CN114101848B - Welding method for repairing thin-wall cracks of metal component - Google Patents
Welding method for repairing thin-wall cracks of metal component Download PDFInfo
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- CN114101848B CN114101848B CN202111659581.6A CN202111659581A CN114101848B CN 114101848 B CN114101848 B CN 114101848B CN 202111659581 A CN202111659581 A CN 202111659581A CN 114101848 B CN114101848 B CN 114101848B
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- 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
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Abstract
The invention belongs to the technical field of welding, and discloses a welding method for repairing a thin-wall crack of a metal component, which comprises the steps of firstly carrying out self-fluxing welding on the crack to realize the closure of the crack; then, respectively carrying out crack arrest welding on two ends of a self-melting welding bead formed by the self-melting welding, wherein the crack arrest welding bead formed by the crack arrest welding is approximately vertical to the self-melting welding bead, and the distance between the crack arrest welding bead and the end part of the self-melting welding bead and the length of the crack arrest welding bead are preferably limited; in addition, before crack arrest welding, multiple transverse overlaying or longitudinal overlaying can be carried out on the self-fluxing welding bead to increase the thickness and strength of the repair area. The invention provides a related process of crack arrest welding, namely, a crack arrest welding bead is added at the front end of a repaired crack to manufacture a compressive stress area, so that the continuous expansion of the crack loses driving force, and the purpose of crack arrest is realized; and moreover, crack arrest welding and overlay welding repair technologies can be combined, so that the on-site rapid repair of penetrating crack defects of some thin-wall components can be realized, and a good effect is finally obtained.
Description
Technical Field
The invention belongs to the technical field of welding, and particularly relates to a method for quickly repairing a crack defect of a metal structure.
Background
The stress corrosion crack or the fatigue crack is easy to generate at the stress concentration part of the large-scale equipment such as nuclear power and the like under special and complex environment and stress condition. A common weld repair method for stress corrosion cracking is a cut repair weld, but residual stress resulting from weld repair may still have some effect on joint life. Moreover, crack excavation repair welding cannot be adopted for some special conditions, for example, a primary loop system in nuclear power equipment has a corrosion cracking defect formed from the inside of a pipeline to the outside, and the defect excavation can cause a large cavity to cause corrosion media to leak. Therefore, overlay welding ("overlay") repair techniques have been developed, i.e., a weld pass is directly welded at the position where leakage occurs, so as to bury crack defects inside and prevent further leakage.
In addition, because titanium and titanium alloy have high strength, density little, corrosion-resistant, non-magnetic, welding property good, sound transmission, impact resistance good and so on merit, especially have good corrosion resistance in sea water, marine environment, titanium surface can form a layer of very thin and firm oxide film, make titanium passivation not by sea water corrosion. The titanium passivation film has good self-healing property, and can be quickly and automatically repaired to form a new protective film after being damaged or scratched. It is this oxide film that protects the titanium from seawater corrosion, and the titanium can completely resist the corrosion of natural seawater without chemical changes and contamination. Compared with stainless steel, aluminum alloy and copper alloy, the corrosion rate of titanium alloy in flowing seawater is almost 0. Therefore, the titanium alloy has a great deal of application in naval vessels, seawater pipelines and the like. For welded titanium alloy thin-wall pipes for ships, the welding of titanium alloy has the problems of large welding deformation, serious grain growth and the like, the joint of the titanium alloy is easy to become a weak part of stress corrosion, and the titanium alloy is often in a cathode hydrogen evolution environment when used, so that the risk of hydrogen embrittlement is caused. Under the comprehensive action of seawater alternating load, corrosive medium and welding residual stress field, stress-oriented corrosion cracking at a welding joint is difficult to avoid, and the maintenance and on-site repair technology of the titanium alloy pipeline for the ship becomes a difficult problem to solve.
Cracks of a thin-wall container or a thin plate often penetrate through a component and cannot be subjected to excavation repair welding, and Liuhong nations and other people adopt non-melting electrode inert gas protection to perform remelting and closing on the cracks, so that the problem of welding repair under the condition that residual cracks are difficult to remove at a welding seam part is solved. For a thin plate container, if the overlaying welding ("overlay") repair technology is directly carried out on the surface of a generated crack, on one hand, original defects cannot be eliminated, the crack body still exists in the container, and the risk of continuous expansion still exists in the future service process. On the other hand, the thin-wall component is different from the medium-thickness component, the cracks of the thin-wall component are basically of a penetrating type, and the conventional operation of digging out defects and then repairing welding is difficult to implement. Even with overlay repair, the crack is at risk of continuing to propagate.
Although remelting and closing of the cracks are carried out under the protection of the non-melting inert gas, the problem that welding repair is difficult under the condition that the cracks cannot be excavated can be solved well, the problems of residual stress field and service life of the repaired cracks are considered, tensile stress exists at the tips of the remelted cracks, and the problem that re-initiation and expansion of the cracks are avoided in a complex environment medium becomes a problem which needs to be solved urgently.
Disclosure of Invention
The invention aims to solve the technical problem of how to avoid the re-initiation and expansion of cracks in a complex environment medium, and provides a welding method for repairing the thin-wall cracks of a metal component.
In order to solve the technical problems, the invention is realized by the following technical scheme:
the invention provides a welding method for repairing thin-wall cracks of a metal component, which adopts TIG welding without wire filling to carry out self-fluxing welding on the cracks to realize the closure of the cracks; and respectively carrying out crack arrest welding on two ends of a self-fusion welding bead formed by self-fusion welding, wherein the crack arrest welding bead formed by the crack arrest welding is approximately perpendicular to the self-fusion welding bead, and the crack arrest welding bead is away from the end part of the self-fusion welding bead.
Further, the distance between the crack arrest welding bead and the end part of the self-melting welding bead is 1 to 10 times of the width of the self-melting welding bead.
Further, the length of the crack arrest welding bead is 10-30 times of the width of the self-melting welding bead.
Further, the crack arrest welding adopts one of filler wire TIG welding, gas metal arc welding and shielded metal arc welding.
Furthermore, when wire filling TIG welding is adopted, direct current positive connection is adopted, the flow of protective gas is 10-15L/min, the welding current is 100-140A, the arc voltage is 11-14V, and the welding speed is 5-10 cm/min; when consumable electrode gas shielded welding is adopted, direct current reverse connection is adopted, the flow of protective gas is 15-25L/min, the welding current is 150-250A, the arc voltage is 20-25V, and the welding speed is 5-10 cm/min; when the shielded metal arc welding is adopted, the welding current is 120-180A, and the arc voltage is 22-30V.
Further, before the crack arrest welding, a plurality of transverse bead welds are performed on the self-fluxing bead to form a plurality of transverse bead welds substantially perpendicular to the self-fluxing bead, and the plurality of transverse bead welds are made to cover the self-fluxing bead.
Further, the transverse overlaying welding adopts one of wire filling TIG welding, gas metal arc welding and shielded metal arc welding.
Further, before the crack arrest welding, a plurality of longitudinal bead welds are performed on the self-fluxing bead to form a plurality of longitudinal bead welds substantially parallel to the self-fluxing bead, and the plurality of longitudinal bead welds are made to cover the self-fluxing bead.
Further, the longitudinal overlay welding uses one of filler wire TIG welding, gas metal arc welding, and shielded metal arc welding.
The beneficial effects of the invention are:
aiming at the welding repair of the thin-wall component crack, the invention provides a related technical scheme of crack arrest welding, namely, a crack arrest welding bead is added at the front end of a self-melting welding bead to manufacture a compressive stress area, so that the continuous expansion of the crack loses the driving force, thereby realizing the purpose of crack arrest in a specific occasion that the excavation repair welding method cannot be adopted, and further combining the crack arrest welding and the surfacing repair technology, realizing the crack repair of some thin-wall components which are corroded quickly, and finally obtaining good effect.
Drawings
FIG. 1 is a schematic view of the distribution of residual stress in the longitudinal direction of the weld along the direction perpendicular to the weld;
FIG. 2 is a schematic view of the arrangement of self-fluxing beads and crack arrest beads formed by the method of the present invention;
fig. 3 is a schematic view of the bead distribution of the self-fluxing bond crack arrest provided in example 1 of the present invention (d is the self-fluxing bead width);
FIG. 4 is a schematic view of a bead distribution of self-fluxing, transverse bead-up welding combined with crack arrest welding provided in example 2 of the present invention (d is the self-fluxing bead width);
fig. 5 is a schematic view of a bead distribution of self-fusion welding and longitudinal bead welding combined with crack arrest welding provided in example 3 of the present invention (d is a self-fusion bead width).
In the above figures: 1-cracking; 2-self-fluxing welding; 3-crack arrest welding bead; 4-transverse bead welding; 5-longitudinal bead welding.
Detailed Description
For a further understanding of the contents, features and effects of the invention, reference will be made to the following detailed description taken in conjunction with the accompanying drawings.
According to the basic theory of stress distribution in a welded structure, the distribution of welding residual stress in the direction perpendicular to the weld joint is shown in fig. 1. Due to the solidification and shrinkage of the metal, tensile stress exists in the weld cladding metal and the vicinity thereof, namely in a narrow range between the dotted lines, and a compressive stress state exists outside the dotted lines. On the other hand, it is known from the basic theory of fracture mechanics that an existing crack continues to propagate only when the crack tip is under tensile stress, and if the crack tip is under compressive stress, the crack cannot continue to propagate.
According to the basic principle of the welding residual stress and the crack propagation, the invention provides a novel crack arrest welding process, namely, a compressive stress area is manufactured at the front end of the crack 1, so that the continuous propagation of the crack 1 loses the driving force, and the purpose of crack arrest is realized in a specific occasion. On the basis, the invention provides a welding method for repairing the thin-wall crack of the metal component, which carries out self-fluxing welding on the crack 1 by TIG welding without wire filling to realize the closing of the crack; then, two crack arrest beads 3 are applied to both ends of the self-fluxing bead 2 formed by self-fluxing welding, so that compressive stress areas are formed at both ends of the crack 1 through the crack arrest beads 3, the repaired crack 1 is prevented from continuously expanding, and the purpose of crack arrest is achieved in a specific occasion, as shown in fig. 2.
The crack arrest welding may be wire-filling TIG welding, gas Metal Arc Welding (GMAW), shielded Metal Arc Welding (SMAW), or the like.
In the method for repairing a thin-walled crack by welding according to the present invention, as a preferred embodiment, the distance δ from the end of the weld bead 2 to the crack arrest bead 3 is selected within a range of d to 10d, and the length L of the crack arrest bead 3 is selected within a range of 10d to 30 d; where d represents the width of the self-fluxing bead 2. The values of delta and L can ensure the enough pressure stress value of the crack tip.
Example 1
As shown in fig. 3, the present embodiment adopts self-fusion welding and crack arrest welding, which can be applied to the defect of crack 1 without corrosion thinning, the repair is simple and reliable, and the function of preventing the crack from continuing to expand can be realized.
Firstly, performing self-fluxing welding repair on the crack 1 by adopting TIG welding without wire filling to form a self-fluxing welding bead 2 and realize the closing of the crack 1.
The relevant welding parameters of TIG self-fluxing welding in the embodiment are as follows: the polarity of the power supply is direct current positive polarity, the diameter phi of the tungsten electrode is 2.6-3.6mm, the inert protective gas is argon, the flow of the protective gas is 10-15L/min, the electric arc current is 90-140A, and the electric arc voltage is 11-14V.
And secondly, respectively carrying out crack arrest welding at a certain distance from both ends of the self-fluxing welding bead 2, wherein the crack arrest welding bead 3 formed by the crack arrest welding is basically vertical to the self-fluxing welding bead 2, so that the continuous crack propagation is prevented. Further, the distance δ between the crack arrest bead 3 and the end of the self weld bead 2 is 5 times the width d of the self weld bead 2, and the length L of the crack arrest bead 3 is 10 times the width d of the self weld bead 2.
The crack arrest welding of the embodiment adopts non-consumable electrode inert gas shielded arc welding, the welding polarity is direct current positive polarity, the non-consumable electrode is a tungsten electrode, the diameter phi is 3.0mm, the inert protective gas is argon, the protective gas flow is 10-15L/min, the welding wire number ERNiCr-3, the welding wire specification phi is 1.0mm or phi 1.2mm, the welding current is 100-140A, the arc voltage is 11-14V, and the welding speed is 5-10 cm/min.
Example 2
As shown in fig. 4, the present embodiment adopts self-fusion welding and transverse overlay welding in combination with crack arrest welding, which may be suitable for repairing crack defects occurring on some thin-walled components with fast corrosion.
Firstly, performing self-fluxing welding repair on the crack 1 by adopting TIG welding without wire filling to form a self-fluxing welding bead 2 and realize the closing of the crack 1.
The relevant welding parameters of TIG self-fluxing welding in the embodiment are as follows: the polarity of the power supply is direct current positive polarity, the diameter of the tungsten electrode is phi 2.6-3.6mm, the inert protective gas is argon, the flow of the protective gas is 10-15L/min, the arc current is 90-140A, and the arc voltage is 11-14V.
And secondly, performing a plurality of transverse bead welds on the self-fluxing bead 2 by adopting TIG welding of filler wires to form a plurality of transverse bead welds 4 which are approximately vertical to the self-fluxing bead 2, and enabling the plurality of transverse bead welds 4 to cover the whole self-fluxing bead 2. The transverse bead 4 increases the thickness of the weld repair zone and thereby increases its corrosion life.
The specific method of TIG transverse overlay welding in this embodiment is to weld the surface of the self-fluxing welding bead 2 one by one, and feed a welding wire into a molten pool while the welding gun arcs to form the molten pool, so as to realize the transverse overlay welding of the surface. The relevant parameters are as follows: adopting non-consumable electrode inert gas to protect electric arc welding, wherein the welding polarity is direct current positive polarity, the non-consumable electrode is a tungsten electrode, the diameter is phi 3.0mm, the inert protective gas is argon, the protective gas flow is 10-15L/min, the welding wire is ERNiCr-3, the specification of the welding wire is phi 1.0mm or phi 1.2mm, the welding current is 80-120A, the arc voltage is 10-14V, and the welding speed is 5-9 cm/min.
In addition, the transverse overlay welding may employ Gas Metal Arc Welding (GMAW), shielded Metal Arc Welding (SMAW), or the like.
And thirdly, respectively performing crack arrest welding at a certain distance from two ends of the self-melting welding bead 2, wherein the self-melting welding bead 3 formed by the crack arrest welding is basically vertical to the self-melting welding bead 2, so that the continuous expansion of cracks is prevented. Further, the distance δ between the crack arrest bead 3 and the end of the self weld bead 2 is 5 times the width d of the self weld bead 2, and the length L of the crack arrest bead 3 is 10 times the width d of the self weld bead 2.
The crack arrest welding of the embodiment adopts non-consumable electrode inert gas shielded arc welding, the welding polarity is direct current positive polarity, the non-consumable electrode is a tungsten electrode, the diameter phi is 3.0mm, the inert protective gas is argon, the protective gas flow is 10-15L/min, the welding wire number ERNiCr-3, the welding wire specification phi is 1.0mm or phi 1.2mm, the welding current is 100-140A, the arc voltage is 11-14V, and the welding speed is 5-10 cm/min.
Example 3
As shown in fig. 5, the present embodiment adopts self-welding, longitudinal overlay welding and crack arrest welding, and may be applied to some repair schemes for crack defects occurring on thin-walled components with fast corrosion and long weld joints.
Firstly, self-fusion welding repair is carried out on the crack 1 by TIG welding without wire filling to form a self-fusion welding bead 2, and the crack 1 is closed.
The relevant welding parameters of TIG self-fluxing welding in the embodiment are as follows: the polarity of the power supply is direct current positive polarity, the diameter of the tungsten electrode is phi 2.6-3.6mm, the inert protective gas is argon, the flow of protective gas is 15L/min, the arc current is 90-140A, and the arc voltage is 11-14V.
And secondly, performing longitudinal overlaying on the self-fluxing weld bead 2 by adopting TIG welding of filler wires to form a plurality of longitudinal overlaying weld beads 5 which are substantially parallel to the self-fluxing weld bead 2, and enabling the longitudinal overlaying weld beads 5 to cover the whole self-fluxing weld bead 2. The longitudinal bead 5 increases the thickness of the weld repair area to improve its corrosion life and minimizes the amount of welding material used for welding to a certain extent to achieve the desired effect.
The specific method of the TIG longitudinal overlay welding of the embodiment is to perform the overlay welding on the surface of the self-fluxing weld bead 2 one by one, and feed a welding wire into a molten pool while the welding gun arcs to form the molten pool, so as to realize the surface longitudinal overlay welding. The relevant parameters are as follows: adopting non-consumable electrode inert gas to protect electric arc welding, wherein the welding polarity is direct current positive polarity, the non-consumable electrode is a tungsten electrode, the diameter is phi 3.0mm, the inert protective gas is argon, the protective gas flow is 15L/min, the welding wire mark ERNiCr-3, the welding wire specification is phi 1.0mm or phi 1.2mm, the welding current is 90-120A, the arc voltage is 10-14V, and the welding speed is 6-12 cm/min.
In addition, the longitudinal overlay welding may employ Gas Metal Arc Welding (GMAW), shielded Metal Arc Welding (SMAW), or the like.
And thirdly, respectively carrying out crack arrest welding at a certain distance from two ends of the self-fluxing welding bead 2, wherein the crack arrest welding bead 3 formed by the crack arrest welding is basically vertical to the self-fluxing welding bead 2, so that the continuous expansion of cracks is prevented. Further, the distance δ between the crack prevention bead 3 and the end of the self-fluxing bead 2 is 5 times the width d of the self-fluxing bead 2, and the length L of the crack prevention bead 3 is 10 times the width d of the self-fluxing bead 2. Meanwhile, the crack-stopping welding bead 3 is also spaced from the end of the longitudinal bead 5.
The crack arrest welding of the embodiment adopts non-consumable electrode inert gas shielded arc welding, the welding polarity is direct current positive polarity, the non-consumable electrode is a tungsten electrode, the diameter phi is 3.0mm, the inert protective gas is argon, the protective gas flow is 10-15L/min, the welding wire number ERNiCr-3, the welding wire specification phi is 1.0mm or phi 1.2mm, the welding current is 100-140A, the arc voltage is 11-14V, and the welding speed is 5-10 cm/min.
Although the preferred embodiments of the present invention have been described with reference to the accompanying drawings, the present invention is not limited to the above-described embodiments, which are only illustrative and not restrictive, and those skilled in the art can make various changes and modifications within the scope of the present invention without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (4)
1. A welding method for repairing thin-wall cracks of a metal component is characterized in that TIG welding without wire filling is adopted to carry out self-fluxing welding on the cracks, so that the cracks are closed;
performing a plurality of transverse bead welds on the self-fusion weld bead formed by the self-fusion weld to form a plurality of transverse bead welds which are substantially perpendicular to the self-fusion weld bead, and enabling the plurality of transverse bead welds to cover the self-fusion weld bead;
then, respectively carrying out crack arrest welding on two ends of a self-melting welding bead formed by self-welding, wherein the crack arrest welding bead formed by the crack arrest welding is approximately vertical to the self-melting welding bead, and a distance is reserved between the crack arrest welding bead and the end part of the self-melting welding bead;
the distance between the crack-stopping welding bead and the end part of the self-melting welding bead is 1 to 10 times of the width of the self-melting welding bead; the length of the crack-stopping welding bead is 10-30 times of the width of the self-melting welding bead.
2. The welding method for repairing a thin-walled crack of a metallic member according to claim 1, wherein the crack arrest welding is one of a wire-filling TIG welding, a gas metal arc welding and a shielded metal arc welding.
3. The welding method for repairing the thin-wall cracks of the metal component according to the claim 2, wherein when the crack arrest welding is wire-filling TIG welding, direct current direct connection is adopted, the flow of protective gas is 10-15L/min, the welding current is 100-140A, the arc voltage is 11-14V, and the welding speed is 5-10 cm/min; when the crack arrest welding adopts consumable electrode gas shielded welding, direct current reverse connection is adopted, the flow of protective gas is 15-25L/min, the welding current is 150-250A, the arc voltage is 20-25V, and the welding speed is 5-10 cm/min; when the crack arrest welding adopts shielded metal arc welding, the welding current is 120-180A, and the arc voltage is 22-30V.
4. The welding method for repairing thin-walled cracks of a metal component according to claim 1, wherein the transverse overlaying welding adopts one of wire-filling TIG welding, gas metal arc welding and shielded metal arc welding.
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| CN112453643A (en) * | 2020-11-20 | 2021-03-09 | 西安热工研究院有限公司 | Cold metal transition welding repair method for crack damage of high-temperature component of gas turbine |
| CN112475548A (en) * | 2020-11-20 | 2021-03-12 | 西安热工研究院有限公司 | Gas turbine high temperature part crack damage welding repair structure |
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| GB2532001B (en) * | 2014-10-24 | 2017-09-27 | Gkn Aerospace Sweden Ab | Crack stopper for welds |
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| CN1107088A (en) * | 1994-04-22 | 1995-08-23 | 国营二一一厂 | Cold-welding recovery method for thin wall of cast iron cylinder |
| JP2008216079A (en) * | 2007-03-05 | 2008-09-18 | Toshiba Corp | Method for sealing defect of reactor structure |
| CN102120292A (en) * | 2011-03-18 | 2011-07-13 | 中国航空工业集团公司北京航空制造工程研究所 | Vacuum brazing repairing method for cracks of high-temperature alloy thin-wall part |
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