CN102756235A - Field welding repair method especially for larger and penetrating defects in steel casting with heavy wall thickness - Google Patents
Field welding repair method especially for larger and penetrating defects in steel casting with heavy wall thickness Download PDFInfo
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- CN102756235A CN102756235A CN2012102547663A CN201210254766A CN102756235A CN 102756235 A CN102756235 A CN 102756235A CN 2012102547663 A CN2012102547663 A CN 2012102547663A CN 201210254766 A CN201210254766 A CN 201210254766A CN 102756235 A CN102756235 A CN 102756235A
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Abstract
The invention relates to a field welding repair method especially for larger and penetrating defects in a steel casting with heavy wall thickness. The method comprises a pre-welding preparation process, a welding repair process and a post-welding quality inspection process, wherein the welding repair process comprises the steps of (1) preheating; (2) carrying out 1 to 2 layers of backing weld for all positions of a groove by adopting TIG weld, and filling the whole bottom of the groove with solid wire materials; (3) warming up to 220 to 330 DEG C, carrying out constant thermal insulation for 3 to 8 hours, adopting manual arc welding to implement the filler welding for the groove, hammering the welded bead immediately with an air hammer, and ensuring the dense and uniform traces of the hammer; (4) carrying out dehydrogenation heat treatment; (5) carrying out post-welding treatment: carrying out stress annealing at the temperature of 500 to 550 DEG C, then carrying out high tempering at the temperature of 700 to 750 DEG C, and finally, cooling at the speed of 65 to 150 DEG C/h to the room temperature. After welding repair, a welding seam is tested to be good in quality, and have low possibility of cracking again.
Description
Technical field
The invention belongs to foundry goods Welding Repair Technology field, particularly a kind of field Welding restorative procedure of heavy wall steel-casting.
Background technology
Vitals such as heat power plant boiler, four large pipelines, steam turbine adopt large-scale steel-casting a lot, and major part is used under the operating mode of HTHP, and abominable condition of work has proposed very high requirement safely to it.Stop valve; Parts such as casting three-way on control valve, stifled valve and the boiler header are owing to factors such as volume are big, the different parts wall thickness change is big; Usually in manufacture process, there is structural heterogenity because of the cooling velocity difference; And usually follow casting flaw, cause under service condition, being easy to take place Cracking Failure.
In the prior art,, therefore adopt heterogeneous cold-welding recovery method to repair usually owing to be difficult to carry out local post weld heat treatment after the REPAIR WELDING at the scene.Yet, to big (reaching the half the of wall thickness) and run through the defective of type, adopt that heterogeneous cold welding technique is difficult to be accomplished.
Summary of the invention
Technical problem to be solved by this invention is the deficiency that overcomes prior art, provides a kind of and is particularly suitable in the heavy wall steel-casting big and runs through the field Welding restorative procedure of type defective.
For solving above technical problem, the present invention takes following technical scheme:
A kind ofly be particularly suitable in the heavy wall steel-casting big and run through the field Welding restorative procedure of type defective, comprise preparatory process before the weldering, REPAIR WELDING operation and postwelding quality inspection operation, particularly:
Before weldering in the preparatory process: polished to form groove in defective position; Inner no wedge angle groove of groove after wherein guaranteeing to polish or corner angle; Polish metallic luster in the inside and outside wall 30mm scope around the groove; The groove that forms gets into the REPAIR WELDING operation after surface inspection is confirmed the noresidue defective and degreased;
The REPAIR WELDING operation comprises the following step that carries out successively:
(1), the said groove of preheating to the inner wall temperature that need carry out the position of REPAIR WELDING reaches the minimum temperature that does not produce welding cold cracking;
(2), adopt the gas tungsten arc welding mode that 1～2 layer of backing welding carried out in whole positions of groove; With the solid welding wire material whole groove bottom is filled; Rounding off is carried out in the violent zone of geometry sudden change in the groove; Wherein, control gas tungsten arc welding interlayer temperature is between 130 ℃～220 ℃;
(3), after step (2) is accomplished; Be warming up to 220 ℃～330 ℃, permanent heat insulation 3～8 hours adopts manual electric arc welding to carry out the filling weldering of groove; Wherein: manual electric arc welding employing and mother metal homogeneity or similar welding rod; And the employing multi-pass welding, the welding bead postwelding carries out hammering with pneumatic hammer immediately, and the hammer trace is gathered evenly;
(4), the postwelding hydrogen heat treatment that disappears: after groove welding is full, the hydrogen heat treatment that under 300 ℃～400 ℃ of temperature, disappears, the hydrogen heat treatment time that disappears is 2～6 hours;
(5), post weld heat treatment: at first under 500 ℃～550 ℃ of temperature, carry out stress relief annealing, under 700 ℃～750 ℃, carry out high tempering then, after heat treatment is accomplished, be cooled to room temperature with the rate of temperature fall of 65 ℃/h～150 ℃/h.
According to further of the present invention and preferred embodiment:
Before weldering in the preparatory process: when polishing, polish to root along straight line earlier, suitably widen gradually, until polishing defective, and groove is polished into the shape of being convenient to the later welded operation.Can be in the preparatory process before weldering through degreasing with the organic solvent wiping.
In the step (1) of REPAIR WELDING operation, preheating can be adopted tracklayer heater, rope formula heater or the combination of the two, perhaps also can adopt existing special-purpose heater to heat.
In the welding process of said step (2) and (3), be aided with the real-time monitoring temperature of hand-held infrared radiation thermometer, when temperature is lower than the minimum of temperature of requirement, reheat, when temperature exceeds the peak of temperature of requirement, stop welding.
Heating plate or heating rope or the combination of the two are adopted in heat treatment in step (4) and (5), perhaps also can adopt existing special-purpose heater to heat.
Said postwelding quality inspection operation comprises that Non-Destructive Testing, hardness detect, on-the-spot metallographic detects and the residual stress test.Wherein, the method that visual examination, magnetic powder inspection and ultrasonic examination combine is adopted in Non-Destructive Testing.
According to a concrete aspect of the present invention, the material of steel-casting is a carbon steel or low alloy steel, in the step (1), is preheated to 130～220 ℃.
According to the described defective in another concrete aspect of the present invention when running through the type defective; Said method also is included in the step (3); Be welded to 1/3 of the groove depth～2/3 hydrogen heat treatment that disappears in the middle of o'clock carrying out once, this centre heat treated temperature of hydrogen that disappears is 300～400 ℃, and the time is 2～6 hours.
According to another concrete aspect of the present invention, the material of heavy wall steel-casting is the ZG15Cr1Mo1V Mayari, and the welding rod that in step (3), adopts is the ultralow hydrogen type high-tenacity welding electrodes.
According to the present invention, the heavy wall steel-casting is often referred to the steel-casting that the wall thickness scope is 40～200mm." big defective " is meant that the degree of depth reaches wall thickness defective over half.It will be understood by those skilled in the art that provided by the inventionly to be particularly suitable in the REPAIR WELDING heavy wall steel-casting big and to run through the welding repair method of type defective, equally also can be used for the REPAIR WELDING of other steel-casting and defect type.Therefore, protection scope of the present invention should not receive the restriction of steel-casting thickness and defect type.
Because the employing of technique scheme, the present invention compared with prior art has the following advantages:
The present invention is before REPAIR WELDING, and thoroughly removing is clean to guarantee defective, avoids crackle to produce once again; Backing welding is carried out in the whole positions of groove after adopting the TIG weldering to polishing, prevents that effectively the more steel-casting of the particularly original casting flaw of steel-casting from cracking once again; The present invention also carries out hammering and eliminates residual stress in the manual electric arc welding welding process, the residual stress of REPAIR WELDING process is effectively controlled; The heat treatment of carrying out at postwelding comprises and eliminating stress and high tempering heat treatment, its can be when tissue and hardness be regulated the elimination welding residual stress.Welding repair method of the present invention is particularly suitable in power station, the chemical industry heavy wall steel-casting big (it is over half to reach wall thickness) and runs through the REPAIR WELDING of type defective, and the quality through testing after of the weld seam after the REPAIR WELDING is good, the difficult crackle that takes place once more.
Description of drawings
Fig. 1 is a valve outer wall crackle photo;
Fig. 2 is for showing the photo of the groove shape after polishing;
Fig. 3 is a repair welding weld seam typical gold phase constitution.
The specific embodiment
Known; The main steam valve is the main heat power equipment in thermal power plant; Bear the effect of HTHP load under the not only even running situation for a long time; And opening, shutting down and meeting the effect that also can receive alternate stress when changing, therefore, at the weak part of main steam valve or exist the zone of inner manufacturing defect to be easy to generate crackle and lost efficacy.
In April, 2011, penetrating crack all appearred in a Russia coal-fired No. 2 steam valve valve bodies of unit of overcritical 500MW (material is the ZG15Cr1Mo1V Mayari) of genco; Cause steam leakage, No. 1 main steam valve also finds to exist defectives such as multiple tracks crackle subsequently.Be that crackle about 100mm is (referring to Fig. 1 with 1 director's degree of No. 2 valve outer surfaces below; The crackle width of dehiscing is 2～3mm; 1 of this corresponding place's inner surface cracks, leak thickness is about 95mm) reparation be example, field Welding restorative procedure of the present invention is described.
According to present embodiment, welding repair method is divided into the preceding preparatory process of weldering, REPAIR WELDING operation and three operations of postwelding quality inspection operation to carry out, specific as follows.
1, preparatory process before the weldering
(1), the polishing defective forms groove: adopt the on-the-spot polishing cutting apparatus (like angle grinding machine, beveling machine etc.) that is suitable for that the polishing of defective position is cleaned out; Should polish to root along straight line earlier during polishing, suitably widen gradually, until polishing defective; And make the region shape that polish be convenient to subsequent operation as far as possible; Groove inside after the polishing is groove (as shown in Figure 2) root rounding off particularly, and inside and outside wall 30mm scope domestic demand polish metallic luster around no wedge angle groove or the corner angle, groove.
(2), the affirmation of defective removing: excavating of crackle is the successful prerequisite of repair welding, and be unclean if crackle is excavated, and stays hidden danger, also can cause crackle to produce once again.The groove zone of final preparation is by specialty flaw detection personnel surface inspection, and quality scale reaches JB/T4730-2005 infiltration I level, and whether affirmation polishing groove district has the residual defects of not cleared up, and thoroughly removes totally if having once more.Defect confirmation polishing eliminate accomplish the back with the acetone and other organic solvent wiping with surface impurities such as removal greasy dirts.
2, REPAIR WELDING operation
The REPAIR WELDING operation is undertaken by disappear hydrogen and heat treated flow process of the manual electric arc welding → postwelding of the preheating → prime coat TIG welding → filler pass of groove, and is specific as follows:
(1), preheating: adopt tracklayer heater, rope formula heater or other special-purpose heater that the inner wall temperature that need carry out the position of REPAIR WELDING is heated to 150 ℃, begin welding job afterwards;
(2), prime coat weldering: adopt gas tungsten arc welding (TIG weldering) mode; Electric arc as thermal source burns between not fusible electrode and workpiece during this period; The welding material of inert protective gas protection fusing is avoided the influence of surrounding air, wherein, adopts and mother metal homogeneity or similar solid welding wire material (welding wire trade mark TIG-R31, specification ф 2.5mm; Weldingvoltage 9-11V, welding current 70-90A); 2 layers of welding of TIG weldering carrying out are filled whole welding line groove bottom with the solid welding wire material, and rounding off is carried out in the violent zone of geometry sudden change in the groove.Welding process is aided with the real-time monitoring temperature of hand-held infrared radiation thermometer, and TIG interpass temperature is controlled at 130 ℃～220 ℃, otherwise stops welding or reheating.
(3), after step (2) accomplishes, be warming up to 250 ℃, permanent heat insulation 4 hours; Adopt manual electric arc welding to carry out the filling weldering of groove, wherein: the welding rod of ultralow hydrogen type high tenacity R317L, specification ф 3.2mm, weldingvoltage 21～26V are adopted in manual electric arc welding; Welding current 100～120A, welding rod is welding electrode, and electric arc burns between welding rod and workpiece; Adopt multi-pass welding, the welding bead postwelding carries out hammering with pneumatic hammer immediately, and the hammer trace is gathered evenly; So can effectively reduce the residual stress that welding produces, the prevention weld crack, the manual electric arc welding interlayer temperature is controlled between 250 ℃～300 ℃; Otherwise stop weldering or reheat, in the middle of manual electric arc welding, the centre of under 400 ℃, carrying out 2 hours when being welded to the degree of depth and the being 40mm hydrogen heat treatment that disappears.
(4), the postwelding hydrogen heat treatment that disappears: after step (3) groove welding is full, under 400 ℃, carry out 2 hours the hydrogen heat treatment that disappears, to avoid the generation of cold crack.
(5), post weld heat treatment: adopt 540 ℃ of average temperings of Electric heating (stress relief annealing)+730 ℃ high tempering heat treatment; Arrange heater during heat treatment at the repair welding position; On two duct and main inlet throttle-stop valve pipeline, arrange rope formula heater temperature control respectively; The effect of post weld heat treatment is in order to eliminate welding residual stress, simultaneously the tissue of weld seam after the repair welding and heat affected area material to be adjusted.The time of stress relief annealing is confirmed (being 8 hours in this example) according to the repair welding throat depth, and during stress relief annealing, material behaviors such as the strength of materials and ductility are not by obvious change.The time of high tempering is also confirmed (being 2 hours in this example) according to the repair welding throat depth, should slowly cool to room temperature (the about 65 ℃/h of rate of temperature fall～150 ℃/h) after heat treatment is accomplished.
3, postwelding quality inspection operation:
The postwelding quality inspection comprises the residual stress test and the valve group distortion thickness measure of Non-Destructive Testing (VT+MT+UT), hardness detection, overlay film metal lographic examination, typical welding point, and is specific as follows:
(1) Non-Destructive Testing: postwelding is cleaned out repair welding zone and heat affected area polishing; Expose metallic luster; The method that adopts visual examination, magnetic powder inspection and ultrasonic examination to combine checks that to the weld seam and the heat affected area of repair welding the moulding of repair welding weld appearance is good; Do not see that defectives such as crackle, incomplete fusion exist, MT and UT all do not see the demonstration that exceeds standard.
(2), hardness detects: use portable hardness tester scene to carry out hardness test, repair welding weld seam and near zone heat affected area and mother metal are measured 3 places respectively, repair welding weld seam and heat affected area hardness number are distributed in the 190-230HB scope, are in than zone of reasonableness.
(3), overlay film metallographic: the surface replica metal lographic examination is carried out in welding point repair welding zone; Typical metallographic structure is as shown in Figure 3; The metallographic structure of repair welding weld seam is tempered sorbite+little ferrite; Grain size is the 9-10 level, and the heat affected area metallographic structure is bainite+ferrite, and grain size is the 4-5.5 level.
(4), residual stress test: adopt the blind hole method that typical repair welding weld seam has been carried out the residual stress test; Wherein test point all is chosen in bigger weld metal zone of stress and heat affected area; Test result shows that the repair welding weld seam maximum residual stress after the process heat treatment appears at the heat affected area; Be 105MPa,, explain that the residual stress measure is eliminated in the hammering of adopting and Technology for Heating Processing can play good elimination residual stress effect far below the yield strength of mother metal 343MPa.
The foregoing description only is explanation technical conceive of the present invention and characteristics; Its purpose is to let the personage who is familiar with this technology can understand content of the present invention and enforcement according to this; Can not limit protection scope of the present invention with this; All equivalences that spirit is done according to the present invention change or modify, and all should be encompassed within protection scope of the present invention.
Claims (10)
1. one kind is particularly suitable in the heavy wall steel-casting big and runs through the field Welding restorative procedure of type defective, comprises preparatory process before the weldering, REPAIR WELDING operation and postwelding quality inspection operation, it is characterized in that:
Before said weldering in the preparatory process: polished to form groove in defective position; Inner no wedge angle groove of groove after wherein guaranteeing to polish or corner angle; Polish metallic luster in the inside and outside wall 30mm scope around the groove; The groove that forms gets into the REPAIR WELDING operation after surface inspection is confirmed the noresidue defective and degreased;
Said REPAIR WELDING operation comprises the following step that carries out successively:
(1), the said groove of preheating to the inner wall temperature that need carry out the position of REPAIR WELDING reaches the minimum temperature that does not produce welding cold cracking;
(2), adopt the gas tungsten arc welding mode that 1 ~ 2 layer of backing welding carried out in whole positions of groove; With the solid welding wire material whole groove bottom is filled; Rounding off is carried out in the violent zone of geometry sudden change in the groove; Wherein, control gas tungsten arc welding interlayer temperature is between 130 ℃ ~ 220 ℃;
(3), after step (2) is accomplished; Be warming up to 220 ℃ ~ 330 ℃, permanent heat insulation 3 ~ 8 hours adopts manual electric arc welding to carry out the filling weldering of groove; Wherein: manual electric arc welding employing and mother metal homogeneity or similar welding rod; And the employing multi-pass welding, the welding bead postwelding carries out hammering with pneumatic hammer immediately, and the hammer trace is gathered evenly;
(4), the postwelding hydrogen heat treatment that disappears: after groove welding is full, the hydrogen heat treatment that under 300 ℃ ~ 400 ℃ of temperature, disappears, the hydrogen heat treatment time that disappears is 2 ~ 6 hours;
(5), post weld heat treatment: at first under 500 ℃ ~ 550 ℃ of temperature, carry out stress relief annealing, under 700 ℃ ~ 750 ℃, carry out high tempering then, after heat treatment is accomplished, be cooled to room temperature with the rate of temperature fall of 65 ℃/h～150 ℃/h.
2. according to claim 1ly be particularly suitable in the heavy wall steel-casting big and run through the field Welding restorative procedure of type defective; It is characterized in that: before said weldering in the preparatory process: when carrying out said polishing; Polish to root along straight line earlier; Suitably widen gradually, until polishing defective, and said groove is polished into the shape of being convenient to the later welded operation.
3. according to claim 1ly be particularly suitable in the heavy wall steel-casting big and run through the field Welding restorative procedure of type defective, it is characterized in that: before said weldering in the preparatory process: through degreasing with the organic solvent wiping.
4. according to claim 1ly be particularly suitable in the heavy wall steel-casting big and run through the field Welding restorative procedure of type defective, it is characterized in that: in the step (1), tracklayer heater, rope formula heater or the combination of the two are adopted in said preheating.
5. describedly be particularly suitable in the heavy wall steel-casting big and run through the field Welding restorative procedure of type defective according to claim 1 or 4; It is characterized in that: in the welding process of said step (2) and (3); Be aided with the real-time monitoring temperature of hand-held infrared radiation thermometer, when temperature is lower than the minimum of temperature of requirement, reheat; When temperature exceeds the peak of temperature of requirement, stop welding.
6. according to claim 1ly be particularly suitable in the heavy wall steel-casting big and run through the field Welding restorative procedure of type defective, it is characterized in that: the material of described steel-casting is a carbon steel or low alloy steel, in the step (1), is preheated to 130 ~ 220 ℃.
7. according to claim 1ly be particularly suitable in the heavy wall steel-casting big and run through the field Welding restorative procedure of type defective, it is characterized in that: the heat treatment in step (4) and (5) adopts heating plate or heating to restrict or the two combination.
8. according to claim 1ly be particularly suitable in the heavy wall steel-casting big and run through the field Welding restorative procedure of type defective; It is characterized in that: described defective is when running through the type defective; Said method also is included in the step (3); Be welded to 1/3 of the groove depth ~ 2/3 hydrogen heat treatment that disappears in the middle of o'clock carrying out once, this said centre heat treated temperature of hydrogen that disappears is 300 ~ 400 ℃, and the time is 2 ~ 6 hours.
9. according to claim 1ly be particularly suitable in the heavy wall steel-casting big and run through the field Welding restorative procedure of type defective; It is characterized in that: the material of described heavy wall steel-casting is the ZG15Cr1Mo1V Mayari, and the welding rod that in step (3), adopts is the ultralow hydrogen type high-tenacity welding electrodes.
10. according to claim 1ly be particularly suitable in the heavy wall steel-casting big and run through the field Welding restorative procedure of type defective, it is characterized in that: said postwelding quality inspection operation comprises that Non-Destructive Testing, hardness detect, on-the-spot metallographic detects and the residual stress test.
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| CN114433982A (en) * | 2022-02-23 | 2022-05-06 | 鲁西工业装备有限公司 | Welding process for high-temperature cast steel furnace tube |
| CN114682883A (en) * | 2022-03-04 | 2022-07-01 | 中国船舶重工集团公司第七二五研究所 | Method for preheating before welding and stress relieving after welding of pulse current auxiliary type high-strength titanium alloy |
| CN115007979A (en) * | 2022-07-11 | 2022-09-06 | 南京钢铁股份有限公司 | Method for repairing defects of over 200mm extra-thick steel casting |
| CN115683905A (en) * | 2022-12-09 | 2023-02-03 | 广东大鹏液化天然气有限公司 | Method and system for detecting and repairing cracks caused by scratching body through long gas transmission pipeline |
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