CN105598655A - Method for strengthening surface of metal turbine runner blade through combination of electric spark deposition and welding - Google Patents
Method for strengthening surface of metal turbine runner blade through combination of electric spark deposition and welding Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 76
- 230000008021 deposition Effects 0.000 title claims abstract description 60
- 238000010892 electric spark Methods 0.000 title claims abstract description 32
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 18
- 239000002184 metal Substances 0.000 title claims abstract description 18
- 238000000034 method Methods 0.000 title claims abstract description 17
- 238000005728 strengthening Methods 0.000 title description 7
- 238000000576 coating method Methods 0.000 claims abstract description 38
- 239000011248 coating agent Substances 0.000 claims abstract description 37
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 34
- 239000002131 composite material Substances 0.000 claims abstract description 22
- 229910009043 WC-Co Inorganic materials 0.000 claims abstract description 21
- 229910001105 martensitic stainless steel Inorganic materials 0.000 claims abstract description 9
- 239000004576 sand Substances 0.000 claims abstract description 9
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims abstract description 7
- 238000005498 polishing Methods 0.000 claims abstract 7
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 50
- 239000007789 gas Substances 0.000 claims description 32
- 229910052786 argon Inorganic materials 0.000 claims description 25
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 claims description 24
- 239000000956 alloy Substances 0.000 claims description 22
- 229910045601 alloy Inorganic materials 0.000 claims description 17
- 239000000919 ceramic Substances 0.000 claims description 17
- 239000001569 carbon dioxide Substances 0.000 claims description 12
- 229910002092 carbon dioxide Inorganic materials 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 11
- 201000001371 inclusion conjunctivitis Diseases 0.000 claims description 6
- 206010044325 trachoma Diseases 0.000 claims description 6
- 239000011159 matrix material Substances 0.000 claims description 4
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 239000000203 mixture Substances 0.000 claims 3
- 238000004062 sedimentation Methods 0.000 claims 3
- 238000010186 staining Methods 0.000 claims 3
- 239000010942 ceramic carbide Substances 0.000 abstract description 7
- 230000007797 corrosion Effects 0.000 abstract description 3
- 238000005260 corrosion Methods 0.000 abstract description 3
- 230000002708 enhancing effect Effects 0.000 abstract 1
- 238000000151 deposition Methods 0.000 description 33
- 229910001220 stainless steel Inorganic materials 0.000 description 10
- 239000013049 sediment Substances 0.000 description 9
- 239000010935 stainless steel Substances 0.000 description 9
- 239000010410 layer Substances 0.000 description 6
- 239000000758 substrate Substances 0.000 description 6
- 230000008901 benefit Effects 0.000 description 4
- 238000012423 maintenance Methods 0.000 description 4
- 238000010248 power generation Methods 0.000 description 4
- 230000003628 erosive effect Effects 0.000 description 3
- 239000011148 porous material Substances 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 229910000851 Alloy steel Inorganic materials 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 238000005253 cladding Methods 0.000 description 2
- 238000005137 deposition process Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000002159 nanocrystal Substances 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 229920002635 polyurethane Polymers 0.000 description 2
- 230000008439 repair process Effects 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 2
- 229910000975 Carbon steel Inorganic materials 0.000 description 1
- 229910001208 Crucible steel Inorganic materials 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000012790 adhesive layer Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000010962 carbon steel Substances 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 230000002301 combined effect Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 229910001651 emery Inorganic materials 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 229910000734 martensite Inorganic materials 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000013081 microcrystal Substances 0.000 description 1
- 239000004570 mortar (masonry) Substances 0.000 description 1
- 239000002105 nanoparticle Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000005488 sandblasting Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000009865 steel metallurgy Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000007751 thermal spraying Methods 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/02—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from one piece
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P23/00—Machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass
- B23P23/04—Machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass for both machining and other metal-working operations
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C26/00—Coating not provided for in groups C23C2/00 - C23C24/00
- C23C26/02—Coating not provided for in groups C23C2/00 - C23C24/00 applying molten material to the substrate
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Arc Welding In General (AREA)
- Hydraulic Turbines (AREA)
Abstract
本发明涉及用电火花沉积结合焊接增强金属水轮机转轮叶片表面的方法，有效解决水轮机转轮叶片的表面的硬度、耐磨性、耐腐蚀性和耐冲击性等性能，延长金属水轮机转轮的使用寿命的问题，方法是，对水轮机转轮进行处理，清除油污、锈斑和氧化物，用熔化极气体保护焊设备把把马氏体不锈钢焊丝焊接在水轮机转轮叶片表面，焊接层用砂片进行表面抛光打磨，用电火花沉积设备将连地线的夹子与作为阴极的水轮机转轮连接，将亚微米WC-Co陶瓷硬质合金电极棒作为阳极固定在沉积枪的夹头上，对水轮机转轮叶片进行电火花沉积，使复合涂层与水轮机转轮叶片冶金结合，本发明方法简单，易操作，涂层厚度大，叶片表面硬度高、致密性好、耐磨性能好，寿命长，成本低。The invention relates to a method for enhancing the surface of a metal water turbine runner blade by electric spark deposition combined with welding, which effectively solves the surface hardness, wear resistance, corrosion resistance and impact resistance of the water turbine runner blade, and prolongs the life of the metal water turbine runner. For the problem of service life, the method is to treat the runner of the turbine to remove oil, rust and oxides, and weld the martensitic stainless steel welding wire to the surface of the blade of the turbine runner with the gas metal shielded welding equipment, and use sand sheets for the welding layer Carry out surface polishing and grinding, use electric spark deposition equipment to connect the clip connected to the ground wire with the water turbine runner as the cathode, and fix the submicron WC-Co ceramic carbide electrode rod as the anode on the chuck of the deposition gun. The runner blades are subjected to electric spark deposition, so that the composite coating is metallurgically combined with the turbine runner blades. The method of the invention is simple, easy to operate, the coating thickness is large, the blade surface has high hardness, good compactness, good wear resistance, and long service life. low cost.
Description
技术领域 technical field
本发明涉及水力发电机械，特别是一种用电火花沉积结合焊接增强金属水轮机转轮叶片表面的方法。 The invention relates to a hydroelectric power generation machine, in particular to a method for strengthening the surface of a runner blade of a metal water turbine by using electric spark deposition combined with welding.
背景技术 Background technique
水轮机是水力发电常用的重要设备，水力发电是电能的重要来源之一，特别是我国是世界上水力资源极为丰富的国家，水电已成为我国重点发展的可再生能源之一，水力可开发的电能力3.8亿kw，年发电量1.9万亿kw.h，相当于11亿吨原煤的发电量。我国河流特点之一是含沙量较大，年平均输沙量1000万t以上的河流有115条，直接入海泥沙总量达19.4亿t。长江及其支流以沙粒硬度高为特点，黄河则以含沙量大为特征，目前已经运行的100多座大中型水电站中，有严重泥沙磨损的约占40%，在黄河干支流上这一数值更是高达66.3%，黄河三门峡河段的年输沙量近16亿t，为世界之最，平均含沙量37.5kg/m3，均居各河流之首。据估计，我国有3000万～4000万kW装机容量的各类水轮机存在比较严重的泥沙磨蚀问题。它是影响水电厂(站)安全运行的重大问题之一，也会使检修周期延长，检修工作量增加，机组运行效率降低，检修成本提高，影响正常发电量。多泥沙河流上的水轮机运行时，往往泥沙磨损和空蚀同时存在(也有单独存在之处)，而且互相促进，破坏叠加，大大加速了水轮机过流部件金属表面的破坏进程，这种磨损和空蚀的联合作用，通常称为磨蚀破坏。虽然经过几代科技工作者和水电厂运行与检修人员的共同研究与实践，已经取得了减缓水轮机磨蚀破坏的不少综合治理成果，但综观全局，我国水轮机磨蚀问题还很严重，尚未取得突破性进展，许多问题还有待深入研究。 Water turbine is an important equipment commonly used in hydropower generation. Hydropower generation is one of the important sources of electric energy. In particular, my country is a country rich in hydropower resources in the world. Hydropower has become one of the renewable energy sources that my country focuses on. Hydropower can be developed. The capacity is 380 million kw, and the annual power generation capacity is 1.9 trillion kw.h, which is equivalent to the power generation capacity of 1.1 billion tons of raw coal. One of the characteristics of my country's rivers is the high sediment content. There are 115 rivers with an average annual sediment discharge of more than 10 million tons, and the total amount of sediment directly entering the sea reaches 1.94 billion tons. The Yangtze River and its tributaries are characterized by high sand hardness, while the Yellow River is characterized by high sand concentration. Among the more than 100 large and medium-sized hydropower stations currently in operation, about 40% have serious sediment wear. This value is even as high as 66.3%. The annual sediment load of the Sanmenxia section of the Yellow River is nearly 1.6 billion tons, which is the highest in the world. The average sediment concentration is 37.5kg/m 3 , ranking first among all rivers. It is estimated that various types of water turbines with an installed capacity of 30 million to 40 million kW in my country have relatively serious problems of sediment erosion. It is one of the major issues affecting the safe operation of hydropower plants (stations), and it will also prolong the maintenance period, increase the maintenance workload, reduce the operating efficiency of the unit, increase the maintenance cost, and affect the normal power generation. When the turbines on the rivers with many sediments are running, the sediment wear and cavitation often exist at the same time (also exist separately), and they promote each other, and the damage is superimposed, which greatly accelerates the damage process of the metal surface of the flow parts of the turbine. The combined effect of cavitation and cavitation is commonly referred to as abrasive damage. Although through the joint research and practice of several generations of scientific and technological workers and hydropower plant operation and maintenance personnel, many comprehensive treatment results have been achieved to slow down the erosion and damage of water turbines, but looking at the overall situation, the problem of water turbine erosion in my country is still very serious, and breakthroughs have not yet been made. progress, many issues remain to be further studied.
目前，制造水轮机转轮的材料代表性的有普通碳钢、低合金钢、普通不锈钢和高强度不锈钢。国内一般的水轮机转轮通常为铸钢、Cr5Cu合金钢、1Cr18Ni9Ti不锈钢、ZG0Cr13Ni5Mo不锈钢、0Cr13Ni5Mo不锈钢、ZG0Cr16Ni5Mo不锈钢、ZG0Cr13Ni4Mo不锈钢、00Cr13Ni4Mo等不锈钢等材料制成的。国内外目前防止水轮机转轮叶片磨损的主要方式是碳化钨喷涂水轮机磨蚀防护、环氧金刚砂涂层防护、聚氨脂弹性涂层防护、抗磨焊条堆焊防护等。碳化钨表面热喷涂前处理一般采用喷砂，有环境污染，涂层加工困难，涂层与基体之间的结合属于机械结合，涂层易疲劳剥落。环氧金刚砂砂浆涂层与水轮机转轮叶片的结合方式也属于机械结合，在强汽蚀区，如叶片进水边背面、间隙空化带、出水边和中环中下部等处的防护材料基本脱落。聚氨脂弹性涂层防护中聚氨脂的抗磨性能虽然较好，但机械强度较差，易于被划伤，一旦局部被划伤，相邻区域就会被撕裂；强空化区空化击穿，使粘接层被破坏，造成涂层脱落。 At present, the typical materials used to manufacture turbine runners include ordinary carbon steel, low alloy steel, ordinary stainless steel and high-strength stainless steel. Domestic general turbine runners are usually made of cast steel, Cr5Cu alloy steel, 1Cr18Ni9Ti stainless steel, ZG0Cr13Ni5Mo stainless steel, 0Cr13Ni5Mo stainless steel, ZG0Cr16Ni5Mo stainless steel, ZG0Cr13Ni4Mo stainless steel, 00Cr13Ni4Mo stainless steel and other materials. At present, the main ways to prevent the wear of turbine runner blades at home and abroad are tungsten carbide spraying turbine abrasion protection, epoxy emery coating protection, polyurethane elastic coating protection, anti-wear electrode surfacing protection, etc. The pretreatment of thermal spraying on the surface of tungsten carbide generally adopts sandblasting, which causes environmental pollution, and the coating process is difficult. The combination between the coating and the substrate is a mechanical combination, and the coating is prone to fatigue and peeling off. The combination of epoxy corundum mortar coating and turbine runner blades is also a mechanical combination. In strong cavitation areas, such as the back of the blade water inlet, gap cavitation zone, water outlet edge, and the middle and lower parts of the middle ring, the protective materials basically fall off. . Although the anti-wear performance of polyurethane elastic coating is good, its mechanical strength is poor and it is easy to be scratched. Once it is partially scratched, the adjacent area will be torn; Chemical breakdown, the adhesive layer is destroyed, causing the coating to fall off.
表面堆焊耐磨材料是目前水轮机转轮磨损修补的主要方式，但是堆焊修补的焊条的硬度强度不够高、耐磨性能差、使用寿命短。因此，如何更好的对水轮机转轮叶片表面进行处理是本领域技术人员一直在研究解决的技术问题。 Surface surfacing of wear-resistant materials is the main way to repair the wear of turbine runners at present, but the hardness and strength of welding electrodes for surfacing repairs are not high enough, their wear resistance is poor, and their service life is short. Therefore, how to better treat the surface of the turbine runner blade is a technical problem that those skilled in the art have been studying and solving.
发明内容 Contents of the invention
针对上述情况，为克服现有技术之缺陷，本发明之目的就是提供一种用电火花沉积结合焊接增强金属水轮机转轮叶片表面的方法，对金属水轮机转轮叶片进行电火花沉积结合焊接处理，可有效解决水轮机转轮叶片的表面的硬度、耐磨性、耐腐蚀性和耐冲击性等性能，延长金属水轮机转轮的使用寿命的问题。 In view of the above situation, in order to overcome the defects of the prior art, the purpose of the present invention is to provide a method for strengthening the surface of the metal water turbine runner blade with electric spark deposition combined with welding, and to carry out the electric spark deposition combined welding process on the metal water turbine runner blade. It can effectively solve the surface hardness, wear resistance, corrosion resistance and impact resistance of the blades of the water turbine runner, and prolong the service life of the metal water turbine runner.
本发明解决的技术方案是，用熔化极气体保护电弧焊（MAG）把马氏体不锈钢气体保护焊丝熔焊在水轮机转轮叶片表面上，形成合金涂层，然后在焊接涂层的基础上再用电火花沉积WC-Co陶瓷硬质合金，制备出电火花沉积结合焊接的复合涂层，步骤是： The technical scheme solved by the present invention is to melt and weld the martensitic stainless steel gas-shielded welding wire on the surface of the runner blade of the hydraulic turbine by melting electrode gas-shielded arc welding (MAG) to form an alloy coating, and then re-weld the alloy coating on the basis of the welding coating The WC-Co ceramic cemented carbide is deposited by electric discharge to prepare a composite coating combined by electric discharge deposition and welding. The steps are:
（1）、对水轮机转轮进行处理，清除油污、锈斑和氧化物，用熔化极气体保护焊设备把把马氏体不锈钢焊丝焊接在水轮机转轮叶片表面，焊接时，电流为220～250A，电弧电压30～38V，焊接速度15～35cm/min，电源极性为直流反接，焊丝直径1-1.2mm，焊丝伸出长12～20mm，采用氩气与二氧化碳混合气体保护，氩气与二氧化碳的体积比为95︰5（即体积百分比为：氩气95%、二氧化碳5%），气体流15～25L/min，水轮机转轮焊接区预热温度100～120℃； (1) Treat the runner of the turbine to remove oil stains, rust spots and oxides, and weld the martensitic stainless steel welding wire on the surface of the runner blade of the turbine with the gas shielded gas welding equipment. When welding, the current is 220-250A, The arc voltage is 30-38V, the welding speed is 15-35cm/min, the polarity of the power supply is DC reversed, the diameter of the welding wire is 1-1.2mm, the length of the welding wire is 12-20mm, and the mixed gas protection of argon and carbon dioxide is used. The volume ratio is 95:5 (that is, the volume percentage is: 95% argon, 5% carbon dioxide), the gas flow is 15-25L/min, and the preheating temperature of the welding zone of the turbine runner is 100-120°C;
（2）、在水轮机转轮叶片焊接层用砂片进行表面抛光打磨，使表面平整，无裂纹，无气孔、无沙眼； (2) Polish the surface of the welded layer of the turbine runner blade with sand to make the surface smooth, free of cracks, pores, and trachoma;
（3）、用电火花沉积设备将连地线的夹子与作为阴极的水轮机转轮连接，将亚微米WC-Co陶瓷硬质合金电极棒作为阳极固定在沉积枪的夹头上，对抛光打磨的水轮机转轮叶片进行电火花沉积，沉积枪夹持的电极采用旋转方式，沉积时沉积枪转速为2400r/min，输出功率为3800～4000W，输出电压为180～200V，放电频率为1800～2000HZ，沉积速率为0.5～2min/cm2，电极的伸长度为2～4mm，在氩气保护下，氩气流量7～9L/min，电极棒与水轮机转轮叶片表面呈倾斜状进行电火花沉积，把亚微米WC-Co陶瓷硬质合金材料熔融在水轮机转轮叶片焊接后的表面上，往复多次成厚度1-8mm细致均匀白亮的电火花沉积焊接复合涂层，焊接和电火花沉积中25000℃的高温使复合涂层与水轮机转轮叶片基体产生冶金结合，构成牢固结合不会脱落的一个整体； (3) Use electric spark deposition equipment to connect the clip connected to the ground wire with the water turbine runner as the cathode, fix the submicron WC-Co ceramic carbide electrode rod as the anode on the chuck of the deposition gun, and polish the The rotor blade of the hydraulic turbine is used for EDM deposition. The electrode held by the deposition gun is rotated. During deposition, the speed of the deposition gun is 2400r/min, the output power is 3800-4000W, the output voltage is 180-200V, and the discharge frequency is 1800-2000HZ. , the deposition rate is 0.5-2min/cm 2 , the elongation of the electrode is 2-4mm, under the protection of argon gas, the flow rate of argon gas is 7-9L/min, and the electrode rod and the surface of the turbine runner blade are inclined for EDM deposition , the submicron WC-Co ceramic hard alloy material is melted on the surface of the turbine runner blade after welding, and it is reciprocated several times to form a fine and uniform white and bright EDM welding composite coating with a thickness of 1-8mm. During welding and EDM deposition The high temperature of 25,000°C makes the composite coating and the turbine runner blade matrix produce metallurgical bonding, forming a solid bond that will not fall off as a whole;
所述的亚微米WC-Co陶瓷硬质合金电极棒是由重量百分计的：WC90-94%、Co6-10%为材料制成。 The submicron WC-Co ceramic hard alloy electrode rod is made of WC90-94% and Co6-10% by weight.
本发明方法简单，易操作，形成的电火花沉积结合焊接复合涂层与基体结合牢固，涂层厚度大，使处理后的叶片表面硬度高、致密性好、耐磨性能好，使用寿命长；复合涂层即发挥了氩弧焊焊接不锈钢焊丝的成本价格低廉、涂层厚度大等优势，又发挥了电火花沉积陶瓷硬质合金的硬度强度高、耐磨性能优异的综合特点，经济效益巨大。 The method of the invention is simple and easy to operate, and the formed electric spark deposition combined with welding composite coating is firmly combined with the substrate, and the thickness of the coating is large, so that the treated blade surface has high hardness, good compactness, good wear resistance and long service life; Composite coating not only takes advantage of the low cost and large coating thickness of argon arc welding stainless steel welding wire, but also takes advantage of the comprehensive characteristics of high hardness, strength and excellent wear resistance of electric spark deposited ceramic carbide, and has huge economic benefits. .
具体实施方式 detailed description
以下结合实施例对本发明的具体实施方式作详细说明。 The specific implementation of the present invention will be described in detail below in conjunction with the examples.
本发明在具体实施中，可由以下实施例给出。 The present invention can be provided by the following examples in concrete implementation.
实施例1 Example 1
本发明在具体实施中，是由以下步骤实现的： In concrete implementation, the present invention is realized by the following steps:
（1）、对水轮机转轮进行处理，清除油污、锈斑和氧化物，用熔化极气体保护焊设备把把马氏体不锈钢焊丝焊接在水轮机转轮叶片表面，焊接时，电流为230～240A，电弧电压32～36V，焊接速度20～30cm/min，电源极性为直流反接，焊丝直径1.1-1.2mm，焊丝伸出长15～18mm，采用氩气与二氧化碳混合气体保护，氩气与二氧化碳的体积比为95︰5（即体积百分比为：氩气95%、二氧化碳5%），气体流18～23L/min，水轮机转轮焊接区预热温度105～115℃； (1) Treat the runner of the turbine to remove oil stains, rust spots and oxides, and weld the martensitic stainless steel welding wire to the surface of the runner blade of the turbine with the gas shielded welding equipment. When welding, the current is 230-240A, The arc voltage is 32-36V, the welding speed is 20-30cm/min, the polarity of the power supply is DC reversed, the diameter of the welding wire is 1.1-1.2mm, the length of the welding wire is 15-18mm, and the mixed gas protection of argon and carbon dioxide is used. The volume ratio is 95:5 (that is, the volume percentage is: 95% argon, 5% carbon dioxide), the gas flow is 18-23L/min, and the preheating temperature of the welding zone of the turbine runner is 105-115°C;
（2）、在水轮机转轮叶片焊接层用砂片进行表面抛光打磨，使表面平整，无裂纹，无气孔、无沙眼； (2) Polish the surface of the welded layer of the turbine runner blade with sand to make the surface smooth, free of cracks, pores, and trachoma;
（3）、用电火花沉积设备将连地线的夹子与作为阴极的水轮机转轮连接，将亚微米WC-Co陶瓷硬质合金电极棒作为阳极固定在沉积枪的夹头上，对抛光打磨的水轮机转轮叶片进行电火花沉积，沉积枪夹持的电极采用旋转方式，沉积时沉积枪转速为2400r/min，输出功率为3850～3950W，输出电压为185～195V，放电频率为1850～1950HZ，沉积速率为1～1.5min/cm2，电极的伸长度为2.5～3.5mm，在氩气保护下，氩气流量7.5～8.5L/min，电极棒与水轮机转轮叶片表面呈倾斜状进行电火花沉积，把亚微米WC-Co陶瓷硬质合金材料熔融在水轮机转轮叶片焊接后的表面上，往复多次成厚度3-6mm细致均匀白亮的电火花沉积焊接复合涂层，焊接和电火花沉积中25000℃的高温使复合涂层与水轮机转轮叶片基体产生冶金结合，构成牢固结合不会脱落的一个整体； (3) Use electric spark deposition equipment to connect the clip connected to the ground wire with the water turbine runner as the cathode, fix the submicron WC-Co ceramic carbide electrode rod as the anode on the chuck of the deposition gun, and polish the The rotor blades of the hydraulic turbine are used for EDM deposition. The electrode held by the deposition gun adopts a rotating method. During deposition, the deposition gun rotates at 2400r/min, the output power is 3850-3950W, the output voltage is 185-195V, and the discharge frequency is 1850-1950HZ. , the deposition rate is 1-1.5min/cm 2 , the elongation of the electrode is 2.5-3.5mm, under the protection of argon gas, the flow rate of argon gas is 7.5-8.5L/min, and the electrode rod and the surface of the turbine runner blade are inclined. EDM deposition, melting the submicron WC-Co ceramic hard alloy material on the welded surface of the turbine runner blade, reciprocating multiple times to form a fine, uniform, white and bright EDM deposition welding composite coating with a thickness of 3-6mm, welding and electric discharge The high temperature of 25,000°C in the spark deposition causes the metallurgical bond between the composite coating and the turbine runner blade substrate, forming a solid bond that will not fall off as a whole;
所述的亚微米WC-Co陶瓷硬质合金电极棒是由重量百分计的：WC91-93%、Co7-9%为材料制成。 The submicron WC-Co ceramic hard alloy electrode rod is made of WC91-93% and Co7-9% by weight.
实施例2 Example 2
本发明在具体实施中，可由以下步骤实现的： In concrete implementation, the present invention can be realized by the following steps:
（1）、对水轮机转轮进行处理，清除油污、锈斑和氧化物，用熔化极气体保护焊设备把把马氏体不锈钢焊丝焊接在水轮机转轮叶片表面，焊接时，电流为235A，电弧电压34V，焊接速度25cm/min，电源极性为直流反接，焊丝直径1.2mm，焊丝伸出长16mm，采用氩气与二氧化碳混合气体保护，氩气与二氧化碳的体积比为95︰5，气体流20L/min，水轮机转轮焊接区预热温度110℃； (1) Treat the runner of the turbine to remove oil stains, rust spots and oxides, and weld the martensitic stainless steel welding wire on the surface of the runner blade of the turbine with the gas metal shielded welding equipment. When welding, the current is 235A, and the arc voltage is 34V, welding speed 25cm/min, power supply polarity reversed, wire diameter 1.2mm, wire extension length 16mm, mixed gas protection of argon and carbon dioxide, the volume ratio of argon and carbon dioxide is 95:5, the gas flow 20L/min, the preheating temperature of the welding zone of the turbine runner is 110°C;
（2）、在水轮机转轮叶片焊接层用砂片进行表面抛光打磨，使表面平整，无裂纹，无气孔、无沙眼； (2) Polish the surface of the welded layer of the turbine runner blade with a sand sheet to make the surface smooth, free of cracks, pores, and trachoma;
（3）、用电火花沉积设备将连地线的夹子与作为阴极的水轮机转轮连接，将亚微米WC-Co陶瓷硬质合金电极棒作为阳极固定在沉积枪的夹头上，对抛光打磨的水轮机转轮叶片进行电火花沉积，沉积枪夹持的电极采用旋转方式，沉积时沉积枪转速为2400r/min，输出功率为3900W，输出电压为190V，放电频率为1900HZ，沉积速率为1.5min/cm2，电极的伸长度为3mm，在氩气保护下，氩气流量8L/min，电极棒与水轮机转轮叶片表面呈倾斜状进行电火花沉积，把亚微米WC-Co陶瓷硬质合金材料熔融在水轮机转轮叶片焊接后的表面上，往复多次成厚度1-8mm细致均匀白亮的电火花沉积焊接复合涂层，焊接和电火花沉积中25000℃的高温使复合涂层与水轮机转轮叶片基体产生冶金结合，构成牢固结合不会脱落的一个整体； (3) Use electric spark deposition equipment to connect the clip connected to the ground wire with the water turbine runner as the cathode, fix the submicron WC-Co ceramic carbide electrode rod as the anode on the chuck of the deposition gun, and polish the The rotor blades of the hydraulic turbine are used for EDM deposition. The electrode held by the deposition gun adopts a rotating method. During deposition, the deposition gun rotates at 2400r/min, the output power is 3900W, the output voltage is 190V, the discharge frequency is 1900HZ, and the deposition rate is 1.5min. /cm 2 , the elongation of the electrode is 3mm, under the protection of argon, the argon flow rate is 8L/min, the electrode rod and the surface of the runner blade of the water turbine are inclined for EDM deposition, and the submicron WC-Co ceramic carbide The material is melted on the welded surface of the turbine runner blade, and reciprocated several times to form a fine, uniform, white and bright EDM welding composite coating with a thickness of 1-8mm. The base of the wheel blade produces a metallurgical bond, forming a whole that is firmly bonded and will not fall off;
所述的亚微米WC-Co陶瓷硬质合金电极棒是由重量百分计的：WC92%、Co8%为材料制成。 The submicron WC-Co ceramic hard alloy electrode rod is made of WC92% and Co8% by weight.
本发明经实验和测试，涂层中出现大量纳米微晶颗粒，致使涂层致密度高；焊接和电火花沉积中25000℃的高温使复合涂层与基体产生了冶金结合；涂层的表面硬度可以达到1678.1HV～1896.3HV，而基体的硬度为310HV，硬度可提高5-6倍；复合涂层的耐磨性比基体的耐磨性可提高3-6倍。与现有技术相比，具有以下突出的有益技术效果： Through experiments and tests of the present invention, a large number of nano-crystalline particles appear in the coating, resulting in high density of the coating; the high temperature of 25,000°C in welding and EDM makes the composite coating and the substrate produce metallurgical bonding; the surface hardness of the coating is It can reach 1678.1HV～1896.3HV, and the hardness of the substrate is 310HV, which can be increased by 5-6 times; the wear resistance of the composite coating can be increased by 3-6 times than that of the substrate. Compared with the prior art, it has the following outstanding beneficial technical effects:
1、本发明采用金属水轮机转轮为处理熔覆对象，可在水轮机转轮的易磨损部位获得大面积和较高表面平整度的高结合力、高硬度、高致密性、厚度能自由控制的的复合合金硬化层，在气体保护状态下获得熔覆耐磨层的厚度为1～8mm，硬度为HRC65～78，耐磨性提高3-6倍，提高了金属水轮机转轮叶片材料表面的耐磨耐蚀耐冲击性能，进而提高了水轮机转轮叶片的使用寿命。 1. The present invention adopts the metal water turbine runner as the cladding object, which can obtain large area and high surface smoothness, high bonding force, high hardness, high compactness, and thickness can be freely controlled at the easy-wear parts of the water turbine runner. The composite alloy hardened layer, under the gas protection state, the thickness of the cladding wear-resistant layer is 1-8mm, the hardness is HRC65-78, the wear resistance is increased by 3-6 times, and the wear resistance of the metal water turbine runner blade material surface is improved. Wear and corrosion resistance and impact resistance, thereby improving the service life of the turbine runner blades.
2、本发明使在复合涂层的表层电火花区域内形成了含有的高硬度非平衡合金组织，含有大量的纳米微晶粒子，其硬化机理为纳米晶强化、微晶强化、高硬度化合物弥散强化、马氏体相变强化等。 2. The present invention forms a high-hardness non-equilibrium alloy structure in the surface electric discharge area of the composite coating, containing a large number of nano-crystal particles, and its hardening mechanism is nano-crystal strengthening, micro-crystal strengthening, and dispersion of high-hardness compounds strengthening, martensitic transformation strengthening, etc.
3、本发明是在金属水轮机转轮上用高能量束的方法使具有高强度、高耐磨性的陶瓷硬质合金熔覆在金属水轮机转轮焊接材料的表面，形成了一层与基体冶金结合的复合合金层，耐磨损，耐冲击。由于沉积处理过程中单个冶金熔池处于无限大的冷态的水轮机转轮母材上，所以熔池的冷却速度非常大，可达10-6～10-7℃/s,就整个水轮机转轮来说，仍处于常温状态或温升较低，水轮机转轮不会退火或热变形。 3. The present invention uses high-energy beams on the metal water turbine runner to clad ceramic hard alloys with high strength and high wear resistance on the surface of the metal water turbine runner welding material, forming a metallurgical The combined composite alloy layer is wear-resistant and impact-resistant. Since a single metallurgical molten pool is on the base material of the turbine runner in an infinitely large cold state during the deposition process, the cooling rate of the molten pool is very high, up to 10 -6 ~ 10 -7 ℃/s, and the entire hydraulic turbine runner In other words, if it is still at normal temperature or the temperature rise is low, the turbine runner will not be annealed or thermally deformed.
4、在金属水轮机转轮上焊接不锈钢焊丝和沉积陶瓷硬质合金后复合涂层的厚度、质量和工作效率与沉积工艺参数电压、电流、频率和速度等有关，因此可通过对操作工艺参数的调节控制来获得不同的技术效果，应用面广。方法简单，易操作，产品质量好，有很强的实际应用价值，可广泛应用于钢铁冶金行业，经济和社会效益巨大。 4. The thickness, quality and work efficiency of the composite coating after welding stainless steel wire and depositing ceramic carbide on the runner of the metal water turbine are related to the deposition process parameters voltage, current, frequency and speed, so it can be determined by adjusting the operating process parameters Adjust the control to obtain different technical effects, with a wide range of applications. The method is simple, easy to operate, good in product quality, has strong practical application value, can be widely used in iron and steel metallurgy industry, and has huge economic and social benefits.
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