the defect positions, then, a 5MHz phase array probe with a distance being 2mm near the field region is used for scanning near the defect positions, the defect depth is precisely positioned, and cracks and other defects are distinguished. The cast steel stator pressing ring repair welding process provided by the invention has the advantages that the defect finding, positioning and determination accuracies are high, the repair welding workload is small, the process route is short, and the repair cost is low.
Description
Technical field
The present invention relates to the cast steel stator pressing ring and search defective and cost-effective process for welding repair.
Background technology
The support of the High power Traction motor of single-machine capacity more than 500kW that Foreign High Power railway motor-car and locomotive use; The general Welding Structure that adopts both sides cast steel trim ring to add middle steel plate; After stator punching laminates, in support and form iron core, be referred to as to call out frame by weld all around.Stator pressing ring is the vitals of this kind of traction electric machine, and it must be connected output torque with gear-box, also must bear the various dynamic loadings that produce in deadweight and the locomotive operation through the Hanging bolt on the bogie.Because the stator pressing ring steel-casting can not effect a radical cure casting flaw, some casting flaws on the product must solve with repair method.At present cast steel stator pressing ring and the out frame master operation of searching defective and carrying out soldering is 1. on cast steel stator pressing ring roughing face, to detect defective with ordinary straight; And mark at defective locations, 2. according to the defective locations and the degree of depth, excavate, the back chipping defective; 3. soldering; 4. in stove, anneal after the soldering, 5. the oxide skin of cleaning workpiece in stove be worked into size to the cast steel stator pressing ring according to its part drawing; 6. cast steel stator pressing ring assembly welding becomes out frame; 7.-and the roughing out frame, 9. 8. out frame magnetic powder inspection finds defective; Soldering again; 10. go up Cutter Body Processing with Machining Center again to size (current last allowance is little, causes fine finishining morpheme and dimension overproof after the soldering of part support, causes support to be scrapped) and then carry out the weld defect inspection and repeat the above-mentioned step and beat till reaching welding standard.According to the important instructions for use of this product,, need under the prerequisite that guarantees certain preheat temperature, could weld according to relevant welding standard.If defective can not once lean out as much as possible, repair welding also need repeat all welding sequences and inspection process.Owing on cast steel stator pressing ring roughing face, detect defective with ordinary straight; The ordinary straight probe is very big to nearly surperficial blind area in detecting; Just can not find to detect the shallow table defective in the face 10mm, the probability of detection of the defective below the 10mm, location and poor reliability qualitatively, the defective that has is just found in the out frame manufacturing procedure; A large amount of repairing time and machining center man-hour have not only been wasted, sometimes even scrap whole out frame.Produce the traction electric machine manufacturer of 1000 this band cast steel frame trim rings per year, the annual defective that produces when the machined because of the cast steel frame trim ring is lost millions of units.
Summary of the invention
The object of the present invention is to provide a kind of cast steel stator pressing ring to search defective and cost-effective cast steel stator pressing ring process for welding repair.
Be to realize above-mentioned purpose, the technical scheme that the present invention adopts is a kind of cast steel stator pressing ring process for welding repair, comprises successively: 1. detect defective on the cast steel stator pressing ring roughing face and mark at defective locations; 2. according to the defective locations and the degree of depth, excavate, the back chipping defective gets the soldering groove; 3. soldering; 4. be worked into size to the cast steel stator pressing ring according to its part drawing; 5. cast steel stator pressing ring assembly welding becomes out frame; 6. the machining out frame is to final size; Its innovation is: detect defective on the said cast steel stator pressing ring roughing face and at first use 4MHz phased array angle probe to search defective and mark at defective locations; And then use 5MHz; The phased array normal probe of near field region 2mm scans near doing defective locations, accurately locatees depth of defect, distinguishes crackle and other types defective.
Cover with non-metal powder powder heat-barrier material immediately after the said soldering, cover the workpiece of soldering just then with a frock cover immediately; Make the soldering position be no more than 1.2 times of mother metal hardness in cooling back hardness fully.
Said non-metal powder powder heat-barrier material is sawdust powder or coal powder.
Said frock cover comprises case and handle, and said case comprises top board and the tubular side plate that is connected as a single entity, and handle is installed on the top board of case, and said top board is provided with through hole.
The top board of said frock cover is provided with six through holes.
Adopt cast steel stator pressing ring process for welding repair of the present invention; Have only 3mm and scanning scope big owing to utilized the nearly surperficial blind area of 4MHz phased array angle probe; Scanning efficient is high; Can guarantee that the defective overwhelming majority below the cast steel stator pressing ring top layer 4mm can found characteristics, after doing ultrasonic wave and scanning for the first time, mark at defective locations; Use 5MHz then, near field region 2mm phased array normal probe scans near doing defective locations, accurately locatees depth of defect, distinguishes crackle and other types defective.Distinguished the defective and the defective on top layer below the cast steel stator pressing ring top layer roughing face 4mm like this, the interior defective of allowance for finish 4mm is not handled, and can directly get rid of through fine finishining.Defective below the roughing face 4mm is through 5MHz, and the phased array normal probe of near field region 2mm is location and qualitative accurately, only needs the unacceptable defective (like crackle) below the repair welding roughing face 4mm.Cover with non-metal powder powder heat-barrier material immediately after the soldering; Cover the cast steel stator pressing ring workpiece of soldering just then immediately with a frock cover; Reduce scattering and disappearing and the increase postweld heat preservation time of heat, this process promptly is equivalent to annealing process, makes the soldering position comprise that heat affected area hardness after cooling off fully is no more than 1.2 times of mother metal hardness; This process is equivalent to differential annealing, reduces the hardness of solder joint and heat affected area; Cast steel stator pressing ring process for welding repair of the present invention has the defective of discovery and location, accuracy is high qualitatively, has saved traditional magnetic powder inspection operation, has avoided repeatedly repeating flaw detection and has practiced thrift flaw detection time and cost; The soldering workload is little short with process route, the advantage that the cost of repairing is low.Greatly reduced scrapping of support, the rate of utilization of work hour of machining center is high.
Description of drawings
Fig. 1 is the structural representation that the frock cover covers the cast steel stator pressing ring among the present invention;
Fig. 2 is the right view of Fig. 1.
The specific embodiment
Below in conjunction with concrete embodiment cast steel stator pressing ring process for welding repair of the present invention is done further explain.
A kind of high-speed overload shipping electric locomotive traction motor material is the cast steel stator pressing ring process for welding repair of G20Mn5, and its detailed step is following:
1. on cast steel stator pressing ring roughing face; At first use 4MHz phased array angle probe to search defective and mark at defective locations, and then use 5MHz, the phased array normal probe of near field region 2mm scans near doing defective locations; Accurately the location depth of defect is distinguished crackle and other types.Mark at defective locations after detecting defective; Find that crackle, incomplete fusion, slag inclusion, pore etc. influence the defective of quality, on foundry goods, directly use oil pike to indicate.Mark the scope of defective with red pen; With blue pen these defectives are numbered 1/4 (represent the 1st defective/have 4 defectives), 2/4 (represent the 2nd defective/have 4 defectives), 3/4,4/4; Can shorten the time that the workman searches defective like this, avoid missing some defective after the preheating; The welder needs a partner to help handling, ajust workpiece to save time, and avoids that temperature does not reach requirement in the welding repair process, in case of necessity, should accomplish welding simultaneously by two welders; So that better guaranteeing repair welding is under 140 ℃-350 ℃ condition, to accomplish.
2. according to the defective locations and the degree of depth, excavate, the back chipping defective gets the soldering groove; Remove the defective method and use carbon arc air gouging, perhaps use the polishing of hand-held abrasive machine, (if use the abrasive machine polishing; Must the sand grains at groove place be blown down clean) the groove shape should be definite according to foundry goods section thickness, groove position and welder's operating condition etc.; Be generally the pattern of non-perforation groove, or for connecting the pattern of single groove, this kind pattern is when soldering; Need backing plate be set at the osculum end that connects single groove, backing plate is removed at postwelding.If can the two sides during welding, a postwelding is answered back chipping, welds another side again, if also can adopt the pattern that connects double groove than heavv section, opens double groove, and a postwelding is answered back chipping, welds another side again.More than all groove faces all should expose the base metals true qualities, groove bottom wants slick and sly with the sidewall transition, 20mm scope planted agent removes sand, greasy dirt, water, rust and other foreign material around the groove.
3. soldering; To treat the workpiece preheating of soldering before the weldering: 200 ℃ of temperature ,-350 ℃ of strict control of palpus temperature, the temperature of steel-casting can not be lower than 140 ℃ in the whole welding repair process.
Welding
Under the situation of condition permission, weld at horizontal level as far as possible;
Repair welding is operated under the situation of condition permission, should carry out continuously.If when haveing no alternative but interrupt, must take the insulation measure.During repair welding, answer weld preheating once more;
During repair welding, welding rod should not done excessive teeter.Amplitude of fluctuation must not surpass 3 times of core diameter.The weld seam that length is big is answered segmentation, staggered welding, reduces distortional stress and produces;
In the process of patch weld, when influencing the defective of quality, answer the report quality inspector as if discovery crackle, incomplete fusion, slag inclusion, pore etc., and the removal of defects of taking measures.After confirming that defective has been eliminated, could continue repair welding;
During the steel casting surface built-up welding, the lap between welding bead must not be less than 1/3 of weld width;
During the multilayer welding, except that ground floor and last one deck, each welding bead of all the other each layers is with the hammering of flat round end pneumatic shovel appropriateness.If two-layer discontinuous soldering is arranged, before carrying out the soldering second time, should remove the welding slag and the foreign material of last layer clean;
Welding manner: manual electric arc welding;
(national standard welding rod model: E5016/E5017) welding rod before use must oven dry for type of electrode: J506 or J507.If do not have particular provisions in the welding rod specification, acidic electrode should be looked the situation of making moist at 70～150 ℃ of oven dry 1～2 h; The alkaline low-hydrogen type structural steel electrode should be at 300～400 ℃ of oven dry 1～2 h, and the welding rod of oven dry should be placed in 100～150 ℃ of heat-preservation cylinders (case), ready access upon use.Note during use keeping dry.
At least the peripheral 30mm covering sawdust powder or the coal powder that surpass the soldering heat affected area that is observed visually after the soldering immediately in soldering place of cast steel stator pressing ring; The sawdust powder or the coal powder that cover are met the oxygen spontaneous combustion in air; Produced little heat in the spontaneous combustion process heat of soldering place can not be scattered and disappeared fast, this process is equivalent to annealing.The sawdust powder or the coal powder of covering make the solder joint place completely cut off cool exterior air, and not oxidation and slowly cooling make the soldering position comprise that heat affected area hardness after cooling off fully is no more than 1.2 times of mother metal hardness.If cover with non-metal powder powder heat-barrier material sawdust powder or coal powder immediately after the soldering, and it is better to cover effect immediately with an aluminum frock cover immediately.Referring to accompanying drawing 1, Fig. 2; Said frock cover comprises case 1 and handle 2; Said case 1 comprises top board 1-1 and the tubular side plate 1-2 that is connected as a single entity, and handle 2 is installed on the top board 1-1 of case 1, and said top board 1-1 is provided with six through hole 1-3; Arrest handle 2 during use case 1 is covered on the cast steel stator pressing ring 3, the case 1 that in this process, is provided with through hole 1-3 plays the effect of chimney and protective cover.Chimney helps burning.Protective cover prevents that gentle breeze from blowing away the sawdust powder or the coal powder of covering; Prevent that people's will from running into the safety effect of solder joint of heat outward; And the lost minimizing to a greater extent of the heat that makes local soldering zone, can guarantee that the soldering position comprises that heat affected area hardness after cooling off fully is no more than 1.2 times of mother metal hardness.
4. be worked into size to the cast steel stator pressing ring that cools off fully after the soldering according to its part drawing.
5. cast steel frame trim ring assembly welding becomes out frame.
6. the machined out frame is to final size.
Cast steel stator pressing ring process for welding repair of the present invention has the defective of discovery and location, accuracy is high qualitatively, has saved traditional magnetic powder inspection operation, has avoided repeatedly repeating flaw detection and has practiced thrift flaw detection time and cost; The soldering workload is little short with process route, the advantage that the cost of repairing is low.Greatly reduced scrapping of out frame, the rate of utilization of work hour of machining center is high.
Claims (5)
1. cast steel stator pressing ring process for welding repair comprises successively: 1. detect defective on the cast steel stator pressing ring roughing face and mark at defective locations; 2. according to the defective locations and the degree of depth, excavate, the back chipping defective gets the soldering groove; 3. soldering; 4. be worked into size to the cast steel stator pressing ring according to its part drawing; 5. cast steel stator pressing ring assembly welding becomes out frame; 6. the machining out frame is to final size; It is characterized in that: detect defective on the said cast steel stator pressing ring roughing face and at first use 4MHz phased array angle probe to search defective and mark at defective locations; And then use 5MHz; The phased array normal probe of near field region 2mm scans near doing defective locations, accurately locatees depth of defect, distinguishes crackle and other types defective.
2. cast steel stator pressing ring process for welding repair according to claim 1 is characterized in that: cover with non-metal powder powder heat-barrier material immediately after the said soldering, cover the workpiece of soldering just then with a frock cover immediately; Make the soldering position be no more than 1.2 times of mother metal hardness in cooling back hardness fully.
3. cast steel stator pressing ring process for welding repair according to claim 1 is characterized in that: said non-metal powder powder heat-barrier material is sawdust powder or coal powder.
4. cast steel stator pressing ring process for welding repair according to claim 1; It is characterized in that: said frock cover comprises case (1) and handle (2); Said case (1) comprises top board (1-1) and the tubular side plate (1-2) that is connected as a single entity; Handle (2) is installed on the top board (1-1) of case (1), and said top board (1-1) is provided with through hole (1-3).
5. cast steel stator pressing ring process for welding repair according to claim 4 is characterized in that: the top board of said frock cover (1-1) is provided with six through holes (1-3).
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN2012101363982A CN102642121A (en) | 2012-05-05 | 2012-05-05 | Cast steel stator pressing ring repair welding process |
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| Application Number | Priority Date | Filing Date | Title |
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| CN2012101363982A CN102642121A (en) | 2012-05-05 | 2012-05-05 | Cast steel stator pressing ring repair welding process |
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| CN102642121A true CN102642121A (en) | 2012-08-22 |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103439409A (en) * | 2013-09-03 | 2013-12-11 | 宁夏共享集团有限责任公司 | Positioning method for groove weld defects of large-wall-thickness pipe fitting |
| CN114888405A (en) * | 2022-03-31 | 2022-08-12 | 阳江核电有限公司 | Method for eliminating defects of large heat-resistant steel special-shaped welded joint of nuclear power station on line |
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2012
- 2012-05-05 CN CN2012101363982A patent/CN102642121A/en active Pending
Patent Citations (6)
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| EP1844894A1 (en) * | 2006-04-12 | 2007-10-17 | Linde Aktiengesellschaft | Process of welding repair of cast materials having a defect; Workpiece made of cast material having such a repaired part; Use of a gas mixing for such process |
| CN1935441A (en) * | 2006-10-16 | 2007-03-28 | 四川东风电机厂有限公司 | Water-wheel generator rotor support hub defect treatment method |
| CN101231298A (en) * | 2007-01-23 | 2008-07-30 | 宝钢集团常州轧辊制造公司 | Method for detection fault detection in roller surface |
| JP2009019887A (en) * | 2007-07-10 | 2009-01-29 | Nippon Steel Corp | Method and device for inspecting weld zone defect of electric resistance welded steel pipe |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103439409A (en) * | 2013-09-03 | 2013-12-11 | 宁夏共享集团有限责任公司 | Positioning method for groove weld defects of large-wall-thickness pipe fitting |
| CN114888405A (en) * | 2022-03-31 | 2022-08-12 | 阳江核电有限公司 | Method for eliminating defects of large heat-resistant steel special-shaped welded joint of nuclear power station on line |
| CN114888405B (en) * | 2022-03-31 | 2023-12-05 | 阳江核电有限公司 | Method for online eliminating defects of special-shaped welding joint of large heat-resistant steel in nuclear power station |
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Application publication date: 20120822 |