CN110883495A - Online repair process for rotary valve rotor sealing surface - Google Patents
Online repair process for rotary valve rotor sealing surface Download PDFInfo
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- CN110883495A CN110883495A CN201911146665.2A CN201911146665A CN110883495A CN 110883495 A CN110883495 A CN 110883495A CN 201911146665 A CN201911146665 A CN 201911146665A CN 110883495 A CN110883495 A CN 110883495A
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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
- B23P6/00—Restoring or reconditioning objects
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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
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
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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
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors
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Abstract
The invention discloses an online repair process for a rotary valve rotor sealing surface, which adopts Cold Metal Transition (CMT) welding as a MIG/MAG additive manufacturing technology and is used for repairing an RPF rotary valve rotor sealing surface. Depending on the rotary valve rotor material: and the bidirectional stainless steel is selected as the additive manufacturing material. The method uses Cold Metal Transition (CMT) additive manufacturing to repair the sealing surface, is easy to operate, has high efficiency and better binding force, repairs on line and saves the repair period.
Description
Technical Field
The invention relates to the technical field of surface treatment, in particular to an online repair process for a rotary valve rotor sealing surface.
Background
PTA (purified terephthalic acid) is widely used in the fields of chemical fiber, light industry, electronics, buildings and the like, and the purposes of large maintenance quantity of rotary valve rotors, inconvenient transportation, quite short construction period, serious abrasion of sealing surfaces, difficult overall disassembly, long complete replacement period and quite high price are considered, so that the purpose of saving cost is achieved by selecting an on-line repair mode.
The main forms and causes of wear of rotary valve rotor sealing surfaces are as follows:
(1) wear state of rotary valve rotor sealing surface: is groove-shaped, and continuously leaks materials in the production and operation process.
(2) The sealing surface of the rotary valve rotor rotates for a long time to cause the sealing surface to accumulate day by month to form abrasion,
the problems caused by the additive manufacturing process in the traditional process are as follows:
(1) the heat is big in the vibration material disk manufacturing process, can influence sealed face deflection.
(2) The manual welding efficiency is low, and the repair cycle is influenced.
(3) The traditional processing needs machine tool processing, and the process can not avoid disassembly, transportation, hoisting and installation, thereby seriously influencing the repair cycle.
Based on the situation, the invention provides an online repair process for the sealing surface of the rotary valve rotor, which can effectively solve the problems.
Disclosure of Invention
The invention aims to provide an online repair process for a rotary valve rotor sealing surface. The on-line repair process for the sealing surface of the rotary valve rotor solves the problems of troublesome overall disassembly, difficult transportation and the like of the rotary valve rotor, and can quickly repair the sealing surface of the rotary valve rotor in short time.
In order to solve the technical problems, the technical scheme provided by the invention is as follows:
an on-line repair process for a rotary valve rotor sealing surface comprises the following steps:
(1) polishing the sealing surface of the rotary valve rotor to remove a fatigue layer at the repair position; then, removing stains on the sealing surface by using a cloth strip, confirming whether the sealing surface has a scratch crack or not by using a dye-based flaw detector, and wiping the sealing surface by using acetone until the sealing surface is free of stains;
the rotary valve rotor sealing surface is seriously abraded due to long-term operation, and a large number of grooves exist, so that the repairing effect of the rotary valve rotor sealing surface online repairing process can be effectively ensured.
(2) Measuring the abrasion size of the abrasion position by using a welding measuring scale; determining the welding height according to the measured dimension and the standard dimension; and adjusting cold metal transition welding parameters;
(3) selecting a Cold Metal Transition (CMT) additive manufacturing material according to the RPF rotary valve rotor material, and repairing the RPF rotary valve rotor sealing surface by adopting Cold Metal Transition (CMT) additive manufacturing;
(4) welding the repaired RPF rotary valve rotor sealing surface;
(5) and after welding repair is finished, machining the sealing surface by using an online lathe, turning off the redundant size of the surface, and performing finish machining to a preset size.
Preferably, in the step (2), the welding height is determined to be at least 1mm higher than the standard size of the sealing surface after welding according to the measurement size and the standard size, so that the turning processing is carried out by an online lathe.
Preferably, in step (2), the cold metal transfer welding parameters are adjusted as follows: welding height is 2.0 ~ 2.5mm, welding width is 8 ~ 10mm, welding current 150 ~ 200A, welding speed 7 ~ 15mm/s, welding bead overlap joint volume 50 ~ 60%, shielding gas: the volume ratio of the mixed gas of 98% argon and 2% carbon dioxide is 8-12L/min, and the diameter of the welding wire is 1.2 mm.
Preferably, in the step (3), the RPF rotary valve rotor material is 2205 duplex stainless steel, and 2209 duplex stainless steel welding wire is selected as a Cold Metal Transition (CMT) additive manufacturing material.
The 2209 duplex stainless steel welding wire has high strength, good impact toughness and good overall and local stress corrosion resistance.
Preferably, the chemical composition of the 2209 duplex stainless steel welding wire comprises the following components: less than or equal to 0.04 percent of C, less than or equal to 1.00 percent of Si, less than or equal to 2.00 percent of Mn, 21-24 percent of Cr, 2.5-4.0 percent of Mo, 7.5-10.0 percent of Ni, less than or equal to 0.04 percent of P, less than or equal to 0.03 percent of S, and less than or equal to 0.5 percent of Cu.
Preferably, the chemical composition of the 2209 duplex stainless steel welding wire comprises the following components: less than or equal to 0.03 percent of C, less than or equal to 0.95 percent of Si, less than or equal to 1.2 percent of Mn, 22-24 percent of Cr, 3-3.8 percent of Mo, 8.2-9.6 percent of Ni, less than or equal to 0.03 percent of P, less than or equal to 0.025 percent of S, and less than or equal to 0.4 percent of Cu.
The density of the 2209 duplex stainless steel welding wire is about 8.0g/cm3, the melting point reaches 1450 ℃, the Brinell hardness is less than or equal to 290HB, the tensile strength reaches 690Mpa, and the elongation reaches 20%; is a preferred choice as a Cold Metal Transition (CMT) additive manufacturing material.
Preferably, in the step (4), the repaired RPF rotary valve rotor sealing surface is welded by using an ABB mechanical arm, and a welding program is compiled for automatic welding.
Preferably, in the step (4), the repair RPF rotary valve rotor sealing surface is welded in a surrounding manner.
Compared with the prior art, the invention has the following advantages and beneficial effects:
(1) the additive manufacturing process has the advantages that the heat is small, the welding temperature is 80-120 ℃, and the influence of the temperature on welding is effectively limited.
(2) The automatic wire feeding welding machine is high in welding efficiency, and automatic welding is achieved through an automatic wire feeding function and an ABB mechanical arm.
(3) The invention has the advantages of small splashing during welding, good welding bridging capability and uniform and consistent welding line.
(4) The invention has no phenomena of obvious deformation, annealing and discoloration, no cracks, no hardening and hard spots and no influence on the machining performance.
(5) The method uses Cold Metal Transition (CMT) additive manufacturing to repair the sealing surface, and has the advantages of easy operation, high efficiency and better bonding force.
Detailed Description
In order that those skilled in the art will better understand the technical solutions of the present invention, the following description of the preferred embodiments of the present invention is provided in connection with specific examples, which should not be construed as limiting the present patent.
The test methods or test methods described in the following examples are conventional methods unless otherwise specified; the reagents and materials, unless otherwise indicated, are conventionally obtained commercially or prepared by conventional methods.
In the specific implementation process, the rotary valve rotor sealing surface on-line repair process of the invention,
(1) features of CMT (Cold Metal transfer) welding
The CMT technology is a novel welding process technology without welding slag splashing, a cold metal transition welding system is developed on the basis of short circuit transition, the heat input is lower compared with the MIG/MAG metal droplet transition of the traditional gas welding shielded welding, cold and hot alternate welding is realized in the welding process, the welding heat output is greatly reduced, the cold metal transition process is small in heat input, small in deformation, free of splashing, good in bridging capacity, uniform and consistent in welding seam, high in welding speed and low in operation cost, and a perfect solution is provided for welding.
(2) Working principle of CMT welding
The CMT welding technology realizes the molten drop transition in a current-free state, when short-circuit current is generated, the welding wire stops advancing and electric arc is ignited, the molten drop enters a molten pool towards the molten drop, the electric arc molten pool is transited to extinguish, and the current is reduced and automatically pumped back. In this way, the process of heat input by the electric arc itself is short, short circuit occurs, the electric arc is extinguished, the heat input is rapidly reduced, and the whole welding process is cyclically repeated in cold and hot alternation.
(3) Automatic wire feeding technology of CMT (China Mobile Teller machine)
The wire feeding driving part of the automatic wire feeder generally comprises an adjustable pretightening force pressure lever, a driving wheel and a driven wheel, the pretightening force pressure lever is used for compressing a welding wire, and a handle can rotate to adjust the compression degree.
(4) ABB mechanical arm welding technology
The mechanical arm has the function of simulating the wrist of the arm and replaces the manual welding of the traditional process, thereby greatly improving the welding efficiency and quality.
(5) Online turning technology
The online turning equipment can realize online processing by manufacturing corresponding tools according to the size of a sealing surface, and has stable processing quality.
Example 1:
an on-line repair process for a rotary valve rotor sealing surface comprises the following steps:
(1) polishing the sealing surface of the rotary valve rotor to remove a fatigue layer at the repair position; then, removing stains on the sealing surface by using a cloth strip, confirming whether the sealing surface has a scratch crack or not by using a dye-based flaw detector, and wiping the sealing surface by using acetone until the sealing surface is free of stains;
the rotary valve rotor sealing surface is seriously abraded due to long-term operation, and a large number of grooves exist, so that the repairing effect of the rotary valve rotor sealing surface online repairing process can be effectively ensured.
(2) Measuring the abrasion size of the abrasion position by using a welding measuring scale; determining the welding height according to the measured dimension and the standard dimension; and adjusting cold metal transition welding parameters;
(3) selecting a Cold Metal Transition (CMT) additive manufacturing material according to the RPF rotary valve rotor material, and repairing the RPF rotary valve rotor sealing surface by adopting Cold Metal Transition (CMT) additive manufacturing;
(4) welding the repaired RPF rotary valve rotor sealing surface;
(5) and after welding repair is finished, machining the sealing surface by using an online lathe, turning off the redundant size of the surface, and performing finish machining to a preset size.
Preferably, in the step (2), the welding height is determined to be at least 1mm higher than the standard size of the sealing surface after welding according to the measurement size and the standard size, so that the turning processing is carried out by an online lathe.
Preferably, in step (2), the cold metal transfer welding parameters are adjusted as follows: welding height is 2.0 ~ 2.5mm, welding width is 8 ~ 10mm, welding current 150 ~ 200A, welding speed 7 ~ 15mm/s, welding bead overlap joint volume 50 ~ 60%, shielding gas: the volume ratio of the mixed gas of 98% argon and 2% carbon dioxide is 8-12L/min, and the diameter of the welding wire is 1.2 mm.
Preferably, in the step (3), the RPF rotary valve rotor material is 2205 duplex stainless steel, and 2209 duplex stainless steel welding wire is selected as a Cold Metal Transition (CMT) additive manufacturing material.
The 2209 duplex stainless steel welding wire has high strength, good impact toughness and good overall and local stress corrosion resistance.
Preferably, the chemical composition of the 2209 duplex stainless steel welding wire comprises the following components: less than or equal to 0.04 percent of C, less than or equal to 1.00 percent of Si, less than or equal to 2.00 percent of Mn, 21-24 percent of Cr, 2.5-4.0 percent of Mo, 7.5-10.0 percent of Ni, less than or equal to 0.04 percent of P, less than or equal to 0.03 percent of S, and less than or equal to 0.5 percent of Cu.
Preferably, the chemical composition of the 2209 duplex stainless steel welding wire comprises the following components: less than or equal to 0.03 percent of C, less than or equal to 0.95 percent of Si, less than or equal to 1.2 percent of Mn, 22-24 percent of Cr, 3-3.8 percent of Mo, 8.2-9.6 percent of Ni, less than or equal to 0.03 percent of P, less than or equal to 0.025 percent of S, and less than or equal to 0.4 percent of Cu.
The density of the 2209 duplex stainless steel welding wire is about 8.0g/cm3, the melting point reaches 1450 ℃, the Brinell hardness is less than or equal to 290HB, the tensile strength reaches 690Mpa, and the elongation reaches 20%; is a preferred choice as a Cold Metal Transition (CMT) additive manufacturing material.
Preferably, in the step (4), the repaired RPF rotary valve rotor sealing surface is welded by using an ABB mechanical arm, and a welding program is compiled for automatic welding.
Preferably, in the step (4), the repair RPF rotary valve rotor sealing surface is welded in a surrounding manner.
Example 2:
an on-line repair process for a rotary valve rotor sealing surface comprises the following steps:
(1) polishing the sealing surface of the rotary valve rotor to remove a fatigue layer at the repair position; then, removing stains on the sealing surface by using a cloth strip, confirming whether the sealing surface has a scratch crack or not by using a dye-based flaw detector, and wiping the sealing surface by using acetone until the sealing surface is free of stains;
the rotary valve rotor sealing surface is seriously abraded due to long-term operation, and a large number of grooves exist, so that the repairing effect of the rotary valve rotor sealing surface online repairing process can be effectively ensured.
(2) Measuring the abrasion size of the abrasion position by using a welding measuring scale; determining the welding height according to the measured dimension and the standard dimension; and adjusting cold metal transition welding parameters;
(3) selecting a Cold Metal Transition (CMT) additive manufacturing material according to the RPF rotary valve rotor material, and repairing the RPF rotary valve rotor sealing surface by adopting Cold Metal Transition (CMT) additive manufacturing;
(4) welding the repaired RPF rotary valve rotor sealing surface;
(5) and after welding repair is finished, machining the sealing surface by using an online lathe, turning off the redundant size of the surface, and performing finish machining to a preset size.
In this embodiment, in step (2), based on the measured dimension and the standard dimension, the welding height is determined to be at least 1mm higher than the seal surface reference dimension after welding, so that turning is performed on an on-line lathe.
In this embodiment, in step (2), the cold metal transfer welding parameters are adjusted as follows: welding height 2.0mm, welding width 8mm, welding current 150A, welding speed 7mm/s, welding bead overlap amount 50%, protective gas: the mixed gas of 98 percent of argon and 2 percent of carbon dioxide by volume ratio has the gas flow of 8L/min and the diameter of the welding wire is 1.2 mm.
In this embodiment, in step (3), the RPF rotary valve rotor material is 2205 duplex stainless steel, and 2209 duplex stainless steel welding wire is selected as the Cold Metal Transition (CMT) additive manufacturing material.
The 2209 duplex stainless steel welding wire has high strength, good impact toughness and good overall and local stress corrosion resistance.
In the embodiment, the chemical composition of the 2209 duplex stainless steel welding wire comprises: less than or equal to 0.03 percent of C, less than or equal to 0.95 percent of Si, less than or equal to 1.2 percent of Mn, 22 percent of Cr, 3 percent of Mo, 8.2 percent of Ni, less than or equal to 0.03 percent of P, less than or equal to 0.025 percent of S, and less than or equal to 0.4 percent of Cu.
The density of the 2209 duplex stainless steel welding wire is about 8.0g/cm3, the melting point reaches 1450 ℃, the Brinell hardness is less than or equal to 290HB, the tensile strength reaches 690Mpa, and the elongation reaches 20%; is a preferred choice as a Cold Metal Transition (CMT) additive manufacturing material.
In this embodiment, in step (4), the RPF rotary valve rotor sealing surface is repaired by welding using an ABB robot, and the welding program is written to perform automated welding.
In this embodiment, in step (4), the repair RPF rotary valve rotor sealing surface is welded by a wrap-around welding method.
Example 3:
an on-line repair process for a rotary valve rotor sealing surface comprises the following steps:
(1) polishing the sealing surface of the rotary valve rotor to remove a fatigue layer at the repair position; then, removing stains on the sealing surface by using a cloth strip, confirming whether the sealing surface has a scratch crack or not by using a dye-based flaw detector, and wiping the sealing surface by using acetone until the sealing surface is free of stains;
the rotary valve rotor sealing surface is seriously abraded due to long-term operation, and a large number of grooves exist, so that the repairing effect of the rotary valve rotor sealing surface online repairing process can be effectively ensured.
(2) Measuring the abrasion size of the abrasion position by using a welding measuring scale; determining the welding height according to the measured dimension and the standard dimension; and adjusting cold metal transition welding parameters;
(3) selecting a Cold Metal Transition (CMT) additive manufacturing material according to the RPF rotary valve rotor material, and repairing the RPF rotary valve rotor sealing surface by adopting Cold Metal Transition (CMT) additive manufacturing;
(4) welding the repaired RPF rotary valve rotor sealing surface;
(5) and after welding repair is finished, machining the sealing surface by using an online lathe, turning off the redundant size of the surface, and performing finish machining to a preset size.
In this embodiment, in step (2), based on the measured dimension and the standard dimension, the welding height is determined to be at least 1mm higher than the seal surface reference dimension after welding, so that turning is performed on an on-line lathe.
In this embodiment, in step (2), the cold metal transfer welding parameters are adjusted as follows: welding height 2.5mm, welding width 10mm, welding current 200A, welding speed 15mm/s, welding bead overlap amount 60%, protective gas: the mixed gas of 98 percent of argon and 2 percent of carbon dioxide by volume ratio has the gas flow of 12L/min and the diameter of the welding wire is 1.2 mm.
In this embodiment, in step (3), the RPF rotary valve rotor material is 2205 duplex stainless steel, and 2209 duplex stainless steel welding wire is selected as the Cold Metal Transition (CMT) additive manufacturing material.
The 2209 duplex stainless steel welding wire has high strength, good impact toughness and good overall and local stress corrosion resistance.
In the embodiment, the chemical composition of the 2209 duplex stainless steel welding wire comprises: less than or equal to 0.03 percent of C, less than or equal to 0.95 percent of Si, less than or equal to 1.2 percent of Mn, 24 percent of Cr, 3.8 percent of Mo, 9.6 percent of Ni, less than or equal to 0.03 percent of P, less than or equal to 0.025 percent of S, and less than or equal to 0.4 percent of Cu.
The density of the 2209 duplex stainless steel welding wire is about 8.0g/cm3, the melting point reaches 1450 ℃, the Brinell hardness is less than or equal to 290HB, the tensile strength reaches 690Mpa, and the elongation reaches 20%; is a preferred choice as a Cold Metal Transition (CMT) additive manufacturing material.
In this embodiment, in step (4), the RPF rotary valve rotor sealing surface is repaired by welding using an ABB robot, and the welding program is written to perform automated welding.
In this embodiment, in step (4), the repair RPF rotary valve rotor sealing surface is welded by a wrap-around welding method.
Example 4:
an on-line repair process for a rotary valve rotor sealing surface comprises the following steps:
(1) polishing the sealing surface of the rotary valve rotor to remove a fatigue layer at the repair position; then, removing stains on the sealing surface by using a cloth strip, confirming whether the sealing surface has a scratch crack or not by using a dye-based flaw detector, and wiping the sealing surface by using acetone until the sealing surface is free of stains;
the rotary valve rotor sealing surface is seriously abraded due to long-term operation, and a large number of grooves exist, so that the repairing effect of the rotary valve rotor sealing surface online repairing process can be effectively ensured.
(2) Measuring the abrasion size of the abrasion position by using a welding measuring scale; determining the welding height according to the measured dimension and the standard dimension; and adjusting cold metal transition welding parameters;
(3) selecting a Cold Metal Transition (CMT) additive manufacturing material according to the RPF rotary valve rotor material, and repairing the RPF rotary valve rotor sealing surface by adopting Cold Metal Transition (CMT) additive manufacturing;
(4) welding the repaired RPF rotary valve rotor sealing surface;
(5) and after welding repair is finished, machining the sealing surface by using an online lathe, turning off the redundant size of the surface, and performing finish machining to a preset size.
In this embodiment, in step (2), based on the measured dimension and the standard dimension, the welding height is determined to be at least 1mm higher than the seal surface reference dimension after welding, so that turning is performed on an on-line lathe.
In this embodiment, in step (2), the cold metal transfer welding parameters are adjusted as follows: welding height 2.2mm, welding width 9mm, welding current 180A, welding speed 11mm/s, welding bead overlap amount 55%, protective gas: the mixed gas of 98 percent of argon and 2 percent of carbon dioxide by volume ratio has the gas flow of 10L/min and the diameter of the welding wire is 1.2 mm.
In this embodiment, in step (3), the RPF rotary valve rotor material is 2205 duplex stainless steel, and 2209 duplex stainless steel welding wire is selected as the Cold Metal Transition (CMT) additive manufacturing material.
The 2209 duplex stainless steel welding wire has high strength, good impact toughness and good overall and local stress corrosion resistance.
In the embodiment, the chemical composition of the 2209 duplex stainless steel welding wire comprises: less than or equal to 0.03 percent of C, less than or equal to 0.95 percent of Si, less than or equal to 1.2 percent of Mn, 23 percent of Cr, 3.4 percent of Mo, 8.8 percent of Ni, less than or equal to 0.03 percent of P, less than or equal to 0.025 percent of S, and less than or equal to 0.4 percent of Cu.
The density of the 2209 duplex stainless steel welding wire is about 8.0g/cm3, the melting point reaches 1450 ℃, the Brinell hardness is less than or equal to 290HB, the tensile strength reaches 690Mpa, and the elongation reaches 20%; is a preferred choice as a Cold Metal Transition (CMT) additive manufacturing material.
In this embodiment, in step (4), the RPF rotary valve rotor sealing surface is repaired by welding using an ABB robot, and the welding program is written to perform automated welding.
In this embodiment, in step (4), the repair RPF rotary valve rotor sealing surface is welded by a wrap-around welding method.
Example 5:
the RPF rotary valve rotor sealing surface of a certain chemical plant is worn, and the rotor sealing surface is made of the following materials: 2205 and the sealing position (4 positions) at the abrasion position has groove-shaped pits, and the surface is cleaned of surface impurities such as oil stains. Adjusting CMT welding parameters by Cold Metal Transition (CMT) welding, 2209 duplex stainless steel wire welding wire: the welding height is 2.0 ~ 2.3mm, and welding width is 8 ~ 9mm, and protective gas adopts: the welding method comprises the following steps of carrying out additive manufacturing on a wear repair position according to a mixed gas of 98% argon and 2% carbon dioxide by volume ratio, a welding current of 180A, a welding speed of 10mm/s, a welding bead lap joint quantity of 50% and a welding wire diameter of 1.2mm, and carrying out dye penetrant inspection after welding is finished without cracks and pores.
After welding repair is finished, an online lathe is used for machining a sealing surface, a tool clamp is manufactured to machine the online lathe according to the size of the sealing surface, the sealing surface completely meets the design requirement, the production efficiency is improved, and the service use effect of the sealing surface of the rotary valve rotor repaired by the process is good.
The example results show that the Cold Metal Transition (CMT) additive manufacturing is used for sealing surface repair, the operation is easy, the efficiency is high, and the bonding force is better.
The above is only a preferred embodiment of the present invention, and it should be noted that the above preferred embodiment should not be considered as limiting the present invention, and the protection scope of the present invention should be subject to the scope defined by the claims. It will be apparent to those skilled in the art that various modifications and adaptations can be made without departing from the spirit and scope of the invention, and these modifications and adaptations should be considered within the scope of the invention.
Claims (8)
1. The rotary valve rotor sealing surface on-line repairing process is characterized by comprising the following steps:
(1) polishing the sealing surface of the rotary valve rotor to remove a fatigue layer at the repair position; then, removing stains on the sealing surface by using a cloth strip, confirming whether the sealing surface has a scratch crack or not by using a dye-based flaw detector, and wiping the sealing surface by using acetone until the sealing surface is free of stains;
(2) measuring the abrasion size of the abrasion position by using a welding measuring scale; determining the welding height according to the measured dimension and the standard dimension; and adjusting cold metal transition welding parameters;
(3) selecting a cold metal transition additive manufacturing material according to the RPF rotary valve rotor material, and repairing the RPF rotary valve rotor sealing surface by adopting cold metal transition additive manufacturing;
(4) welding the repaired RPF rotary valve rotor sealing surface;
(5) and after welding repair is finished, machining the sealing surface by using an online lathe, turning off the redundant size of the surface, and performing finish machining to a preset size.
2. An on-line repair process for a sealing surface of a rotary valve rotor according to claim 1, wherein in the step (2), according to the measurement size and the standard size, the welding height is determined to be at least 1mm higher than the reference size of the sealing surface after welding, so that turning can be carried out by an on-line lathe.
3. An on-line repair process for a rotary valve rotor sealing surface according to claim 1, wherein in step (2), the cold metal transfer welding parameters are adjusted as follows: welding height is 2.0 ~ 2.5mm, welding width is 8 ~ 10mm, welding current 150 ~ 200A, welding speed 7 ~ 15mm/s, welding bead overlap joint volume 50 ~ 60%, shielding gas: the volume ratio of the mixed gas of 98% argon and 2% carbon dioxide is 8-12L/min, and the diameter of the welding wire is 1.2 mm.
4. A rotary valve rotor sealing surface on-line repairing process according to claim 1, wherein in the step (3), the RPF rotary valve rotor material is 2205 duplex stainless steel, and 2209 duplex stainless steel welding wires are selected as Cold Metal Transition (CMT) additive manufacturing materials.
5. A rotary valve rotor seal face online repair process as claimed in claim 4 wherein the chemical composition of the 2209 duplex stainless steel wire comprises: less than or equal to 0.04 percent of C, less than or equal to 1.00 percent of Si, less than or equal to 2.00 percent of Mn, 21-24 percent of Cr, 2.5-4.0 percent of Mo, 7.5-10.0 percent of Ni, less than or equal to 0.04 percent of P, less than or equal to 0.03 percent of S, and less than or equal to 0.5 percent of Cu.
6. A rotary valve rotor seal face online repair process as claimed in claim 4 wherein the chemical composition of the 2209 duplex stainless steel wire comprises: less than or equal to 0.03 percent of C, less than or equal to 0.95 percent of Si, less than or equal to 1.2 percent of Mn, 22-24 percent of Cr, 3-3.8 percent of Mo, 8.2-9.6 percent of Ni, less than or equal to 0.03 percent of P, less than or equal to 0.025 percent of S, and less than or equal to 0.4 percent of Cu.
7. A rotary valve rotor sealing surface on-line repairing process according to claim 1, wherein in the step (4), the RPF rotary valve rotor sealing surface is repaired by welding through an ABB mechanical arm, and a welding program is written to perform automatic welding.
8. A rotary valve rotor sealing surface on-line repairing process according to claim 1, wherein in the step (4), the RPF rotary valve rotor sealing surface is repaired by adopting a surrounding type welding method.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114310143A (en) * | 2021-12-14 | 2022-04-12 | 甘肃银光化学工业集团有限公司 | Method for repairing corrosion of sealing surface of compressor under strong acid working condition |
| CN114682999A (en) * | 2022-03-21 | 2022-07-01 | 中建隧道装备制造有限公司 | Remanufacturing process of central revolving body of shield tunneling machine |
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| CN114310143A (en) * | 2021-12-14 | 2022-04-12 | 甘肃银光化学工业集团有限公司 | Method for repairing corrosion of sealing surface of compressor under strong acid working condition |
| CN114682999A (en) * | 2022-03-21 | 2022-07-01 | 中建隧道装备制造有限公司 | Remanufacturing process of central revolving body of shield tunneling machine |
| CN114682999B (en) * | 2022-03-21 | 2023-07-28 | 中建隧道装备制造有限公司 | Remanufacturing process for central revolving body of shield tunneling machine |
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Application publication date: 20200317 |