CN102756235B - 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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Abstract
本发明涉及特别适于厚壁铸钢件中较大及贯穿型缺陷的现场焊接修复方法，包括焊前准备工序、焊接修复工序、焊后质量检验工序，焊接修复工序包括：（1）预热；（2）采用TIG焊对坡口的全部位置进行1～2层打底焊，用实心焊丝材料对整个坡口底部进行填充；（3）升温至220℃～330℃，恒热保温3～8小时，采用手工电弧焊进行坡口的填充焊，焊道焊后立即用气锤进行锤击，且使锤痕密布均匀；（4）消氢热处理；（5）焊后热处理：先在温度500～550℃下进行消除应力退火，然后在700～750℃下进行高温回火，完成后，以65～150℃/h的速率降温冷却至室温。本发明焊接修复后的焊缝经测试后质量好，不易再次发生裂纹。
The invention relates to an on-site welding repair method especially suitable for larger and through-type defects in thick-walled steel castings, including a pre-welding preparation process, a welding repair process, and a post-weld quality inspection process. The welding repair process includes: (1) preheating ; (2) Use TIG welding to perform 1-2 layers of bottom welding on all positions of the groove, and fill the bottom of the entire groove with solid welding wire material; 8 hours, using manual arc welding for filling welding of the groove, hammering with an air hammer immediately after the bead welding, and making the hammer marks dense and uniform; (4) hydrogen elimination heat treatment; (5) post-weld heat treatment: first at the temperature Stress relief annealing is carried out at 500-550°C, and then high-temperature tempering is carried out at 700-750°C. After completion, the temperature is cooled to room temperature at a rate of 65-150°C/h. The quality of the weld repaired by the invention is good after being tested, and cracks are not easy to occur again.
Description
Technical field
The invention belongs to foundry goods Welding Repair Technology field, particularly a kind of Site Welding restorative procedure of heavy wall steel-casting.
Background technology
The vitals such as heat power plant boiler, four large pipelines, steam turbine adopt large-scale steel-casting a lot, and most of under the operating mode of HTHP, and severe condition of work has proposed safely very high requirement to it.Stop valve, the parts such as the casting three-way on control valve, stifled valve and boiler header are due to factors such as volume are large, different parts wall thickness change is large, usually in manufacture process, there is structural heterogenity because cooling velocity is different, and usually follow casting flaw, cause under service condition, being easy to occur Cracking Failure.
In prior art, owing to being difficult to carry out local post weld heat treatment after REPAIR WELDING at the scene, therefore conventionally adopt heterogeneous cold-welding recovery method to repair.But, for large (reaching the half of wall thickness) and run through the defect of type, adopt that heterogeneous cold welding technique is more difficult to be completed.
Summary of the invention
Technical problem to be solved by this invention is to overcome the deficiencies in the prior art, provides a kind of and is particularly suitable in heavy wall steel-casting large and runs through the Site Welding restorative procedure of type defect.
For solving above technical problem, the present invention takes following technical scheme:
Be particularly suitable in heavy wall steel-casting large and run through the Site Welding restorative procedure of type defect, comprising preparatory process before weldering, REPAIR WELDING operation and postwelding quality inspection operation, particularly:
Before weldering in preparatory process: groove is polished to form in defective position, wherein guarantee polishing after groove inside without wedge angle groove or corner angle, groove polish metallic luster within the scope of inside and outside wall 30mm around, the groove forming, after surface inspection is confirmed noresidue defect and degreased, enters REPAIR WELDING operation;
REPAIR WELDING operation comprises the following step carrying out successively:
(1), described in preheating, groove 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 gas tungsten arc welding mode to carry out 1～2 layer of backing welding to whole positions of groove, whole groove bottom is filled with solid welding wire material, rounding off is carried out in the violent region that suddenlys change of geometry in groove, wherein, control gas tungsten arc welding interlayer temperature between 130 DEG C～220 DEG C;
(3), after step (2) completes, be warming up to 220 DEG C～330 DEG C, permanent heat insulation 3～8 hours, adopt 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 employing multi-pass welding, welding bead postwelding carries out hammering with pneumatic hammer immediately, and it is evenly densely covered to make to hammer into shape trace;
(4), the postwelding hydrogen heat treatment that disappears: after groove welding is full, the hydrogen heat treatment that disappears at 300 DEG C～400 DEG C of temperature, the hydrogen heat treatment time that disappears is 2～6 hours;
(5), post weld heat treatment: first carry out stress relief annealing at 500 DEG C～550 DEG C of temperature, then carry out high tempering at 700 DEG C～750 DEG C, after heat treatment completes, be cooled to room temperature with the rate of temperature fall of 65 DEG C/h～150 DEG C/h.
According to further of the present invention and preferred embodiment:
Before weldering in preparatory process: while polishing, first polish to root along straight line, suitably widen gradually, until polish defect, and groove is polished into the shape of being convenient to follow-up welding operation.Can be by degreasing with organic solvent wiping in preparatory process before weldering.
In the step (1) of REPAIR WELDING operation, preheating can adopt tracklayer heater, rope formula heater or the combination of the two, or also can adopt existing Special heater to heat.
In the welding process of described step (2) and (3), be aided with the real-time monitoring temperature of hand-held infrared radiation thermometer,, reheat during lower than the minimum of the temperature requiring in temperature, in the time that temperature exceeds the peak of temperature of requirement, stop welding.
Heat treatment in step (4) and (5) adopts heating plate or heating rope or the combination of the two, or also can adopt existing Special heater to heat.
Described postwelding quality inspection operation comprises that Non-Destructive Testing, hardness detect, on-the-spot metallographic detects and residual stress test.Wherein, Non-Destructive Testing adopts the method that visual examination, magnetic powder inspection and ultrasonic examination combine.
According to a concrete aspect of the present invention, the material of steel-casting is carbon steel or low alloy steel, in step (1), is preheated to 130～220 DEG C.
According to the defect described in another concrete aspect of the present invention when running through type defect, described method is also included in step (3), be welded to 1/3 of groove depth～2/3 o'clock and carry out once the middle hydrogen heat treatment that disappears, this centre heat treated temperature of hydrogen that disappears is 300～400 DEG C, and the time is 2～6 hours.
According to another concrete aspect of the present invention, the material of heavy wall steel-casting is ZG15Cr1Mo1V Mayari, and the welding rod adopting in step (3) is ultralow hydrogen type high-tenacity welding electrodes.
According to the present invention, heavy wall steel-casting is often referred to the steel-casting that wall thickness scope is 40～200mm." larger defect " refers to that the degree of depth reaches wall thickness defect over half.It will be understood by those skilled in the art that be provided by the inventionly particularly suitable in REPAIR WELDING heavy wall steel-casting large and run through the welding repair method of type defect, equally also can be for the REPAIR WELDING of other steel-casting and defect type.Therefore, protection scope of the present invention should not be subject to the restriction of steel-casting thickness and defect type.
Due to 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 defect, and Crack prevention produces once again; Backing welding is carried out in the whole positions of groove after adopting TIG weldering to polishing, effectively prevent steel-casting particularly the more steel-casting of original casting flaw crack once again; The present invention also carries out hammering and eliminates residual stress in manual electric arc welding welding process, and 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, and it can eliminate welding residual stress when microstructure and hardness is regulated.Welding repair method of the present invention is particularly suitable in power station, chemical industry heavy wall steel-casting large (reaching wall thickness over half) and runs through the REPAIR WELDING of type defect, the weld seam after REPAIR WELDING after tested after quality good, be difficult for again occurring crackle.
Brief description of the drawings
Fig. 1 is valve outer wall crackle photo;
Fig. 2 is the photo that shows the groove shape after polishing;
Fig. 3 is repair welding weld seam typical gold phase constitution.
Detailed description of the invention
Known; main steam valve is the main heat power equipment in thermal power plant; under not only even running situation, bear for a long time HTHP load; and opening, shut down and meet the effect that also can be subject to alternate stress while changing; therefore, at the weak part of main steam valve or exist the region of inner manufacturing defect easily crack and lost efficacy.
All there is penetrating crack in a Russia coal-fired No. 2 steam valve valve bodies of unit of overcritical 500MW (material is ZG15Cr1Mo1V Mayari) of genco in April, 2011, cause steam leakage, No. 1 main steam valve also finds to exist multiple tracks defects i.e.cracks subsequently.Below taking 1 director's degree of No. 2 valve outer surfaces as 100mm the crackle of left and right (referring to Fig. 1, 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, Site Welding restorative procedure of the present invention is described.
According to the present embodiment, welding repair method is divided into the front 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 weldering
(1), polishing defect forms groove: adopt on-the-spot applicable polishing cutting apparatus (as angle grinding machine, beveling machine etc.) that the polishing of defective position is cleaned out, when polishing, should first polish to root along straight line, suitably widen gradually, until polish defect, and make as far as possible the region shape polishing be convenient to subsequent operation, groove inside after polishing is groove (as shown in Figure 2) root rounding off particularly, without wedge angle groove or corner angle, groove around inside and outside wall 30mm scope domestic demand polish metallic luster.
(2), the confirmation of Defect removal: excavating of crackle is the successful prerequisite of repair welding, unclean if crackle is excavated, and leaves hidden danger, also can cause crackle to produce once again.The groove region of final preparation is by specialty flaw detection personnel surface inspection, and quality scale reaches JB/T4730-2005 infiltration I level, confirms whether polishing groove district has the residual defects of not cleared up, and again thoroughly removes clean if having.Defect confirmation polishing has been eliminated the wiping of rear use acetone and other organic solvent with surface impurities such as wipe oils.
2, REPAIR WELDING operation
REPAIR WELDING operation is undertaken by disappear hydrogen and heat treated flow process of the manual electric arc welding → postwelding of preheating → prime coat TIG welding → filler pass of groove, specific as follows:
(1), preheating: the inner wall temperature that adopts tracklayer heater, rope formula heater or other Special heater that need are carried out to the position of REPAIR WELDING is heated to 150 DEG C, starts afterwards welding job;
(2), prime coat weldering: adopt gas tungsten arc welding (TIG weldering) mode, burn between not fusible electrode and workpiece as the electric arc of thermal source during this period, the welding material of inert protective gas protection fusing is avoided the impact of surrounding air, wherein, adopt 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 are carried out in TIG weldering, whole weld groove bottom is filled with solid welding wire material, rounding off is carried out in the violent region that suddenlys change of geometry in 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 DEG C～220 DEG C, otherwise stops weldering or reheat.
(3), after step (2) completes, be warming up to 250 DEG C, permanent heat insulation 4 hours, adopt manual electric arc welding to carry out the filling weldering of groove, wherein: manual electric arc welding adopts ultralow hydrogen type high tenacity R317L, the welding rod of specification ф 3.2mm, weldingvoltage 21～26V, welding current 100～120A, welding rod is welding electrode, electric arc burns between welding rod and workpiece, adopt multi-pass welding, welding bead postwelding carries out hammering with pneumatic hammer immediately, and making to hammer into shape trace gathers evenly, so can effectively reduce the residual stress that welding produces, prevention weld crack, manual electric arc welding interlayer temperature is controlled between 250 DEG C～300 DEG C, otherwise stop weldering or reheat, in the middle of manual electric arc welding, the centre of carrying out at 400 DEG C 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, carry out the hydrogen heat treatment that disappears of 2 hours at 400 DEG C, to avoid the generation of cold crack.
(5), post weld heat treatment: adopt 540 DEG C of average temperings of Electric heating (stress relief annealing)+730 DEG C high tempering heat treatment, when heat treatment, arrange heater at repair welding position, on both sides pipeline 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, the tissue of weld seam after repair welding and heat affected area material is adjusted simultaneously.The time of stress relief annealing is determined (in this example, being 8 hours) according to repair welding throat depth, and during stress relief annealing, the material behaviors such as the strength of materials and ductility are not obviously changed.The time of high tempering is also determined (in this example, being 2 hours) according to repair welding throat depth, should slowly cool to room temperature (approximately 65 DEG C of rate of temperature fall/h～150 DEG C/h) after heat treatment completes.
3, postwelding quality inspection operation:
Postwelding quality inspection comprises 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, specific as follows:
(1) Non-Destructive Testing: postwelding is cleaned out repair welding region and heat affected area polishing, expose metallic luster, the method that adopts visual examination, magnetic powder inspection and ultrasonic examination to combine, weld seam and heat affected area to repair welding check, the moulding of repair welding weld appearance is good, have no the defect such as crackle, incomplete fusion and exist, MT and UT are showed no the demonstration that exceeds standard.
(2), hardness detects: use portable hardness tester scene to carry out hardness test, 3 places are measured respectively in repair welding weld seam and near zone heat affected area and mother metal, repair welding weld seam and heat affected area hardness number are distributed within the scope of 190-230HB, in compared with zone of reasonableness.
(3), overlay film metallographic: surface replica metal lographic examination is carried out in Welded Joints repair welding region, typical metallographic structure as shown in Figure 3, the metallographic structure of repair welding weld seam is tempered sorbite+a small amount of ferrite, grain size is 9-10 level, heat affected area metallographic structure is bainite+ferrite, and grain size is 4-5.5 level.
(4), residual stress test: adopt Blind Hole Method to carry out residual stress test to typical repair welding weld seam, wherein test point is all chosen in weld metal zone and the heat affected area that stress is larger, test result shows that the repair welding weld seam maximum residual stress after heat treatment appears at heat affected area, for 105MPa, far below the yield strength of mother metal 343MPa, illustrate that residual stress measure is eliminated in the hammering adopting and Technology for Heating Processing can play good elimination residual stress effect.
Above-described embodiment is only explanation technical conceive of the present invention and feature; its object is to allow person skilled in the art can understand content of the present invention and implement according to this; can not limit the scope of the invention with this; all equivalences that Spirit Essence is done according to the present invention change or modify, within all should being encompassed in protection scope of the present invention.
Claims (9)
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