CN113414392B - Preparation method of special-shaped pipeline based on 3D printing technology - Google Patents
Preparation method of special-shaped pipeline based on 3D printing technology Download PDFInfo
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- CN113414392B CN113414392B CN202110510130.XA CN202110510130A CN113414392B CN 113414392 B CN113414392 B CN 113414392B CN 202110510130 A CN202110510130 A CN 202110510130A CN 113414392 B CN113414392 B CN 113414392B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
- B22F5/106—Tube or ring forms
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/80—Data acquisition or data processing
- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M7/00—Vibration-testing of structures; Shock-testing of structures
- G01M7/02—Vibration-testing by means of a shake table
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N17/00—Investigating resistance of materials to the weather, to corrosion, or to light
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N19/00—Investigating materials by mechanical methods
- G01N19/04—Measuring adhesive force between materials, e.g. of sealing tape, of coating
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/91—Investigating the presence of flaws or contamination using penetration of dyes, e.g. fluorescent ink
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
- G01N23/02—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material
- G01N23/04—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and forming images of the material
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N3/08—Investigating strength properties of solid materials by application of mechanical stress by applying steady tensile or compressive forces
- G01N3/10—Investigating strength properties of solid materials by application of mechanical stress by applying steady tensile or compressive forces generated by pneumatic or hydraulic pressure
- G01N3/12—Pressure testing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
The invention relates to a preparation method of a special-shaped pipeline based on a 3D printing technology, which comprises the following steps of S10, selecting welding wires according to the service working condition of the special-shaped pipeline, and determining technological parameters; s20, welding the two trial-manufactured plates through welding wires and process parameters to obtain a plate-shaped process test piece, and evaluating the performance of the special-shaped pipeline; welding the two sections of trial pipes by welding wires and process parameters to obtain a tubular process test piece, and evaluating the shape and the size of the special-shaped pipeline; s30, judging whether the performance evaluation and the shape and the size meet the requirements or not; s40, printing the special-shaped pipeline, wherein layered liquid penetration detection and segmented ray detection are carried out in the printing process; and S50, carrying out application identification evaluation on the printed special-shaped pipeline. By performing a process assessment prior to pipe preparation; in the process of preparing the pipeline, defect detection is carried out; after the pipeline is prepared, application evaluation is carried out, so that qualified special-shaped pipelines are obtained, and 3D printing of various special-shaped pipelines can be realized through the method.
Description
Technical Field
The invention relates to the technical field of 3D printing of special-shaped pipelines, in particular to a preparation method of a special-shaped pipeline based on a 3D printing technology.
Background
The special-shaped pipeline has a complex structure and uneven wall thickness, and particularly needs higher performance requirements in the field of nuclear power, for example, an emergency diesel engine cooling water pipeline in nuclear power supervision equipment, when in use, the emergency diesel engine generator vibrates greatly during operation, so that the vibration of the cooling water pipeline is relatively large, cracks are easily generated under the vibration condition, and in addition, the phenomena of pipeline leakage, fracture and the like caused by material corrosion failure are easily generated due to the erosion of a long-term cooling water medium.
The metal 3D printing technology is a novel preparation technology, and can solve the problems of large mould opening difficulty, complex process and poor quality of the casting of the special-shaped pipeline, but lacks of applicable technology evaluation, detection and application evaluation methods.
Disclosure of Invention
Based on this, it is necessary to provide a method for preparing a special-shaped pipeline based on a 3D printing technology, aiming at the problem that the method for evaluating, detecting and applying the special-shaped pipeline prepared based on the 3D printing technology lacks a process evaluation method.
A preparation method of a special-shaped pipeline based on a 3D printing technology comprises the following steps:
s10, selecting welding wires according to the service working condition of the special-shaped pipeline, and determining technological parameters;
s20, welding the two trial-made plates through the welding wires and the process parameters to obtain a plate-shaped process test piece, and evaluating the performance of the special-shaped pipeline through the plate-shaped process test piece; welding the two sections of trial-manufactured pipes through the welding wires and the process parameters to obtain a tubular process test piece, and evaluating the shape and the size of the special-shaped pipeline through the tubular process test piece;
s30, when the performance evaluation meets the performance requirement required by the special-shaped pipeline in the service process and the shape and the size meet the shape and the size requirement required by the special-shaped pipeline in the service process, executing a step S40; otherwise, adjusting the technological parameters by controlling a variable method, and executing the step S20;
s40, printing the special-shaped pipeline through a 3D printing technology, wherein in the printing process, the in-layer defects of the special-shaped pipeline are detected through a layered liquid permeation detection method; detecting the defects in the special-shaped pipeline by a segmented ray detection method; and timely processing the abnormal-shaped pipeline with unqualified layer internal defect detection and internal defect detection.
And S50, carrying out application identification evaluation on the printed special-shaped pipeline.
In one embodiment, in step S20, the step of evaluating the performance of the profiled pipe through the plate-shaped process test piece includes:
s21, dividing the plate-shaped process test piece into a plurality of performance test samples by welding seams perpendicular to the plate-shaped process test piece;
and S22, respectively carrying out a tensile test, a bending test, an impact test, a surface hardness test and a metallographic test on the performance test samples.
In one embodiment, the performance test samples at least comprise two tensile test samples, two face bending test samples, two back bending test samples, at least one impact test sample and at least one spare test sample, wherein the two tensile test samples are two performance test samples which are not adjacent on the plate-shaped process test sample, the two face bending test samples are two performance test samples which are not adjacent on the plate-shaped process test sample, the two back bending test samples are two performance test samples which are not adjacent on the plate-shaped process test sample, and the spare test sample is used for performing a surface hardness test and a metallographic test.
In one embodiment, the performance requirements of the special-shaped pipeline in the service process in step S30 are as follows: when the tensile test is carried out, the tensile strength of a tensile sample is not lower than 500MPa, and the yield strength is not lower than 320MPa; when the bending test is carried out, the front surface of a face bending test sample is bent by 180 degrees, the back surface of a back bending test sample is bent by 180 degrees, wherein the lengths of single cracks, air holes or inclusions in the bent face bending test sample and the bent back surface test sample are not more than 3.0mm; when the impact test is carried out, the impact toughness value is more than or equal to 60J; when the surface hardness test is carried out, the range of the surface hardness is 170HB-230HB; when the metallographic test is carried out, the macroscopic metallographic test has no visible cracks, no incomplete penetration welding seams, no incomplete fusion welding seams and no pores with the size of more than or equal to 1mm, and the microscopic metallographic test: there should be no microcracking and no microstructure affecting the joint performance, with the microscopic metallographic examination being performed at a magnification of 200.
In one embodiment, the impact test comprises an impact test of a weld zone and an impact test of a heat affected zone.
In one embodiment, in step S20, the tubular process test piece includes two pipe sections welded in the vertical direction and two pipe sections welded in the horizontal direction.
In one embodiment, in step S40, the layered liquid penetration detection method specifically includes the steps of: and carrying out liquid permeation detection once when three layers of pipelines are printed, wherein the interlayer temperature ranges from 10 ℃ to 50 ℃ when the liquid permeation detection is carried out.
In one embodiment, in step S40, the intralayer defect includes: linear defect display and non-linear defect display larger than 4mm, display with edge spacing smaller than 3mm and 3 or more than 3 arranged in a straight line, and display with maximum side length not more than 20cm and area of 100cm 2 There are 5 or more than 5 dense displays in the rectangular area of (a), wherein a profiled conduit having any one or more defects thereon is shown to be a faulty profiled conduit.
In one embodiment, in step S40, the method for detecting segmented rays specifically includes the following steps: the special-shaped pipeline is divided into a plurality of sections according to the difference of wall thickness and structure, and then the ray detection is carried out on each section of the special-shaped pipeline.
In one embodiment, when the in-layer defects are detected, the in-layer defects are removed in time in a mechanical grinding mode; when the defect in the pipe is detected, the section of the special-shaped pipeline is marked as an abnormal pipe section.
In one embodiment, in step S50, the applying the qualification evaluation test comprises: the method comprises the following steps of hydrostatic test strength evaluation, dissimilar material contact stability evaluation, rusting comparison evaluation, vibration state influence evaluation, coating performance evaluation and anti-seismic evaluation.
According to the preparation method of the special-shaped pipeline based on the 3D printing technology, process evaluation is carried out before the pipeline is prepared; in the process of preparing the pipeline, defect detection is carried out; after the pipeline is prepared, application evaluation is carried out, so that a qualified special-shaped pipeline is obtained; the method comprises the steps of evaluating the performance of the special-shaped pipeline through a plate-shaped process test piece, and evaluating the shape and the size of the special-shaped pipeline through a tubular process test piece, namely, combining the two aspects to realize comprehensive evaluation of the preparation process of the special-shaped pipeline, wherein the plate-shaped process test piece and the tubular process test piece are formed by welding two plates or tubes and are consistent with the actual printing environment, the fusion problem of a molten metal welding wire and a cold metal plate or tube can be effectively verified, the complete process test piece does not need to be printed, and the process evaluation problem of arc additive 3D printing in the nuclear power field is solved.
Drawings
FIG. 1 is a flow chart of a method for manufacturing a special-shaped pipeline based on a 3D printing technology;
FIG. 2 is a schematic structural diagram of a cooling water pipeline of an emergency diesel engine;
FIG. 3 is a schematic sectional view of a cooling water pipeline of an emergency diesel engine in sectional ray detection according to an embodiment of the present invention;
10-a main body conduit; 20-a special-shaped part; 30-a first flange; 31-a first flange hole; 32-first bolt hole; 40-a second flange; 41-second flange hole; 42-second bolt hole; 50-convex ring.
Detailed Description
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.
In the description of the present invention, it is to be understood that the terms "central," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," "circumferential," and the like are used in the orientations and positional relationships indicated in the drawings for convenience in describing the invention and to simplify the description, and are not intended to indicate or imply that the referenced device or element must have a particular orientation, be constructed and operated in a particular orientation, and are not to be considered limiting of the invention.
Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "a plurality" means at least two, e.g., two, three, etc., unless specifically limited otherwise.
In the present invention, unless otherwise explicitly stated or limited, the terms "mounted," "connected," "fixed," and the like are to be construed broadly, e.g., as being permanently connected, detachably connected, or integral; can be mechanically or electrically connected; they may be directly connected or indirectly connected through intervening media, or they may be connected internally or in any other suitable relationship, unless expressly stated otherwise. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
In the present invention, unless otherwise expressly stated or limited, the first feature "on" or "under" the second feature may be directly contacting the first and second features or indirectly contacting the first and second features through an intermediate. Also, a first feature "on," "over," and "above" a second feature may be directly or diagonally above the second feature, or may simply indicate that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature may be directly under or obliquely under the first feature, or may simply mean that the first feature is at a lesser elevation than the second feature.
It will be understood that when an element is referred to as being "secured to" or "disposed on" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. As used herein, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and the like are for purposes of illustration only and do not denote a single embodiment.
An embodiment of the invention provides a method for preparing a special-shaped pipeline based on a 3D printing technology, taking an emergency diesel engine cooling water pipeline in nuclear power supervision equipment printed by the 3D printing technology as an example, referring to fig. 2, the emergency diesel engine cooling water pipeline comprises a main pipeline 10, a special-shaped part 20 arranged in the middle of the main pipeline 10 and a first flange 30 connected to one side of the special-shaped part 20, two convex rings 50 are further arranged on the main pipeline 10, one side of each convex ring 50 is connected with a second flange 40, the two convex rings 50 are symmetrically distributed on two sides of the special-shaped part 20, the middle of the special-shaped part 20 is of a concave structure, the first flange 30 and the special-shaped part 20 form a special-shaped three-way structure, first bolt holes 32 and first flange holes 31 are arranged on the first flange 30, second bolt holes 42 and second flange holes 41 are arranged on the second flange 40, and the diameter of the first flange 30 is larger than that of the second flange 40.
Referring to fig. 1, the emergency diesel engine cooling water pipeline manufacturing method based on the 3D printing technology includes:
s10, selecting welding wires according to the service working condition of the emergency diesel engine cooling water pipeline, and determining technological parameters;
the emergency diesel engine cooling water pipeline is prepared by adopting an arc additive technology in a 3D printing technology, wherein in order to avoid the problem that a molten pool can splash due to heat accumulation generated by continuous heat input in the melting and stacking process of welding wires, preferably, the emergency diesel engine cooling water pipeline is prepared by adopting a cold metal transition arc additive technology, wherein the working pressure of the emergency diesel engine cooling water pipeline is 6bar, the highest temperature is 95 ℃, the temperature at full power is 68-88 ℃, and the design temperature is 95 ℃ according to the consideration of a nuclear safety monitoring part; the working pressure-bearing strength of the special-shaped pipeline is not more than 500MPa, and a flowing medium in the special-shaped pipeline is ethylene glycol cooling liquid. Therefore, a carbon steel welding wire is selected as a raw material based on the principle of target part strength matching, preferably, the welding wire is an ER50-6 carbon steel welding wire, wherein the deposited metal mechanical properties of the ER50-6 carbon steel welding wire are as follows: the room temperature tensile strength is more than or equal to 500MPa, the room temperature yield strength is more than or equal to 420MPa, and the room temperature tensile rate is more than or equal to 22 percent, namely the requirement that the raw materials meet the normal service working condition of the special-shaped pipeline is met; in order to ensure good fusion performance between welding layers during overlaying welding, and the mechanical property of printed cooling water pipeline is good, the specification of the welding wire is phi 0.8mm-1.6mm, the length of the welding wire from the nozzle is 6mm-14mm at the beginning of each time, the distance between the tail end of the welding wire and the substrate is 3mm-7mm, the material adding current is 150A-190A, the wire feeding speed is 4.0m/min-6.0m/min, the material adding speed is 0.4m/min-0.6m/min, the volume fraction of the gas protection gas is 85 percent Ar +15 CO 2 The gas protection flow is 10L/min-20L/min.
The electric arc material increase technology takes electric arc as energy carrying beam, the volume of a molten pool is large in the manufacturing process, and disturbance factors such as material types, electric arc blowing force and power supply characteristics exist, so that the instability of the molten pool is enhanced. The ability to build up layers continuously and consistently is a prerequisite for achieving arc additive manufacturing, and therefore good reproducibility of the structure, composition, properties, etc. of each layer is required. Due to the particularities of the arc additive manufacturing process, the potential for performance organization anomalies in the actual product printing can still occur even if the process parameters are cured. For this purpose, it is necessary to verify or to justify the already cured process parameters by means of process assessment, in particular mechanical properties (product availability). However, as the electric arc additive manufacturing is applied to the emergency diesel engine cooling water pipeline in the nuclear-grade monitoring pipe component as a new technology, the technology is different from casting, forging and welding processes, and therefore, no process evaluation method is available.
Therefore, in the embodiment, the following process evaluation method is provided for the particularity of the arc additive process and the diesel engine cooling water pipeline, and specifically includes the steps of S20, welding two trial-made plates through the welding wire and the process parameters to obtain a plate-shaped process test piece, and evaluating the performance of the diesel engine cooling water pipeline through the plate-shaped process test piece; welding the two sections of trial pipes into a tubular process test piece through the welding wires and the process parameters, and evaluating the shape and the size of the diesel engine cooling water pipeline through the tubular process test piece;
specifically, electric arc additive belongs to a special process of fast thermal chilling, the accumulation of molding heat is serious, the heat dissipation condition is poor, and a moving molten pool is rapidly solidified under the conditions of ultrahigh temperature gradient and strong constraint, so that the shapes and orientations of crystal grains at different parts of parts and components, and the microstructure characteristics and the evolution rule are obviously changed. The consideration of the process evaluation is to consider whether the product structure state is abnormal under the process condition, and more importantly, how to ensure that the comprehensive mechanical property of any part of the whole part meets the requirement; meanwhile, the cooling water pipeline of the diesel engine is special in shape as a special-shaped tee joint structure, and how to ensure that parts can meet the size and shape of final requirements in the whole forming process in the preparation process, therefore, the invention realizes the requirement of controllability through a plate-shaped process test piece, realizes the requirement of shape control through a tubular process test piece, combines two schemes to comprehensively realize process evaluation, and in addition, the plate-shaped process test piece and the tubular process test piece are both formed by welding two plates or tubes, so that the complete process test piece does not need to be printed, the material is saved, and the time consumption is small.
The plate-shaped process test piece is characterized in that two test plates with the size of 520mm multiplied by 350mm are adopted, the process parameters in the step S10 and ER50-6 carbon steel welding wires are adopted to weld the two test plates, and the heat treatment is carried out by adopting the same process as the diesel engine cooling water pipeline; the inner diameter and the outer diameter of the section 4 of the tubular process test piece are consistent with those of the main pipeline 10 of the cooling water pipeline of the diesel engine.
When the performance evaluation meets the performance requirement required by the special-shaped pipeline in the service process and the shape and the size meet the shape and the size required by the special-shaped pipeline in the service process, executing a step S40; otherwise, adjusting the process parameters by controlling the variable method, and executing the step S20.
The performance requirements of the special-shaped pipeline in the service process are as follows: when the tensile test is carried out, the tensile strength of a tensile sample is not lower than 500MPa, and the yield strength is not lower than 320MPa; when the bending test is carried out, the front surface of the face bending test sample is bent by 180 degrees, the back surface of the back bending test sample is bent by 180 degrees, and the lengths of single cracks, air holes or inclusions in the bent face bending test sample and the bent back surface test sample are not more than 3.0mm; when the impact test is carried out, the impact strength is more than or equal to 60J; when the surface hardness test is carried out, the range of the surface hardness is 170HB-230HB; the metallographic test comprises a macroscopic metallographic test and a microscopic metallographic test, wherein the macroscopic metallographic test has no visible cracks, no penetration, no fusion and/or pores with the size of more than or equal to 1mm, and the microscopic metallographic test (amplification is 200 times): the presence of microcracks and/or anomalous structures affecting joint performance, including widmannstatten structures, hardened structures, etc., should be absent. If the test result does not meet the mechanical property requirement, firstly, whether sampling is reasonable and whether material selection of the welding wire is proper in process evaluation should be verified and confirmed; if no problem exists, the process parameters are readjusted by controlling a variable method, such as the wire feeding speed, the material increasing speed, the volume fraction proportion of the protective gas and the protective flow are not changed, and the structure and the performance of the raw material welding wire in the melting and solidifying process in the material increasing manufacturing process are further adjusted by adjusting the material increasing current, so that the mechanical property of the product part is changed.
In addition, the tubular process test piece should be capable of printing the desired straight tube section and be dimensionally compatible with the desired inner and outer diameter dimensions.
Because the inherent heat input of electric arc vibration material disk technique is big, easy deformation scheduling problem and the special outward appearance size structure of emergent diesel engine cooling water pipeline, emergent diesel engine cooling water pipeline is at the defect that printing in-process most probably appears including: the quality of the raw material welding wire is improperly controlled or the protective atmosphere is abnormal during printing, so that air holes are formed in the melting and solidifying process; non-fusion defects between layers or between tracks during printing; and the defect of inclusion layering caused by unclean cleaning of each layer is printed layer by layer. Performing final defect detection after printing is finished, wherein the detection method and the detection time are limited, so that in order to ensure the final shape and quality requirement of the part, the special-shaped pipeline is printed by a 3D printing technology as shown in step S40, wherein in the printing process, the in-layer defects of the special-shaped pipeline are detected by a layered liquid penetration detection method; detecting the defects in the special-shaped pipeline by a segmented ray detection method; and timely processing the abnormal-shaped pipeline with unqualified layer internal defect detection and internal defect detection.
Liquid permeation detection is carried out in a layered mode in the printing process, each layer of defects in the part printing process can be cleared in time, the defect that the defects in the layer cannot be effectively detected after parts are printed is overcome, and the defects of the whole part can be guaranteed.
Secondly, when the radiation detection is carried out, the radiation detection sensitivity is the comprehensive result of three major factors of the radiation detection contrast (the blackness difference between a defect image and the surrounding background), the unsharp (the width of a blackness transition area at the edge of the image outline) and the granularity (the uneven degree of the image blackness), and the three major factors are respectively influenced by different process factors.
And S50, carrying out application identification evaluation on the printed emergency diesel engine cooling water pipeline. The normal use operating mode of emergent diesel engine cooling water pipeline is simulated promptly, uses the aassessment through each item experiment to verify the application condition of the emergent diesel engine cooling water pipeline of preparing through 3D printing technique.
In some embodiments, in step S20, the step of evaluating the performance of the emergency diesel engine cooling water pipe through the plate-shaped process test piece includes:
s21, dividing the plate-shaped process test piece into a plurality of performance test samples by using a welding line perpendicular to the plate-shaped process test piece;
and S22, respectively carrying out a tensile test, a bending test, an impact test, a surface hardness test and a metallographic test on the performance test samples.
In some embodiments, the plurality of performance test specimens includes at least two tensile specimens, two bending specimens, two back bending specimens, at least one impact specimen, and at least one spare specimen, wherein the two tensile specimens are two performance test specimens that are not adjacent to the plate-shaped process specimen, the two bending specimens are two performance test specimens that are not adjacent to the plate-shaped process specimen, the two back bending specimens are two performance test specimens that are not adjacent to the plate-shaped process specimen, and the spare specimen is used for performing the surface hardness test and the metallographic test.
In some embodiments, the emergency diesel engine cooling water pipeline is printed by a 3D printing technology, and due to the special structure of the emergency diesel engine cooling water pipeline, in the 3D printing process, the pipeline needs to be printed in sections, for example, CB section is printed on the substrate firstly, then DE section is printed on the other side of the substrate, then F section is printed continuously on the basis of the DE section, and finally a section is printed on the basis of the CB section; therefore, in the printing process, a process of overlaying on a cooled pipe section or a substrate exists, for example, a process of printing a CB section and a DE section on the substrate, and a process of printing an a section on the basis of the CB section, wherein the substrate and the CB section are both cooled pipe sections, so that both the plate-shaped process test piece and the tubular process test piece are similar to the actual printing environment, that is, the plate-shaped process test piece is formed by overlaying between two cooled plate-shaped test pieces, so that the fusion problem of the molten metal welding wire and the cold metal plate or the pipe can be effectively verified, and therefore, the impact test of the embodiment also includes an impact test and a heat affected zone impact test of a weld zone, that is, the impact of the sectional printing on the toughness of the printed pipe section is comprehensively detected through the weld zone and the heat affected zone.
In some embodiments, in order to consider the shape control requirements of different welding directions, in step S20, the tubular process test piece includes two pipe sections welded in the vertical direction and two pipe sections welded in the horizontal direction, the welding in the vertical direction is used to simulate the welding process under the condition that the pipe diameter is unchanged, and the welding in the horizontal direction is used to simulate the welding process when a part of welding is suspended due to the increase of the pipe diameter.
In some embodiments, in step S40, the layered fluid penetration detection method specifically comprises the following steps: and carrying out liquid permeation detection once when three layers of pipelines are printed, wherein the interlayer temperature ranges from 10 ℃ to 50 ℃ when the liquid permeation detection is carried out.
Specifically, liquid penetration detection is performed once when each layer is actually printed to be about 1.5mm thick, and each layer is printed to be about 3 layers, namely about 4-5mm thick, impurities such as oxide skin and the like on the surface of the printing layer need to be cleaned once under normal conditions, if defects are seen by naked eyes after polishing and cleaning, the defects need to be treated in time, but other defects possibly occur due to frequent arc striking and arc withdrawing and fusion states between molten metal spreading and layer channels when the second layer is printed again on the basis of the first layer, and therefore the balance of efficiency, economy and defect detection can be achieved by performing liquid penetration detection once on every three layers. And each layer of defects can be timely removed in the part printing process, the defect that the defects in the layer can not be effectively detected after the parts are printed is overcome, and the defects of the whole part can be guaranteed.
In some embodiments, in step S40, failingEmergent diesel engine cooling water pipeline includes: linear defect display, nonlinear defect display larger than 4mm, defect display in which the edge distance between two adjacent defects is less than 3mm and 3 or more than 3 defects are arranged in a straight line, and defect display in which the maximum side length is not more than 20cm and the area is 100cm 2 There are 5 or more than 5 dense displays in the rectangular area of (a), wherein a profiled conduit having any one or more defects thereon appears to be an unacceptable profiled conduit. If unacceptable defects appear in the inspection, firstly, the types of the defects are confirmed, the defect generation reasons are searched, such as defect generation, quality control of welding wires, printing process parameters and other factors, the process parameters need to be further optimized and adjusted to ensure that the defects do not appear any more, and the defects in the layers are timely polished and removed in a mechanical polishing mode.
In some embodiments, in step S40, the specific steps of the segmented ray detection method are: and dividing the pipe section into a plurality of sections according to the wall thickness and the structure of each section on the special-shaped pipeline, and then respectively carrying out ray detection on each section of the special-shaped pipeline. Referring to fig. 3, for example, the pipe segment C and the pipe segment D have the same structure, during the printing process, the pipe segment C may be printed first, and the pipe segment C may be subjected to the radiation detection; then, printing the pipe section D on the basis of the pipe section C, carrying out ray detection on the pipe section CD, and comparing an imaging of the pipe section CD with the pipe section C to obtain the defect condition of the pipe section D; printing a printing pipe section E on the basis of the pipe section CD, then carrying out ray detection on the pipe section CDE, and comparing an imaged image of the pipe section CDE with the pipe section CD to obtain the defect condition of the pipe section E; printing a pipe section B on the basis of the pipe section CDE, then carrying out ray detection on the pipe section BCDE, and comparing an imaged image of the pipe section BCDE with the pipe section CDE to obtain the defect condition of the pipe section B; wherein, the normal pipe sections of the A and F sections can be detected according to a common ray detection method; it should be noted that the above-mentioned segmentation method is only one example, and the specific number of segments and the location of the segments are not limited herein, and when the internal defect is detected by the segmentation ray detection method, the abnormal segment of the special-shaped pipeline is marked as an abnormal segment and waits for recovery processing.
In some embodiments, in step S50, the applying a qualification assessment test comprises: hydraulic pressure strength evaluation, corrosion resistance evaluation, dissimilar material contact stability evaluation, vibration state influence evaluation, coating performance evaluation and anti-seismic evaluation.
Wherein, the evaluation of water pressure intensity carries out the hydrostatic test to the emergent diesel generator cooling water pipeline that the printing was accomplished promptly, ensures that the part of electric arc vibration material disk preparation satisfies the water pressure under the normal operating mode and bears the requirement, and hydrostatic test pressure is at least: 7.5bar, the pressure maintaining time is at least 30min, and pressure drop or leakage and permanent deformation should not occur in the test process;
because the cooling water pipeline of the emergency diesel generator is changed into the ER50-6 carbon steel welding wire, the parts which are assembled and contacted with the cooling water pipeline are considered, the galvanic corrosion of the printed cooling water pipeline material of the emergency diesel generator and the nodular cast iron material connected with the cooling water pipeline material of the emergency diesel generator is researched, and the pipeline leakage or failure caused by the contact galvanic corrosion in the long-term service process is avoided;
a rust contrast test, namely immersing the printed emergency diesel generator cooling water pipeline and the original emergency diesel generator cooling water pipeline in an experimental solution for 48 hours, placing the two pipelines in the air for at least 24 hours without drying, and then performing appearance state contrast evaluation;
the diesel engine belongs to multi-cylinder reciprocating power machinery, the vibration of a body is large during operation, especially, the occurrence of abnormal vibration can cause the vibration amplitude of a cooling water pipe section connected with the body to be overlarge, and further, a failure mode of pipe section leakage or breakage occurs, therefore, vibration stress testing needs to be carried out on the printed cooling water pipe, if stress levels under three working conditions of continuous load, continuous load + thermal expansion load, continuous load + accidental load are considered, and the printed pipe can meet the operation vibration working condition of the diesel engine.
According to the general requirement of emergency diesel engine coating, the verification of the coating performance is carried out on the cooling water pipeline, the thickness of the paintable film is ensured, and the specific process is as follows: firstly, spraying the surface of the cooling water pipeline, then coating, and then testing the adhesive force of a paint film by a pull-open method, wherein the adhesive force is at least more than 2.0MPa.
The emergency diesel engine belongs to anti-seismic equipment, anti-seismic identification is needed to be carried out on the printed cooling water pipeline, anti-seismic calculation is carried out through anti-seismic software, and anti-seismic evaluation verification of the cooling water pipeline section is completed.
It should be noted that the invention is not limited to the printing of the emergency diesel generator cooling water pipeline, but also can be the printing of special-shaped pipelines for other purposes, such as various pressure pipelines, medium pipelines, special-shaped pipe joints and the like, and the process evaluation is carried out before the pipeline preparation; in the process of preparing the pipeline, defect detection is carried out; after the pipeline is prepared, application evaluation is carried out, so that qualified special-shaped pipelines are obtained, and 3D printing of various special-shaped pipelines can be realized through the method.
All possible combinations of the technical features of the above embodiments may not be described for the sake of brevity, but should be considered as within the scope of the present disclosure as long as there is no contradiction between the combinations of the technical features.
The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that various changes and modifications can be made by those skilled in the art without departing from the spirit of the invention, and these changes and modifications are all within the scope of the invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (9)
1. A preparation method of a special-shaped pipeline based on a 3D printing technology is characterized by comprising the following steps:
s10, selecting welding wires according to the service working condition of the special-shaped pipeline, and determining technological parameters; the special-shaped pipeline is an emergency diesel engine cooling water pipeline; the emergency diesel engine cooling water pipeline is prepared by adopting an electric arc additive technology in a 3D printing technology; the emergency diesel engine cooling water pipeline has the working pressure of 6bar, the highest temperature of 95 ℃, the temperature of 68-88 ℃ at full power, the design temperature of 95 ℃, the working pressure-bearing strength of not more than 500MPa, and a flowing medium in the pipeline is glycol cooling liquid; selecting the raw material of the welding wire as a carbon steel welding wire based on the strength matching principle of the target part;
s20, welding the two trial-made plates through the welding wires and the process parameters to obtain a plate-shaped process test piece, and evaluating the performance of the special-shaped pipeline through the plate-shaped process test piece, wherein the step of evaluating the performance of the special-shaped pipeline through the plate-shaped process test piece comprises the following steps: s21, dividing the plate-shaped process test piece into a plurality of performance test samples by using a welding line perpendicular to the plate-shaped process test piece; s22, respectively carrying out a tensile test, a bending test, an impact test, a surface hardness test and a metallographic test on the performance test samples;
welding the two sections of trial pipes through the welding wires and the process parameters to obtain a tubular process test piece, and evaluating the shape and the size of the special-shaped pipeline through the tubular process test piece, wherein the tubular process test piece can be used for printing a required straight pipe section, and the size of the tubular process test piece meets the required inner diameter and outer diameter;
s30, when the performance evaluation meets the performance requirement of the special-shaped pipeline in the service process and the shape and the size meet the shape and the size requirement of the special-shaped pipeline in the service process, executing a step S40; otherwise, adjusting the technological parameters by controlling a variable method, and executing the step S20;
s40, printing the special-shaped pipeline through a 3D printing technology, wherein in the printing process, the in-layer defects between layers of the special-shaped pipeline are detected through a layered liquid permeation detection method; detecting the defects in the special-shaped pipeline by a sectional ray detection method; and timely processing abnormal pipelines with unqualified in-layer defect detection and internal defect detection; when the defects in the layer are detected, the defects in the layer are removed in time in a mechanical grinding mode; when the defects in the pipe are detected, the special-shaped pipeline is marked as an abnormal pipe section;
and S50, carrying out application identification evaluation test on the printed special-shaped pipeline.
2. The method for preparing the special-shaped pipeline based on the 3D printing technology as claimed in claim 1, wherein the plurality of performance test samples at least comprise two tensile test samples, two face bending test samples, two back bending test samples, at least one impact test sample and at least one spare test sample, wherein the two tensile test samples are two performance test samples which are not adjacent on the plate-shaped process test sample, the two face bending test samples are two performance test samples which are not adjacent on the plate-shaped process test sample, the two back bending test samples are two performance test samples which are not adjacent on the plate-shaped process test sample, and the spare test sample is used for performing a surface hardness test and a metallographic test.
3. The method for preparing the special-shaped pipeline based on the 3D printing technology according to claim 1, wherein in the step S30, the required performance requirements of the special-shaped pipeline in the service process are as follows: when the tensile test is carried out, the tensile strength of a tensile sample is not lower than 500MPa, and the yield strength is not lower than 320MPa; when the bending test is carried out, the front surface of a face bending test sample is bent by 180 degrees, the back surface of a back bending test sample is bent by 180 degrees, wherein the lengths of single cracks, air holes or inclusions in the bent face bending test sample and the bent back surface test sample are not more than 3.0mm; when the impact test is carried out, the impact strength is more than or equal to 60J; when the surface hardness test is carried out, the range of the surface hardness is 170HB-230HB; when the metallographic test is carried out, the macroscopic metallographic test has no visible cracks, no incomplete penetration welding seams, no incomplete fusion welding seams and no pores with the size of more than or equal to 1mm, and the microscopic metallographic test: there should be no microcracking and no microstructure affecting the joint performance, with the microscopic metallographic examination being performed at a magnification of 200.
4. The method for preparing the profiled pipeline based on the 3D printing technology as claimed in claim 3, wherein the impact test comprises an impact test of a weld zone and an impact test of a heat affected zone.
5. The method for preparing the special-shaped pipeline based on the 3D printing technology is characterized in that in the step S20, the tubular process test piece comprises two sections of pipe sections welded along the vertical direction and two sections of pipe sections welded along the horizontal direction.
6. The method for preparing the special-shaped pipeline based on the 3D printing technology according to the claim 1, wherein in the step S40, the layered liquid penetration detection method comprises the following specific steps: and carrying out liquid permeation detection once when three layers of pipelines are printed, wherein the interlayer temperature of the three layers of pipelines ranges from 10 ℃ to 50 ℃ when liquid permeation detection is carried out.
7. The method for preparing the special-shaped pipeline based on the 3D printing technology is characterized in that in the step S40, the in-layer defects comprise: linear defect display, non-linear defect display larger than 4mm, defect display in which the edge distance is smaller than 3mm and 3 or more than 3 are arranged in a straight line, and defect display in which the maximum side length is not more than 20cm and the area is 100cm 2 There are 5 or more than 5 dense defect indications in the rectangular area of (a), wherein the profiled conduit has any one or more defect indications thereon that are unacceptable.
8. The method for preparing the special-shaped pipeline based on the 3D printing technology according to the claim 1, wherein in the step S40, the step of the segmented ray detection method comprises the following specific steps: the special-shaped pipeline is divided into a plurality of sections according to the difference of wall thickness and structure, and then the ray detection is carried out on each section of the special-shaped pipeline.
9. The method for preparing the profiled pipeline based on the 3D printing technology as claimed in claim 1, wherein in step S50, the application identification evaluation test comprises: the method comprises the following steps of hydrostatic test strength evaluation, dissimilar material contact stability evaluation, rusting comparison evaluation, vibration state influence evaluation, coating performance evaluation and anti-seismic evaluation.
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| KR101298656B1 (en) * | 2011-03-30 | 2013-08-21 | 한국지역난방공사 | Shape tube for district heating heat pipe having shear control ring |
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