CN102814573A - Local pressure stress method for improving anti-fatigue performance of mixed-flow runner - Google Patents
Local pressure stress method for improving anti-fatigue performance of mixed-flow runner Download PDFInfo
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- CN102814573A CN102814573A CN2012101637342A CN201210163734A CN102814573A CN 102814573 A CN102814573 A CN 102814573A CN 2012101637342 A CN2012101637342 A CN 2012101637342A CN 201210163734 A CN201210163734 A CN 201210163734A CN 102814573 A CN102814573 A CN 102814573A
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Abstract
The invention provides a local pressure stress method for improving anti-fatigue performance of a mixed-flow runner. Optimization, regulation and control to the distribution of welding residual fields are performed by optimizing a welding process of a runner, residual tensile stress in blade water-outlet-side weld joints and nearby regions is reduced obviously and converted into pressure stress, thereby achieving the local pressure stress in blade water-outlet-side easily-cracking regions of the mixed-flow runner. On the basis, a local heat treatment method is adopted to perform local treatment on the water-outlet-side weld joint regions of the runner, a residual stress value of the water-outlet-side easily-cracking regions of the runner is further reduced, a high residual stress region is formed, the improvement of the pressure stress degree of the easily-cracking regions of the runner is promoted, and the anti-fatigue performance of the runner is improved.
Description
Technical field: the present invention relates to a kind of local compression method that improves the francis turbine runner anti-fatigue performance.
Background technology: the hydraulic turbine is the dynamic power machine that a kind of mechanical energy current changes rotating mechanical energy into.And runner is one of parts of hydraulic turbine most critical, and its quality directly influences the efficient and the service life of the hydraulic turbine.At present, large hydropower station generally adopts Francis turbine, and its runner is formed by blade, crown and following ring assembly welding mostly, and in service at runner, it is the fatigue that is caused by dynamic load that the most frequent failure mode takes place.And; The fatigue cracking of francis turbine runner tends to occur in projected life; Inefficacy is caused by low-cycle fatigue and high cycle fatigue acting in conjunction, if load enough greatly, start-stall cycles will make the expansion of manufacturing defect crackle or make region of stress concentration germinating crackle; When the runner rotating speed reaches the commentaries on classics of per minute hundreds of; Vibration frequency or high cycle fatigue cycle, in case crackle reaches the critical value of the crack Propagation of high cycle fatigue loading, the fracture of runner bucket will expanded and cause to crackle in the very short time.Therefore, last decade, the Machine Design process of runner has been introduced the dynamic load pattern to the runner Fatigue Life.
In recent years, along with the development and utilization of China's water resource, large-scale unit continues to bring out; The major diameter francis turbine runner extensively should; In the domestic large-scale power station that has built up, the francis turbine runner of operation after putting into operation all in various degree appearance crackle, seriously injure the safe operation of unit.It is regional with the T type welding point of following ring or crown junction that the francis turbine runner maximum stress in bend appears at blade, because stress is concentrated, the local stress in these two zones is the highest, therefore the most dangerous zone of tired generation just.Through the analysis report of crackle accidents more both domestic and external and the research of relevant documents and materials are shown; The position that crackle produces mostly runner go out the waterside weld seam, heat affected area and near blade edge, and the runner fatigue crack mainly is to produce the coefficient result of higher welding residual stress owing to suffered alternation stress and the runner of runner in welding process.Since this cracking be can not expect and also occur within projected life, therefore harm is very big, not only has a strong impact on runner service life, threatens the safe operation in power station.Simultaneously, the turbine efficiency that the blade cracking causes reduces, the shutdown of inspection and maintenance process, and the input of maintenance cost all can have influence on the economic benefit in power station.
The hydroelectric facility manufacturing company of various countries all drops into manpower and materials; Research blade crack problem; To relevant unit runner crackle accident, carried out field assay and investigation, and proposed the method for some solution runner crackles; Wedge is installed like the welding bead hammering of multi-pass welding, at girth joint middle part down, is increased stiffener in girth joint outside down, burn-on earlier in the upper and lower end parts of ring down and take piece and before weldering, load onto dummy shaft etc. at the crown place; Also proposed corresponding weld crack reclamation activities in light of the circumstances, but all failed to tackle the problem at its root, the blade crack problem has become the power station and has been badly in need of one of key technology difficult problem that solves.
Summary of the invention: the purpose of this invention is to provide a kind of runner of having realized and go out the local compressionization in zone easy to crack, waterside; Effectively solve interior fatigue cracking problem projected life of runner, the local compression method of the raising francis turbine runner anti-fatigue performance of the anti-fatigue performance of raising runner.Technical scheme of the present invention is: a kind of local compression method that improves the francis turbine runner anti-fatigue performance; In the process of francis turbine runner assembly welding; At first accomplish the welding of blade outlet (water flows out the edge of runner channel one lateral lobe sheet) weldering section; The welding process starting the arc is in going out the waterside, and length of increment is controlled in the 40mm-90mm scope; Accomplish the welding of water inlet limit (water flows into the edge of runner channel one lateral lobe sheet) weldering section then, the welding process starting the arc is in the water inlet limit, and length of increment is controlled in the 90mm-110mm scope; Middle all the weldering sections all starting the arc are received arc near going out waterside one side in the side near the water inlet limit, are begun by water inlet limit one side, accomplish the welding of runner in order, and every section weldering section extent control are in the 500mm-600mm scope.Before runner welding completion and integrally annealed, increased local heat treatmet technology; Welding residual stress field to the blade outlet welded seam area is regulated and control, and adopts acetylene that blade is heated in the processing procedure, wherein; Heating-up temperature is 580 ℃; Be employed in the method that heats on the direction of vertical weld, heated length is 200mm, and width is 100mm; When the temperature of blade outlet near zone arrives 50 ℃, stop heating, the edge of heating region is controlled at 150mm from the distance at blade outlet edge.
The welding vestige stress that the present invention is based on francis turbine runner blade outlet welded seam area is the major reason that causes the francis turbine runner fatigue cracking; And the existence of welding residual compressive stress can effectively improve welded anti-fatigue performance; Welding residual stress through regulation and control runner zones easy to crack (blade outlet welded seam area) distributes, and realizes that the local compressionization in this zone improves the antifatigue cracking performance of francis turbine runner.
The present invention is optimized regulation and control through optimizing the welding procedure of runner to the distribution of welding the residual stress field, and the residual tension of blade outlet weld seam and near zone thereof obviously reduces; And be converted into compression; Realize the local compressionization in francis turbine runner blade outlet zone easy to crack, on this basis, adopted the method for local heat treatmet that Local treatment is carried out in runner water outlet side weld seam zone; Further reduce the residual-stress value that runner goes out zone easy to crack, waterside; Form higher residual compressive stress district, promote the raising of the compression degree in runner zone easy to crack, thereby improve the anti-fatigue performance of runner.
Description of drawings
Fig. 1 is the francis turbine runner welding procedure sketch map of optimizing
Fig. 2 is the localized distribution schematic diagram
Fig. 3 is the original welding procedure of francis turbine runner
Fig. 4 is the local compression welding procedure of francis turbine runner
Fig. 5 is that vertical weld direction residual stress test position distributes
Fig. 6 is that parallel bead direction residual stress test position distributes
Fig. 7 is that runner water outlet edge regions vertical weld direction welding residual stress distributes
Fig. 8 is that the parallel bead direction welding residual stress of runner water outlet edge regions distributes
Fig. 9 is that runner water outlet edge regions vertical weld direction welding residual stress distributes
Figure 10 is that the parallel bead direction welding residual stress of runner water outlet edge regions distributes
Figure 11 be after postwelding, the local heat treatmet and bulk heat treatmet after the parallel bead direction residual stress distribution of outlet edge of runner blade
The specific embodiment
As shown in Figure 1, in the process of francis turbine runner assembly welding, at first accomplish the welding of blade outlet weldering section 1, the welding process starting the arc is in going out the waterside, and length of increment is controlled in 40mm-90mm scope; Accomplish the welding of water inlet side weld section 2 then, the welding process starting the arc is in the water inlet limit, and length of increment is controlled in the 90mm-110mm scope; Middle all welderings section equal starting the arc is received arc near going out waterside one side in the side near the water inlet limit, begins by water inlet limit one side, the weldering of completion remainder in order section (3,4 ..., welding n), and every section weldering section extent control is in 500mm-600mm scope.Before runner welding completion and integrally annealed, increased local heat treatmet technology; Welding residual stress field to the blade outlet welded seam area is regulated and control, and adopts acetylene that blade is heated in the processing procedure, wherein; Heating-up temperature is 580 ℃; Be employed in the method that heats on the direction of vertical weld, heated length is 200mm, and width is 100mm; The edge of heating region is controlled at 150mm from the distance at blade outlet edge, and the local heat position distribution is as shown in Figure 2.When the temperature of blade outlet near zone arrives 50 ℃, stop heating.
The local compression method that improves the francis turbine runner anti-fatigue performance is applied to the actual processing and manufacturing process of Nan Shui and francis turbine runner.For understanding the effect of local compression method, use the welding procedure of original manufacturing process and local compressionization respectively runner is welded.Original welding procedure is as shown in Figure 3, begins to weld (a weldering section I) by the middle part of runner bucket, and the method for the segmentation welding of taking to regress is accomplished welding (1 of the weldering section II and the III part of whole runner; 2 ..., n), for outlet edge of runner blade; The welding of water outlet side weld section is accomplished at last; And, by opening arc, going out waterside one side receipts arc away from going out waterside one side.The local compression welding procedure of runner is as shown in Figure 4, at first accomplishes the welding of water outlet side weld section (weldering section I), and the welding process starting the arc is in going out the waterside; Accomplish the welding of water inlet side weld section (weldering section II) then; And middle all weldering sections are received arc near going out waterside one side by near the water inlet limit one side starting the arc, accomplish all the other weldering sections (1 of weldering section III part in order; 2 ..., welding n).
Adopt the blind hole stress free method that the residual stress test has been carried out at runner bucket and following ring water outlet side weld seam position.Testing equipment comprises: stress ga(u)ge, model: YC-III type; Stress measurement device, the special-purpose residual stress measurement device of the runner of Big Motor Reserch Academy, Ha Erbin City's development; Foil gauge, model: Tj120-1.5-Φ 1.5, aperture Φ 1.5mm, hole depth 2.0mm.Measurement standard: CB 3395-1992.Test process is carrying out after postwelding, the local heat treatmet and after the heat treatment respectively.Test position is like Fig. 5, shown in 6.
Instance 1: Fig. 7 and Fig. 8 are respectively near runner welding residual stress original and local compression welding condition lower blade goes out the waterside and distribute; Wherein Fig. 6 is vertical weld direction (the figure middle distance is the distance of test point to the weld seam center); Fig. 7 is parallel bead direction (the figure middle distance is represented the distance of test point to blade outlet, and all test points are 20mm apart from the distance of melt run).As can be seen from the figure; When adopting original technology to weld; There is higher residual tension in (the nearly seam district of weld seam and heat affected area thereof) in outlet edge of runner blade zone easy to crack; And compression appears at the zone away from weld seam, and the peak value of residual tension near melt run, occurs.When adopting the welding procedure of local compressionization to weld; The welding residual stress in runner zone easy to crack distributes significant change takes place; Near the blade outlet residual stress is a compression; In the following local compression of the formation district in ring and the scope that goes out waterside 100mm * 80mm of distance, and the closer to going out the waterside, the residual compressive stress value is big more.Realized local compressionization,
Instance 2: Fig. 9 and Figure 10 are respectively near runner welding residual stress original and local compression welding condition lower blade goes out the waterside and distribute, and wherein Fig. 8 is the vertical weld direction, and Fig. 9 is parallel bead direction
As can be seen from the figure; When adopting original technology to weld; There is higher residual tension in (the nearly seam district of weld seam and heat affected area thereof) in outlet edge of runner blade zone easy to crack; And compression appears at the zone away from weld seam, and the peak value of residual tension near melt run, occurs.When adopting the welding procedure of local compressionization to weld; The welding residual stress in runner zone easy to crack distributes significant change takes place; Near the blade outlet residual stress is a compression; In the following local compression of the formation district in ring and the scope that goes out waterside 220mm * 90mm of distance, realized should the zone local compressionization, can effectively improve the anti-fatigue performance of runner.
Instance 3: after the runner welding is accomplished, the francis turbine runner that local compression welding procedure obtains has been used local heat treatmet technology, to confirm the local compression effect of local heat treatmet technology.
Figure 11 be after postwelding, the local heat treatmet and bulk heat treatmet after be parallel to the welding residual stress distribution situation of bead direction near the weld-fusion line; Can see that local heat can effectively regulate and control the distribution of residual stress field; The welding residual stress value that makes runner go out zone easy to crack, waterside significantly reduces; Form higher residual compressive stress district, and, cause the rising of residual tension value away from the zone that goes out the waterside.After runner is carried out bulk heat treatmet; The residual compressive stress value of water outlet edge regions has certain reduction; And significantly reduce away from the high tensile stress value of water outlet edge regions; Connect the residual stress distribution situation with postwelding water outlet side weld and compare, the welding residual stress that two comprehensive results of heat treatment process use the waterside welded seam area further descends, and has effectively promoted the realization of the local compressionization in francis turbine runner blade outlet zone easy to crack.
Claims (1)
1. local compression method that improves the francis turbine runner anti-fatigue performance; It is characterized in that: in the process of francis turbine runner assembly welding; At first accomplish the welding of blade outlet (water flows out the edge of runner channel one lateral lobe sheet) weldering section; The welding process starting the arc is in going out the waterside, and length of increment is controlled in the 40mm-90mm scope; Accomplish the welding of water inlet limit (water flows into the edge of runner channel one lateral lobe sheet) weldering section then, the welding process starting the arc is in the water inlet limit, and length of increment is controlled in 90mm-110mm scope; Middle all the weldering sections all starting the arc are received arc near going out waterside one side in the side near the water inlet limit, are begun by water inlet limit one side, accomplish the welding of runner in order, and every section weldering section extent control are in 500mm-600mm scope.Before runner welding completion and integrally annealed, increased local heat treatmet technology; Welding residual stress field to the blade outlet welded seam area is regulated and control, and adopts acetylene that blade is heated in the processing procedure, wherein; Heating-up temperature is 580 ℃; Be employed in the method that heats on the direction of vertical weld, heated length is 200mm, and width is 100mm; When the temperature of blade outlet near zone arrives 50 ℃, stop heating, the edge of heating region is controlled at 150mm from the distance at blade outlet edge.
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| CN2012101637342A CN102814573A (en) | 2012-03-15 | 2012-05-24 | Local pressure stress method for improving anti-fatigue performance of mixed-flow runner |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103722296A (en) * | 2013-11-22 | 2014-04-16 | 瓮福（集团）有限责任公司 | Repairing method for blade abrasion of high-temperature warm air machine |
| CN107201487A (en) * | 2016-03-17 | 2017-09-26 | 福特全球技术公司 | Highly strain the restoring heat treatment of part |
| CN109255202A (en) * | 2018-11-01 | 2019-01-22 | 上海工程技术大学 | A kind of predictor method for mechanical component fatigue crack initiation life |
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| CN1106108A (en) * | 1994-08-05 | 1995-08-02 | 中国水利水电第四工程局机电安装处 | In-situ welding method for assembling split wheels of large-scale mixed turbine |
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| CN1106108A (en) * | 1994-08-05 | 1995-08-02 | 中国水利水电第四工程局机电安装处 | In-situ welding method for assembling split wheels of large-scale mixed turbine |
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103722296A (en) * | 2013-11-22 | 2014-04-16 | 瓮福（集团）有限责任公司 | Repairing method for blade abrasion of high-temperature warm air machine |
| CN103722296B (en) * | 2013-11-22 | 2015-11-18 | 瓮福（集团）有限责任公司 | A kind of restorative procedure of blade abrasion of high-temperature warm air machine |
| CN107201487A (en) * | 2016-03-17 | 2017-09-26 | 福特全球技术公司 | Highly strain the restoring heat treatment of part |
| CN109255202A (en) * | 2018-11-01 | 2019-01-22 | 上海工程技术大学 | A kind of predictor method for mechanical component fatigue crack initiation life |
| CN109255202B (en) * | 2018-11-01 | 2023-06-06 | 上海工程技术大学 | Method for estimating fatigue crack initiation life of mechanical component |
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Application publication date: 20121212 |