CN107520526A - 一种防硫井口阀体焊接修复方法 - Google Patents
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Abstract
本发明属于焊接行业，具体是涉及的是一种防硫井口阀体焊接修复方法，特别是涉及一种用于防硫阀体的硬度为197‑‑237HBW 4130中碳合金钢的焊接修复方法，一种防硫井口阀体焊接修复方法，其特征是：对待返修产品进行清洗确定损伤位置，对于冲蚀较严重的凹坑需打磨，焊前工件整体预热至130℃；首先采用钨极氩弧焊对凹坑进行填充；然后对加工表面进行补焊；焊后在640℃下局部或整体热处理保温3小时；上述的焊接修复方法中，焊前预热至130℃，焊后在640℃下局部或整体热处理保温3小时，本发明其采用Ar+CO2混合气体保护焊，本发明大大提高产品的利用率，提高综合效率。
Description
技术领域
本发明属于焊接行业，具体是涉及的是一种防硫井口阀体焊接修复方法，特别是涉及一种用于防硫阀体的硬度为197--237 HBW 4130中碳合金钢的焊接修复方法。
背景技术
井口阀体类(包括压裂阀、平板阀等)的很多产品都会应用到一种硬度为 197～237 HBW 4130中碳合金钢的材料，这些产品在加工、测试以及使用过程中难免会因为如下问题导致结构失效：
1.在使用过程中，井口阀体类(包括压裂阀、平板阀等)的流道孔以及垫环槽处会受到冲蚀并且经常出现阀座安装面被划伤，导致整个结构失效的问题，此类阀体不经过修复则无法继续使用。
2.在加工过程中，经常会因为扎刀等问题造成产品尺寸超差并且在测试的环节中也出现过密封面被划伤的事例，若不经过修复只能报废处理。
以上阀体大多有防硫成分和硬度等的要求，基体为4130中碳合金钢，仅通过普通补焊修复后热影响区硬度会超过防硫要求，并且焊接接头的-59℃冲击吸收功、接头强度、焊缝成分等很难达到相关要求，接头无法达到预期的修复目的。并且大多数情况下产品均已加工到尺寸，需要考虑焊接变形，咬边以及其他焊接缺陷对产品尺寸造成影响，修复难度大，只能报废处理，产生巨大浪费。若能使用较低的成本针对局部进行修复将产生巨大的经济效益。
发明内容
本发明的目的是针对上述存在的问题和不足，而提供一种用于硬度为197～237HBW 4130材料井口阀体的焊接修复方法，实现该种阀体的修复再生。
一种防硫井口阀体焊接修复方法，其特征是：
1)对待返修产品进行清洗确定损伤位置，若密封面损伤则需对密封面进行加工，单边去除1.5mm；
2)对于冲蚀较严重的凹坑需打磨补焊凹坑及周围20～30mm的表面，去除铁锈和油污，露出金属光泽，用无水乙醇或丙酮将打磨后的表面清洗干净；
3)焊前工件整体预热至130℃；
4)首先采用钨极氩弧焊对凹坑进行填充，填充655MPa高韧性焊丝，用纯氩气保护，焊接参数为：钨极直径2.4mm，直流正极性，填充焊丝直径1.2mm，焊接电流80-120A，保护气体流量14～20L/min；或者采用Ar+CO2混合气体保护焊对凹坑进行填充，填充655MPa高韧性焊丝，用Ar+CO2混合气体保护，焊接参数为：填充焊丝直径1.2mm，焊接电压22～26V，焊接电流200-260A，保护气体流量15～22L/min；
5)然后对加工表面进行补焊，若采用自动送丝钨极氩弧多道多层焊，填充 655MPa高韧性焊丝，控制层间温度130～180℃，工艺参数为：钨极直径 2.4mm，直流正极性，填充焊丝直径1.2mm，焊接电流100-140A，保护气体流量 14～20L/min；若采用Ar+CO2混合气体保护多道多层焊，填充655MPa高韧性焊丝，控制层间温度130～180℃，工艺参数为：填充焊丝直径1.2mm，焊接电压24～28V，焊接电流220-280A，保护气体流量15～22L/min，焊接热输入控制在10～18kJ/cm，焊接过程中严格控制焊接热输入，控制焊接速度，收弧处填满弧坑；
6)焊后在640℃下局部或整体热处理保温3小时；
7)上述的焊接修复方法中，焊前预热至130℃，焊后在640℃下局部或整体热处理保温3小时，焊接过程中须保持连续施焊，中途不得中断焊接。整个焊接过程中注意保持层间温度130～180℃，收弧部位不允许出现弧坑；
8)补焊后的区域重新按照图纸尺寸加工；
9)其中：步骤(4)中所述655MPa高韧性焊丝优选直径为1.2mm，其熔敷金属化学成分以质量百分比计为：C≤0.11％，Si 0.5％～0.9％，Mn 1.4％～ 1.8％，Cu≤0.5％，Cr0.20％～0.6％，Ti≤0.17％，S≤0.025％，P≤ 0.025％，余量为Fe；熔敷金属力学性能为：抗拉强度σb≥655MPa，伸长率δ≥19％，-20℃冲击吸收功AKV≥47J。
10)其中：步骤(4)中所述纯氩气为纯度99.99％Ar的氩气。
11)其中：步骤(4)中所述氩弧焊所用喷嘴直径优选为12mm，喷嘴到工件距离12mm。
12)其中：步骤(4)所述Ar+CO2混合气体保护焊采用的Ar与CO2的体积比优选为80％～90％：20％～10％，且两者体积之和为100％。
本发明其特征是，采用Ar+CO2混合气体保护焊采用的Ar与CO2的体积为80％～90％：20％～10％，且两者体积之和为100％；或采用钨极氩弧焊，所用喷嘴直径优选为12mm，喷嘴到工件距离12mm，采用的纯氩气为纯度
99.99％Ar的氩气。
本发明其特征是，640℃下局部或整体热处理保温3小时，焊后修复区的硬度在197～237HBW。
本发明所产生积极的效果：
本专利中涉及的修复技术所使用的焊接材料不含Ni，且焊接接头性能能够满足-59℃的低温冲击吸收功大于27J要求。
本专利中涉及的修复技术焊后焊接接头的硬度在197～237HBW。
本专利中涉及的修复技术焊后焊接接头强度抗拉强度σb≥655MPa，伸长率δ≥19％，具有较高的承载能力，能满足其使用性能要求。焊缝区形成低温韧性较好的针状铁素体组织，热影响区中形成强韧性较好的索氏体组织，避免了热影响区软化问题。
本专利中涉及的修复技术可以完成密封面的修复，修复后保证密封面结构及功能完好。
本专利焊后无气孔夹杂，能够一次通过渗透探伤，避免重复补焊返工。
附图说明
图1是本发明的半剖视结构图。
1、处出现划伤，密封出现泄漏，2、处出现冲蚀凹坑。
具体实施方式
实施例1
1.对待返修产品进行清洗，对1处损伤密封面则进行加工，单边去除1.5mm；
2.对2处冲蚀较凹坑需打磨补焊凹坑及周围20～30mm的表面，去除铁锈和油污，露出金属光泽，用无水乙醇或丙酮将打磨后的表面清洗干净；
3.焊前工件整体预热至130℃；
4.采用Ar+CO2混合气体保护焊对2处凹坑进行填充，填充655MPa高韧性焊丝，其熔敷金属化学成分以质量百分比计为：C≤0.11％，Si 0.5％～ 0.9％，Mn 1.4％～1.8％，Cu≤0.5％，Cr 0.20％～0.6％，Ti≤0.17％，S≤0.025％，P≤0.025％，余量为Fe；Ar和CO2气体的体积比为 80％：20％，焊接参数为：填充焊丝直径1.2mm，焊接电压22～26V，焊接电流200-260A，保护气体流量15～22L/min。
5.然后对1处密封面加工表面进行补焊，采用Ar+CO2混合气体保护多道多层焊，填充655MPa高韧性焊丝，其熔敷金属化学成分以质量百分比计为： C≤0.11％，Si 0.5％～0.9％，Mn 1.4％～1.8％，Cu≤0.5％，Cr 0.20％～0.6％，Ti≤0.17％，S≤0.025％，P≤0.025％，余量为 Fe；Ar和CO2气体的体积比为80％：20％，控制层间温度130～180℃，工艺参数为：钨极直径2.4mm，直流正极性，填充焊丝直径1.2mm，焊接电流100-140A，保护气体流量14～20L/min；若采用Ar+CO2混合气体保护多道多层焊，填充655MPa高韧性焊丝，控制层间温度130～180℃，工艺参数为：填充焊丝直径1.2mm，焊接电压24～28V，焊接电流 220-280A，保护气体流量15～22L/min，焊接热输入控制在10～ 18kJ/cm，焊接过程中严格控制焊接热输入，控制焊接速度，收弧处填满弧坑。
6.按照图纸尺寸粗加工1处密封面，单边留量0.2mm进行探伤。
7.焊后在640℃下整体放入真空热处理炉热处理保温3小时。
8.精加工1处密封面，2处流道孔按照补焊前的尺寸进行加工，对于不连贯处抛光处理，其余氧化密封面进行抛光处理。
综上所述，本发明具有如下优点：
1、本专利中涉及的一种用于硬度为197～237 HBW 4130材料井口阀体的焊接修复方法，能够实现该种阀体的修复再生。
2、通过该焊接工艺，4130材料焊接接头强度抗拉强度σb≥655MPa，伸长率δ≥19％，同时能够满足-59℃的低温冲击吸收功大于27J要求。
3、本专利中涉及的一种4130材料防硫井口阀体修复技术采用无Ni焊丝，其熔敷金属化学成分以质量百分比计为：C≤0.11％，Si 0.5％～0.9％， Mn 1.4％～1.8％，Cu≤0.5％，Cr 0.20％～0.6％，Ti≤0.17％，S ≤0.025％，P≤0.025％，余量为Fe。
4、本专利中涉及的一种4130材料防硫井口阀体修复技术能够满足阀体密封面的损伤修复，保证修复后保证密封面结构及功能完好。
5、本发明大大提高产品的利用率，提高综合效率。
Claims (3)
1.一种防硫井口阀体焊接修复方法，其特征是：
1)对待返修产品进行清洗确定损伤位置，若密封面损伤则需对密封面进行加工，单边去除1.5mm；
2)对于冲蚀较严重的凹坑需打磨补焊凹坑及周围20～30mm的表面，去除铁锈和油污，露出金属光泽，用无水乙醇或丙酮将打磨后的表面清洗干净；
3)焊前工件整体预热至130℃；
4)首先采用钨极氩弧焊对凹坑进行填充，填充655MPa高韧性焊丝，用纯氩气保护，焊接参数为：钨极直径2.4mm，直流正极性，填充焊丝直径1.2mm，焊接电流80-120A，保护气体流量14～20L/min；或者采用Ar+CO2混合气体保护焊对凹坑进行填充，填充655MPa高韧性焊丝，用Ar+CO2混合气体保护，焊接参数为：填充焊丝直径1.2mm，焊接电压22～26V，焊接电流200-260A，保护气体流量15～22L/min；
5)然后对加工表面进行补焊，若采用自动送丝钨极氩弧多道多层焊，填充655MPa高韧性焊丝，控制层间温度130～180℃，工艺参数为：钨极直径2.4mm，直流正极性，填充焊丝直径1.2mm，焊接电流100-140A，保护气体流量14～20L/min；若采用Ar+CO2混合气体保护多道多层焊，填充655MPa高韧性焊丝，控制层间温度130～180℃，工艺参数为：填充焊丝直径1.2mm，焊接电压24～28V，焊接电流220-280A，保护气体流量15～22L/min，焊接热输入控制在10～18kJ/cm，焊接过程中严格控制焊接热输入，控制焊接速度，收弧处填满弧坑；
6)焊后在640℃下局部或整体热处理保温3小时；
7)上述的焊接修复方法中，焊前预热至130℃，焊后在640℃下局部或整体热处理保温3小时，焊接过程中须保持连续施焊，中途不得中断焊接。整个焊接过程中注意保持层间温度130～180℃，收弧部位不允许出现弧坑；
8)补焊后的区域重新按照图纸尺寸加工；
9)其中：步骤(4)中所述655MPa高韧性焊丝优选直径为1.2mm，其熔敷金属化学成分以质量百分比计为：C≤0.11％，Si 0.5％～0.9％，Mn 1.4％～1.8％，Cu≤0.5％，Cr 0.20％～0.6％，Ti≤0.17％，S≤0.025％，P≤0.025％，余量为Fe；熔敷金属力学性能为：抗拉强度σb≥655MPa，伸长率δ≥19％，-20℃冲击吸收功AKV≥47J；
10)其中：步骤(4)中所述纯氩气为纯度99.99％Ar的氩气；
11)其中：步骤(4)中所述氩弧焊所用喷嘴直径优选为12mm，喷嘴到工件距离12mm；
12)其中：步骤(4)所述Ar+CO2混合气体保护焊采用的Ar与CO2的体积比优选为80％～90％：20％～10％，且两者体积之和为100％。
2.根据权利要求1所述的一种防硫井口阀体焊接修复方法，其特征是：采用Ar+CO2混合气体保护焊采用的Ar与CO2的体积为80％～90％：20％～10％，且两者体积之和为100％；或采用钨极氩弧焊，所用喷嘴直径优选为12mm，喷嘴到工件距离12mm，采用的纯氩气为纯度99.99％Ar的氩气。
3.根据权利要求1所述的一种防硫井口阀体焊接修复方法，其特征是：640℃下局部或整体热处理保温3小时，焊后修复区的硬度在197～237HBW。
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| US11668175B2 (en) | 2020-06-24 | 2023-06-06 | Bj Energy Solutions, Llc | Automated diagnostics of electronic instrumentation in a system for fracturing a well and associated methods |
| US11274537B2 (en) | 2020-06-24 | 2022-03-15 | Bj Energy Solutions, Llc | Method to detect and intervene relative to cavitation and pulsation events during a hydraulic fracturing operation |
| US11692422B2 (en) | 2020-06-24 | 2023-07-04 | Bj Energy Solutions, Llc | System to monitor cavitation or pulsation events during a hydraulic fracturing operation |
| US11299971B2 (en) | 2020-06-24 | 2022-04-12 | Bj Energy Solutions, Llc | System of controlling a hydraulic fracturing pump or blender using cavitation or pulsation detection |
| US11608727B2 (en) | 2020-07-17 | 2023-03-21 | Bj Energy Solutions, Llc | Methods, systems, and devices to enhance fracturing fluid delivery to subsurface formations during high-pressure fracturing operations |
| US11603744B2 (en) | 2020-07-17 | 2023-03-14 | Bj Energy Solutions, Llc | Methods, systems, and devices to enhance fracturing fluid delivery to subsurface formations during high-pressure fracturing operations |
| US11365615B2 (en) | 2020-07-17 | 2022-06-21 | Bj Energy Solutions, Llc | Methods, systems, and devices to enhance fracturing fluid delivery to subsurface formations during high-pressure fracturing operations |
| US11994014B2 (en) | 2020-07-17 | 2024-05-28 | Bj Energy Solutions, Llc | Methods, systems, and devices to enhance fracturing fluid delivery to subsurface formations during high-pressure fracturing operations |
| US11193360B1 (en) | 2020-07-17 | 2021-12-07 | Bj Energy Solutions, Llc | Methods, systems, and devices to enhance fracturing fluid delivery to subsurface formations during high-pressure fracturing operations |
| US11920450B2 (en) | 2020-07-17 | 2024-03-05 | Bj Energy Solutions, Llc | Methods, systems, and devices to enhance fracturing fluid delivery to subsurface formations during high-pressure fracturing operations |
| US11255175B1 (en) | 2020-07-17 | 2022-02-22 | Bj Energy Solutions, Llc | Methods, systems, and devices to enhance fracturing fluid delivery to subsurface formations during high-pressure fracturing operations |
| US11193361B1 (en) | 2020-07-17 | 2021-12-07 | Bj Energy Solutions, Llc | Methods, systems, and devices to enhance fracturing fluid delivery to subsurface formations during high-pressure fracturing operations |
| US11639654B2 (en) | 2021-05-24 | 2023-05-02 | Bj Energy Solutions, Llc | Hydraulic fracturing pumps to enhance flow of fracturing fluid into wellheads and related methods |
| US11732563B2 (en) | 2021-05-24 | 2023-08-22 | Bj Energy Solutions, Llc | Hydraulic fracturing pumps to enhance flow of fracturing fluid into wellheads and related methods |
| US11867045B2 (en) | 2021-05-24 | 2024-01-09 | Bj Energy Solutions, Llc | Hydraulic fracturing pumps to enhance flow of fracturing fluid into wellheads and related methods |
| CN114799426A (zh) * | 2022-04-06 | 2022-07-29 | 天津市英源焊接技术有限公司 | 一种在煤矿液支架27SiMn立柱内表面堆焊铜合金的工艺 |
| CN115319242B (zh) * | 2022-07-19 | 2023-12-29 | 广西防城港核电有限公司 | 阀门唇焊缺陷修复方法 |
| CN115319242A (zh) * | 2022-07-19 | 2022-11-11 | 广西防城港核电有限公司 | 阀门唇焊缺陷修复方法 |
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