CN114012267A - Gas turbine high-temperature component crack damage laser-electric arc hybrid welding method - Google Patents
Gas turbine high-temperature component crack damage laser-electric arc hybrid welding method Download PDFInfo
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- CN114012267A CN114012267A CN202111402113.0A CN202111402113A CN114012267A CN 114012267 A CN114012267 A CN 114012267A CN 202111402113 A CN202111402113 A CN 202111402113A CN 114012267 A CN114012267 A CN 114012267A
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- 238000003466 welding Methods 0.000 title claims abstract description 132
- 238000000034 method Methods 0.000 title claims abstract description 50
- 238000010891 electric arc Methods 0.000 title claims abstract description 31
- 239000000945 filler Substances 0.000 claims abstract description 19
- 239000002131 composite material Substances 0.000 claims abstract description 15
- 230000008569 process Effects 0.000 claims abstract description 8
- 230000008439 repair process Effects 0.000 claims description 21
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 8
- 230000004927 fusion Effects 0.000 claims description 6
- 238000005498 polishing Methods 0.000 claims description 6
- 238000004140 cleaning Methods 0.000 claims description 5
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 claims description 4
- 239000002932 luster Substances 0.000 claims description 4
- 230000001681 protective effect Effects 0.000 claims description 4
- 244000137852 Petrea volubilis Species 0.000 claims description 3
- 229910000856 hastalloy Inorganic materials 0.000 claims description 3
- 238000004506 ultrasonic cleaning Methods 0.000 claims description 3
- 230000007547 defect Effects 0.000 abstract description 11
- 238000003756 stirring Methods 0.000 abstract description 11
- 230000008901 benefit Effects 0.000 abstract description 5
- 230000001808 coupling effect Effects 0.000 abstract 1
- 238000005272 metallurgy Methods 0.000 abstract 1
- 239000000306 component Substances 0.000 description 27
- 230000000694 effects Effects 0.000 description 6
- 239000000463 material Substances 0.000 description 6
- 239000011148 porous material Substances 0.000 description 5
- 229910045601 alloy Inorganic materials 0.000 description 4
- 239000000956 alloy Substances 0.000 description 4
- 230000007704 transition Effects 0.000 description 3
- 230000007246 mechanism Effects 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 239000010754 BS 2869 Class F Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
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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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/346—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding
- B23K26/348—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding in combination with arc heating, e.g. TIG [tungsten inert gas], MIG [metal inert gas] or plasma welding
Abstract
The invention discloses a laser-arc hybrid welding method for crack damage of a high-temperature component of a gas turbine, belonging to the technical field of metallurgy. The method combines the advantages of a laser stirring welding head and an electric arc composite filler wire, can increase laser spots and reduce air hole defects, further improves the width of a molten pool and the filling property of a welding seam by utilizing the coupling effect of a stirring laser beam and the electric arc filler wire, effectively solves the outstanding problems of poor adaptability of a crack gap, high air hole rate and the like existing in the process of repairing crack damage of a high-temperature component of a gas turbine by welding in the traditional single laser welding, and finally obtains the welding seam which is wide at the top and narrow at the bottom, slightly convex at the front and back, full in filling and free of air hole defects. The method is simple to operate, reliable, high in applicability and universality and high in economy, and can fully meet the repairing requirement of large-gap crack damage of the high-temperature component of the gas turbine.
Description
Technical Field
The invention belongs to the technical field of automatic welding, and particularly relates to a laser-electric arc hybrid welding method for crack damage of a high-temperature part of a gas turbine.
Background
High-temperature components such as a gas turbine flame tube, a transition section, a turbine stator blade, a retaining ring and the like are used as core components of the gas turbine, and are the components with the worst working environment, the most complex structure, the most faults and the highest replacement cost. The high-temperature parts are in service under the conditions of long-time high temperature, high stress and frequent start and stop, and the high-temperature parts inevitably generate different degrees of crack damage (crack gaps are as high as 3mm), thereby seriously influencing the service safety of the high-temperature parts. In order to reduce the rejection rate of high-temperature components and ensure the economical and safe operation of gas turbine power generation equipment, the repairing method of the crack damage of the high-temperature components of the gas turbine has been paid attention by researchers at home and abroad.
Laser welding has become the primary fusion weld repair method for class F gas turbine hot path components. However, the laser welding has more strict requirements on assembly gaps than the traditional fusion welding process, the gaps are generally required to be controlled within 10-15% of the plate thickness, the maximum gap cannot exceed 0.3mm, and a single laser beam is easy to cause the generation of pore defects of welding seams, so that the rejection rate of workpieces is provided, and the application of the laser welding in the field of large-gap crack welding repair of high-temperature components is limited. According to the characteristics of large range of thickness of the high-temperature component substrate, large crack gap and the like, the laser welding head with a simple structure, better adaptability and larger spot diameter is explored, the welding efficiency is improved, the repair cost is reduced, and the method is a development trend of the future hot channel component welding repair technology.
Disclosure of Invention
The invention aims to overcome the defects of the prior art that the invention provides a gas turbine high-temperature component crack damage laser-arc hybrid welding method, and effectively solves the problems of poor crack gap adaptability and high porosity of a single laser beam welding head.
The invention is realized by the following technical scheme:
a laser-arc hybrid welding method for crack damage of a high-temperature component of a gas turbine comprises the following steps:
and 4, in the welding process, controlling the swing frequency and swing diameter of the laser spot to enable the spot path to be a spiral welding path, enabling the electric arc filler wire and the laser spot to be coupled to melt the welding wire to increase the fusion width, and performing single-side and single-pass filler wire welding and double-side forming along the direction of the slotted hole to finish the crack damage repair of the workpiece to be repaired.
Preferably, the open slots in step 1 are V-shaped or I-shaped slots.
Preferably, the slope of the slot is 60-90 degrees, and the gap between the bottom surfaces of the slot is 3mm at most.
Preferably, the grinding and cleaning method in step 1 is as follows:
and (3) polishing the surface area of the crack and the part nearby by using sand paper to obtain metallic luster, and then carrying out ultrasonic cleaning in acetone and dilute hydrochloric acid.
Preferably, the welding parameters in step 3 are as follows: the laser power is 2000-5000A, the arc current is 80A-180A, the welding speed is 10-30 mm/s, the wire speed is 20-120 mm/s, and the front rake angle of the welding gun is 60-90 degrees.
Preferably, in the step 4, the swing diameter is 0.3-3 mm, and the swing frequency is 10-300 HZ.
Preferably, the swing position of the laser spot in the step 4 is within a range of +/-0.5 mm of the bottom surface gap of the slotted hole.
Preferably, the material of the repairing workpiece is Hastelloy X, HS-188, Nimonic263, SS309, RA333, Tomilloy, FSX414, GTD111, GTD222, MGA1400, MAR-M200Hf or MAR-M002.
Preferably, the thickness of the repairing workpiece is 3-12 mm.
Compared with the prior art, the invention has the following beneficial technical effects:
the invention relates to a gas turbine high-temperature component crack damage laser-electric arc composite welding method, which combines a laser stirring welding head and an electric arc composite filler wire, and couples the laser stirring welding head with the electric arc filler wire by controlling an output path of the laser. On the other hand, the advantages of electric arc wire filling are combined, welding wires are continuously fed into a molten pool, a good filling effect is achieved on crack welding seams, meanwhile, the input of electric arcs can further increase the fusion width, the adaptability of the welding method to crack gaps is improved, and finally the welding seams which are wide at the top and narrow at the bottom, slightly convex at the front and back, full in filling and free of pore defects are obtained. The laser welding repair method is more suitable for pore-free defect repair of larger-gap cracks of medium plate components, and overcomes the prominent problems of poor crack gap adaptability, high porosity and the like of the traditional single laser filler wire welding of high-temperature alloy.
Drawings
FIG. 1 is a laser stir-arc hybrid welding repair process for crack damage of a high-temperature component of a gas turbine according to an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of a laser stir-arc hybrid welding joint for crack damage of a high temperature component of a gas turbine according to the present invention;
FIG. 3 shows the weld morphology after the laser stirring-arc hybrid welding head and the traditional single laser welding head weld repair the crack damage of the turbine stationary blade material.
In the figure: 1-swinging the laser welding head; 101-collimating lens; 102-Y axis oscillating lens; 103-X axis oscillating mirror; 104-Y axis drive motor; 105-X axis drive motor; 106-focusing lens; 2-arc welding gun; 3-welding gun clamping ring; 4-wire feeding mechanism; 5-arc welding power supply; 6-spot and puddle area.
Detailed Description
In order to make the technical solutions of the present invention better understood, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It should be noted that the terms "first," "second," and the like in the description and claims of the present invention and in the drawings described above are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used is interchangeable under appropriate circumstances such that the embodiments of the invention described herein are capable of operation in sequences other than those illustrated or described herein. Furthermore, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed, but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.
Referring to fig. 1-3, a crack damage laser-arc hybrid welding method for a high temperature component of a gas turbine includes the following steps:
Specifically, the cross section of a crack of a workpiece is corrected into a V-shaped or I-shaped slotted hole by adopting a mechanical polishing method, the gradient of the slotted hole is 60-90 degrees, the maximum clearance of the bottom surface of the slotted hole is 3mm, then the crack and the surface area of the part nearby the crack are polished to have metallic luster by using abrasive paper, and finally ultrasonic cleaning is carried out in acetone and dilute hydrochloric acid.
Step 2: fixing the parts to be welded and introducing protective gas to the back of the area to be welded.
Specifically, a workpiece to be repaired is fixed by a welding tool clamp, so that the workpiece to be repaired is accurately positioned and clamped, and the workpiece to be repaired is prevented from deforming in the welding process.
And 3, adjusting the laser-electric arc composite welding head to enable the formed laser spot to be positioned at the center of the slotted hole, and then setting welding parameters.
The welding parameters were as follows: the laser power is 2000-5000A, the arc current is 80A-180A, the welding speed is 10-30 mm/s, the wire speed is 20-120 mm/s, and the front rake angle of the welding gun is 60-90 degrees.
And 4, in the welding process, controlling the swing frequency and swing radian of the laser spots to enable the laser spot paths to be spiral welding paths, simultaneously enabling the electric arc filler wires to be coupled with the laser spots, and performing single-pass filler wire welding on the single surface and double-surface forming along the direction of the slotted holes to finish crack damage repair of the workpiece to be repaired.
The swing radian is 0-3 mm, and the swing frequency is 10-300 HZ.
Under the condition of a certain crack gap, the swing radian of the laser spot is within +/-0.5 mm of the bottom surface gap of the slotted hole, and the heat input of welding can be reduced by selecting proper laser power, arc current and swing frequency.
The workpiece is made of Hastelloy X, HS-188, Nimonic263, SS309, RA333, Tomilloy, FSX414, GTD111, GTD222, MGA1400, MAR-M200Hf, MAR-M002 and the like, and the thickness is 3-12 mm.
The workpiece is a high-temperature part of the gas turbine and comprises a flame tube, a transition section, a fuel nozzle, a turbine stator blade and the like.
The invention relates to a gas turbine high-temperature component crack damage laser-electric arc composite welding method, which combines a laser stirring welding head and an electric arc composite filler wire, and couples the laser stirring welding head with the electric arc filler wire by controlling an output path of the laser. On the other hand, the advantages of electric arc wire filling are combined, welding wires are continuously fed into a molten pool, a good filling effect is achieved on crack welding seams, meanwhile, the input of electric arcs can further increase the fusion width, the adaptability of the welding method to crack gaps is improved, and finally the welding seams which are wide at the top and narrow at the bottom, slightly convex at the front and back, full in filling and free of pore defects are obtained. The laser welding repair method is more suitable for pore-free defect repair of larger-gap cracks of medium plate components, and overcomes the prominent problems of poor crack gap adaptability, high porosity and the like of the traditional single laser filler wire welding of high-temperature alloy. Taking a service turbine stator blade material as an example, when the crack gap is 3.0mm, the welding repair method is applied to obtain the large-gap crack weld joint of the turbine stator blade, wherein the front side and the back side of the large-gap crack weld joint are slightly convex and full without pore defects.
The welding method is particularly suitable for the crack welding repair of high-temperature components of active E-grade, F-grade and even H-grade gas turbines, is used for the welding repair of crack damage of the high-temperature components of main gas turbines such as flame tubes, transition sections, turbine stator blades and the like of the active heavy-duty gas turbines, and has extremely strong universality. The crack damage of the high-temperature component is a main consideration factor for determining whether the component can be continuously used, so the method is used for repairing the high-temperature component, and can be continuously used for the next overhaul period after being repaired, thereby reducing the rejection rate of the component, bringing great economic benefit and having wide application prospect. The main procedures of the method comprise groove processing, part fixing and laser welding, the main welding repair processes of different high-temperature parts are basically the same, and the method is simple to operate, reliable, high in applicability and universality and convenient for flow operation.
Referring to fig. 2, the laser-arc hybrid welding head in step 3 comprises a swinging laser welding head 1, an arc welding gun 2 and a welding gun clamping ring 3; a collimating lens 101, an X-axis reflecting lens 103, a Y-axis reflecting lens 102 and a focusing lens 106 are arranged in the swinging laser welding head 1, the collimating lens 101 is positioned on an output light path of laser, the X-axis reflecting lens 103 is positioned on a reflected light path of the collimating lens 101, the Y-axis reflecting lens 102 is positioned on the reflected light path of the X-axis reflecting lens 103, and the focusing lens 106 is positioned on the reflected light path of the X-axis reflecting lens 103 to sequentially form a laser transmission light path of the laser welding head from top to bottom; the X-axis mirror 103 and the Y-axis mirror 102 respectively realize the swinging of the X-axis mirror and the Y-axis mirror through an X-axis driving motor 105 and a Y-axis driving motor 104 to form a required light spot path, thereby achieving the effects of amplifying laser light spots and stirring a molten pool; the electric arc welding gun is connected with an arc welding power supply and a wire feeding mechanism, the swinging laser welding head is connected with the welding gun through a welding gun clamping ring, and a welding wire 201 sent out by the electric arc welding gun is always kept in the molten pool area 6.
The laser-electric arc composite welding head realizes the swinging of a laser beam along an X axis and a Y axis through a driving motor, a welding gun clamping ring is connected with a welding gun, and a stirring laser beam output by the welding gun is coupled with an electric arc filler wire to enable a molten pool to be wider and filled fully, so that the laser welding repairing method is more suitable for pore-free defect repairing of larger-gap cracks of medium plate parts, and overcomes the prominent problems of poor crack gap adaptability, high porosity and the like of the traditional single laser filler wire welding of high-temperature alloy.
Example 1
Forming a V-shaped slotted hole in an FSX414 high-temperature alloy test plate material used for a turbine stationary blade with the thickness of 6mm, wherein the bottom surface clearance of the slotted hole is 3.0 mm; polishing the V-shaped groove hole and the surface area of the material nearby the V-shaped groove hole with sand paper to obtain metallic luster, and then ultrasonically cleaning the V-shaped groove hole and the surface area of the material nearby the V-shaped groove hole in acetone and dilute hydrochloric acid to remove dirt, oil stains, dust and the like; fixing a test plate by using a flat plate tool with a cooling system, and introducing protective gas to the back surface, wherein the gas flow is 25L/min; the swing radian is 2.5mm, the swing frequency is 150HZ, the laser power is 3500A, the arc current is 145A, the welding speed is 12mm/s, the wire speed is 70mm/s, and the forward rake angle of the welding gun is 60 degrees. After welding, the welding seam with the upper width of about 3.8mm and the lower width of about 1.3mm, good molding, full filling and no pore defect is obtained.
FIG. 3 is a graph comparing the effects of using the laser-arc hybrid bond of the present invention and a conventional single laser bond to repair crack damage in a turbine stator blade, where FIG. 3a is a graph of the weld using the laser stir-arc hybrid bond, and FIG. 3b is a graph of the weld using a conventional single laser bond. The cross section of the welding seam obtained by the laser stirring-electric arc composite welding head is Y-shaped, but the welding seam obtained by the laser stirring-electric arc composite welding head is wider, the front width of the welding seam obtained by the laser stirring-electric arc composite welding head is about 8-10 times of the front width of the welding seam obtained by the traditional single laser welding head, and the welding seam is attributed to the effects of amplifying laser spots, stirring a molten pool, coupling electric arc filler wires and laser to increase the width of the molten pool and the like of the laser stirring-electric arc composite welding head.
The invention relates to a gas turbine high-temperature component crack damage laser-electric arc composite welding method, which combines the advantages of a novel laser stirring welding head and an electric arc composite filler wire, not only considers the thickness difference and the crack gap size of different gas turbine components, but also can finally form a large T-shaped nail head-shaped welding joint with good welding line forming, full appearance and performance meeting the requirements through a method of grooving, laser stirring welding heads and electric arc filler wires, and has strong applicability. Meanwhile, the welding repair method provided by the invention is simple to operate, reliable, high in applicability and universality, convenient for flow operation and capable of meeting the repair requirement of the crack damage of the high-temperature component of the gas turbine.
The above-mentioned contents are only for illustrating the technical idea of the present invention, and the protection scope of the present invention is not limited thereby, and any modification made on the basis of the technical idea of the present invention falls within the protection scope of the claims of the present invention.
Claims (9)
1. A laser-arc hybrid welding method for crack damage of a high-temperature component of a gas turbine is characterized by comprising the following steps of:
step 1, opening an open type slotted hole along a crack of a workpiece to be repaired, and polishing and cleaning the slotted hole;
step 2, fixing the workpiece and introducing protective gas to the back of the area to be welded;
step 3, adjusting the laser-electric arc composite welding head to enable the formed laser spot to be positioned at the center of the slotted hole, and then setting welding parameters;
and 4, in the welding process, controlling the swing frequency and swing diameter of the laser spot to enable the spot path to be a spiral welding path, enabling the electric arc filler wire and the laser spot to be coupled to melt the welding wire to increase the fusion width, and performing single-side and single-pass filler wire welding and double-side forming along the direction of the slotted hole to finish the crack damage repair of the workpiece to be repaired.
2. The method for performing crack damage laser-arc hybrid welding on the high-temperature component of the gas turbine as claimed in claim 1, wherein the open-type slot hole in the step 1 is a V-type or I-type slot hole.
3. The laser-arc hybrid welding method for crack damage of high-temperature components of gas turbines as claimed in claim 2, wherein the slope of the slots is 60 ° to 90 °, and the gap between the bottom surfaces of the slots is at most 3 mm.
4. The laser-arc hybrid welding method for the crack damage of the high-temperature gas turbine component as claimed in claim 1, wherein the grinding and cleaning method in step 1 is as follows:
and (3) polishing the surface area of the crack and the part nearby by using sand paper to obtain metallic luster, and then carrying out ultrasonic cleaning in acetone and dilute hydrochloric acid.
5. The laser-arc hybrid welding method for the crack damage of the high-temperature gas turbine component as claimed in claim 1, wherein the welding parameters in the step 3 are as follows: the laser power is 2000-5000A, the arc current is 80A-180A, the welding speed is 10-30 mm/s, the wire speed is 20-120 mm/s, and the front rake angle of the welding gun is 60-90 degrees.
6. The laser-arc hybrid welding method for the crack damage of the high-temperature component of the gas turbine as claimed in claim 1, wherein the swing diameter in step 4 is 0.3-3 mm, and the swing frequency is 10-300 Hz.
7. The laser-arc hybrid welding method for the crack damage of the high-temperature component of the gas turbine as claimed in claim 1, wherein the swing position of the laser spot in the step 4 is within ± 0.5mm of the gap of the bottom surface of the slot.
8. The laser-arc hybrid welding method for crack damage of high-temperature components of gas turbines as claimed in claim 1, wherein the repair workpieces are made of Hastelloy X, HS-188, Nimonic263, SS309, RA333, Tomilloy, FSX414, GTD111, GTD222, MGA1400, MAR-M200Hf or MAR-M002.
9. The laser-arc hybrid welding method for the crack damage of the high-temperature component of the gas turbine as claimed in claim 8, wherein the thickness of the repaired workpiece is 3-12 mm.
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CN103056533A (en) * | 2012-12-20 | 2013-04-24 | 华中科技大学 | Oscillatory scanning laser beam-electric arc hybrid welding method and system |
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CN110102898A (en) * | 2019-03-24 | 2019-08-09 | 北京工业大学 | A kind of compound molten welding method of laser scanning-TIG |
CN112453703A (en) * | 2020-11-25 | 2021-03-09 | 南京航空航天大学 | Complex special-shaped structure remote laser welding method based on visual sensing |
CN112453709A (en) * | 2020-11-20 | 2021-03-09 | 西安热工研究院有限公司 | Welding method for crack damage of deformed high-temperature alloy thin-wall part |
CN113146046A (en) * | 2021-04-14 | 2021-07-23 | 华中科技大学 | Ultrahigh-power laser-arc/welding wire double-swing welding method and device |
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2021
- 2021-11-19 CN CN202111402113.0A patent/CN114012267A/en active Pending
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CN103056533A (en) * | 2012-12-20 | 2013-04-24 | 华中科技大学 | Oscillatory scanning laser beam-electric arc hybrid welding method and system |
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