CN115255575A - Submerged-arc welding manufacturing method for main stud of hydraulic generator - Google Patents

Submerged-arc welding manufacturing method for main stud of hydraulic generator Download PDF

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Publication number
CN115255575A
CN115255575A CN202210974944.3A CN202210974944A CN115255575A CN 115255575 A CN115255575 A CN 115255575A CN 202210974944 A CN202210974944 A CN 202210974944A CN 115255575 A CN115255575 A CN 115255575A
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welding
stud
groove
vertical rib
auxiliary
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CN115255575B (en
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吴双辉
李明奎
朱洪滨
李景
钱文川
霍岩
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Harbin Electric Machinery Co Ltd
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Harbin Electric Machinery Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/18—Submerged-arc welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/235—Preliminary treatment
    • 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
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/20—Hydro energy

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Arc Welding In General (AREA)

Abstract

A submerged arc welding method for a main vertical rib of a hydraulic generator belongs to the field of welding and manufacturing of the main vertical rib of the giant hydraulic generator and solves the problems that welding production efficiency of the main vertical rib and an auxiliary vertical rib is low, welding deformation control is difficult, welding quality is not easy to guarantee, welding cost is high, and repeated turning is achieved.

Description

Submerged-arc welding manufacturing method for main stud of hydraulic generator
Technical Field
The invention belongs to the field of welding and manufacturing of a main vertical rib of a giant water turbine generator, and particularly relates to a submerged-arc welding manufacturing method of the main vertical rib of the water turbine generator.
Background
The inclined support arm disc type rotor support is a key part of a giant hydroelectric generating set and is formed by assembling and welding a rotor central body, an excircle component, a main stud and an auxiliary stud, a plurality of layers of magnet yokes are stacked on the excircle of the auxiliary stud, and magnetic poles are hung on the excircle of the magnet yoke, so that the part with the largest weight in the whole generator is formed. As the capacity of the unit increases, the size and weight of the rotor become very large, with a brookfield rotor having an outer diameter of 13.7 meters, an overall height of about 3.49 meters, a weight of 1600 tons, a beachtop rotor diameter of about 1.65 meters, an overall height of 3.9 meters, and a weight of surprisingly 2300 tons, which is a very heavy object with very strict installation and manufacturing requirements.
The diameter of the rotor support is generally more than 10m, the height is more than 3m, because the problem of limited road transportation, the rotor support is separately welded into three main parts including a rotor central body, a rotor excircle assembly and a main stud and auxiliary stud separately welded structure in a factory, scattered parts are sent to a construction site and then are integrally welded, because the magnetic yoke reaches a finish machining state in the factory, in order to ensure the smooth proceeding of the magnetic yoke lamination, the requirements on the manufacturing quality and the installation and processing precision of the separately welded parts of the main stud and the auxiliary stud are extremely high, the straightness requirement of the separately welded parts of the main stud and the auxiliary stud with the height of 3m is within 0.30mm, meanwhile, in the process of high-speed rotation of the whole rotor, because the rotor support, the magnetic yoke and the magnetic pole have large weights, and the welding seams of the main stud and the auxiliary stud are subjected to great centrifugal force, and therefore, higher requirements are provided for the welding deformation control and the internal quality of the main stud and the auxiliary stud.
The number of main vertical ribs and auxiliary vertical ribs of the inclined support arm disc type rotor support is large, the main vertical ribs and the auxiliary vertical ribs are generally 24-28, the length is more than 3m and can reach 3.6m to the maximum, the groove is in a K-shaped groove form, the welding workload is large, CO2 manual gas shielded welding is adopted in the conventional welding mode, and narrow-gap submerged arc welding is adopted less.
Because the auxiliary stud is large in thickness and large in welding filling amount, the welding efficiency is low due to the adoption of CO2 manual gas shielded welding, the production period is not easy to guarantee, the welding deformation is difficult to control, the welding quality is not easy to guarantee, and welding repair is easy to occur.
For narrow-gap submerged arc welding, in the actual welding process, submerged arc welding can be implemented only by large submerged arc welding equipment with an operating frame, the number of the large submerged arc welding equipment with the operating frame is small, the occupied area of a field is large, welding of other parts is affected, as the submerged arc welding is high in cladding efficiency and large in heat input, welding deformation of the auxiliary stud after welding is often broken waves, the welding deformation is difficult to control, and the requirement of straightness cannot be met, meanwhile, when the original design is adopted, the groove form of the auxiliary stud is K-shaped, the groove filling amount of a welding wire is large, the welding deformation amount is large, and the welding cost is high.
In the actual production process, the two traditional welding modes both need to be welded repeatedly in a turnover mode, and the production efficiency is greatly influenced.
Disclosure of Invention
The invention provides a submerged-arc welding manufacturing method of a main stud of a hydraulic generator, aiming at overcoming the defects of the prior art and solving the problems of low welding production efficiency, difficult welding deformation control, difficult guarantee of welding quality, high welding cost and repeated turning over of the main stud and the auxiliary stud; the method is realized by the following steps:
the method comprises the following steps: installing a roller tire, and performing tack welding on a main stud and an auxiliary stud, wherein the front roller tire and the rear roller tire are respectively arranged on a front guide rail and a rear guide rail, and are respectively fixed by a first stop block at the left side and the right side, the main stud is tack welded in a groove of the roller tire, the auxiliary stud is tack welded on the main stud, and an arc-shaped lacing wire is welded between the small-slope-mouth side vertical face of the auxiliary stud and the plane of the main stud;
step two: performing bottom sealing welding on the root part at the small bevel side, rotating the roller tire anticlockwise until the auxiliary vertical rib is in an approximately horizontal state, enabling the small bevel side to be upward, preheating the to-be-welded areas of the main vertical rib and the auxiliary vertical rib, and performing bottom sealing welding on the root part at the small bevel side by adopting gas shielded welding;
step three: backing welding is carried out on the side of the large slope, the roller is rotated clockwise until the auxiliary vertical ribs are in an approximately horizontal state, the side of the large slope faces upwards, a second stop block is welded on the auxiliary vertical ribs, triangular backing plates are arranged on the auxiliary vertical ribs along the length direction, meanwhile, a submerged arc welding trolley and a track are laid on the triangular backing plates, after the welding areas of the main vertical ribs and the auxiliary vertical ribs are preheated to a preset temperature, the backing welding is carried out by adopting submerged arc welding, and the welding thickness is controlled according to 3-5 mm;
step four: filling and welding the large slope side, wherein the large slope side is filled and welded to the height of 20-30 mm, and a square is adopted to control the perpendicularity of the auxiliary vertical rib and the main vertical rib to be 5-10 mm/m;
step five: back chipping is conducted on the side of the small groove, the roller is rotated anticlockwise until the auxiliary vertical rib is in an approximately horizontal state, the side of the small groove is upward, back chipping is conducted on a root back sealing welding line on the side of the small groove and a back-chipping welding line on the side of the large groove, metal luster is exposed after back chipping, then PT flaw detection is conducted, the root defect of the welding line is guaranteed to be cleared completely, and meanwhile the arc-shaped lacing wire is cleared;
step six: backing welding is conducted on the side of the small groove, after the to-be-welded areas of the main vertical ribs and the auxiliary vertical ribs are preheated to a preset temperature, third stop blocks are welded on the auxiliary vertical ribs, triangular backing plates are arranged on the auxiliary vertical ribs along the length direction, meanwhile, submerged-arc welding trolleys and rails are laid on the triangular backing plates, and backing welding is conducted on the side of the small groove through submerged-arc welding;
step seven: filling and welding the small-groove side, namely filling and welding the small-groove side of the auxiliary vertical rib by adopting submerged arc welding, and detecting and controlling the verticality of the auxiliary vertical rib and the main vertical rib within the range of 3-5 mm/m by using a square ruler;
step eight: repeatedly turning over, filling and welding, rotating the roller tire clockwise until the auxiliary vertical rib is in an approximately horizontal state, enabling the large slope side to face upwards, filling and welding the large slope side, controlling the perpendicularity of the auxiliary vertical rib and the main vertical rib to be 0-2 mm/m by using a square rule, rotating the roller tire anticlockwise until the auxiliary vertical rib is in an approximately horizontal state, enabling the small slope side to face upwards, filling and welding the small slope side, controlling the perpendicularity of the auxiliary vertical rib and the main vertical rib to be 0-2 mm/m by using the square rule, and repeatedly turning over, filling and welding until the welding is full;
step nine: transition and cap face welding, clockwise rotation rolls child to vice stud be in approximate horizontality, makes big notch side up, passes through and cap face welding big notch side, adopts the squareness ruler control to vice stud and the straightness that hangs down of main stud between 0 ~ 2mm/m, anticlockwise rotation rolls child to vice stud be in approximate horizontality, makes little notch side up, passes through and cap face welding little notch side, adopts the squareness ruler control to vice stud and the straightness that hangs down of main stud between 0 ~ 2mm/m, stands up repeatedly until accomplishing welding seam weld corner welding.
In the submerged arc welding manufacturing method of the main stud of the hydraulic generator, the rolling die in the first step is formed by assembling and welding an arc section, a groove and a horizontal section, and the material of the rolling die is a Q345B steel plate.
In the submerged arc welding manufacturing method for the main stand bar of the hydraulic generator, in the first step, the main stand bar and the auxiliary stand bar are both made of Q345B steel plates.
In the submerged arc welding manufacturing method of the main stud of the hydraulic generator, the welding wire used for the positioning welding in the step one and the small-groove side root back sealing welding in the step two is phi 1.2mm ER50-6.
In the submerged-arc welding manufacturing method of the main stud of the hydraulic generator, the large-bevel side backing welding in the third step, the large-bevel side filling welding in the fourth step, the small-bevel side backing welding in the sixth step, the small-bevel side filling welding in the seventh step, the repeated turning over filling welding in the eighth step, the preheating temperature in the transition and cover welding stages in the ninth step is not lower than 100 ℃, the interlayer temperature is not higher than 260 ℃, and welding wires and welding fluxes are phi 4mm H08MnA and 10-60 mesh HJ431 respectively.
In the submerged arc welding manufacturing method for the main stud of the hydraulic generator, the welding specifications of the tack welding in the step one and the small-groove side root back sealing welding in the step two are as follows: the current is 210-280A, the voltage is 22-29V, the welding speed is 180-350 mm/min, and the components of the shielding gas are as follows: 78% Ar +22% of 2 Flow rate: 12 to 20L/min.
In the submerged arc welding manufacturing method for the main stud of the hydraulic generator, the welding specification of backing welding at the large-slope side in the third step is as follows: the current is 500-600A, the voltage is 36-40V, and the welding speed is 330-420 mm/min.
In the submerged arc welding manufacturing method for the main stud of the hydraulic generator, the welding specifications of the fourth large-middle-diameter groove side filling welding, the seventh small-middle-diameter groove side filling welding and the eighth repeated turning over filling welding are as follows: the current is 650-700A, the voltage is 34-38V, and the welding speed is 330-420 mm/min.
In the submerged arc welding manufacturing method for the main stud of the hydraulic generator, the welding specification of backing welding at the small-notch side in the sixth step is as follows: the current is 700-750A, the voltage is 36-40V, and the welding speed is 250-330 mm/min.
In the submerged arc welding manufacturing method for the main stud of the hydraulic generator, the welding specifications of transition and cover surface welding in the ninth step are as follows: the current is 650-700A, the voltage is 34-38V, and the welding speed is 330-420 mm/min.
In the submerged arc welding manufacturing method for the main stud of the hydraulic generator, the welding specifications of transition and cover surface welding in the ninth step are as follows: the current is 500-600A, the voltage is 36-40, and the welding speed is 420-500 mm/min.
In the submerged arc welding manufacturing method of the main stud of the hydraulic generator, the large groove and the small groove of the auxiliary stud are polygonal transitional grooves.
Compared with the prior art, the invention has the following beneficial effects:
1) The roller and the triangular cushion plate are adopted to realize the submerged-arc welding manufacture of the main vertical bar of the giant water turbine generator, the production efficiency can be effectively improved, and the production and manufacture period is obviously shortened.
2) The invention solves the problem of repeated turnover of the main stud welding of the hydraulic generator, reduces the occupation of large submerged arc welding equipment, reduces the hoisting operation time, further improves the production efficiency and shortens the production and manufacturing period.
3) The welding deformation of the main vertical bar and the vertical bar is effectively controlled by using a mode of controlling the verticality by using a reverse deformation method and a square, and reasonable welding specifications are set in different welding stages of backing welding, filling welding, transition and cover surface welding, so that the internal quality and the forming quality of a welding seam are effectively ensured.
4) The groove form of the auxiliary stud is changed from the original K-shaped groove into a broken line transition type groove, so that the welding wire filling amount is reduced, and the welding cost is effectively saved.
Drawings
FIG. 1 is a schematic front view of a station for tack welding of a mounting roller, a main stud and an auxiliary stud according to the present invention;
FIG. 2 is a schematic left view of a station for tack welding of the main stud and the auxiliary stud to the mounting roller of the present invention;
FIG. 3 is a schematic view of a welding station of the small-groove side root back seal welding of the present invention;
FIG. 4 is a schematic view of a welding station for backing welding the major stud and the minor stud at the large-slope side of the invention;
FIG. 5 is a schematic view of the mounting positions of a second stop dog, a triangular backing plate, a rail and a submerged arc welding trolley in the invention;
FIG. 6 is a schematic view of a welding station for filling and welding a large-slope side of a main stud and an auxiliary stud in the invention;
FIG. 7 is a schematic view of a welding station for back chipping and backing welding of the small-slope sides of the main stud and the auxiliary studs in the invention;
FIG. 8 is a schematic view of a welding station for filling and welding the small-slope sides of the main stud and the auxiliary stud according to the present invention;
FIG. 9 is a schematic view of a welding station after the main stud and the auxiliary stud are welded by repeatedly turning over the body in the invention;
FIG. 10 is a schematic view of a welding station after the transition and facing welding of the primary and secondary studs of the present invention is completed;
FIG. 11 is a schematic view of the structure of the tire of the present invention;
FIG. 12 is a schematic view of a broken line groove of the secondary stud according to the present invention.
The notation in the figure is: 1-rolling tyre, 2-main vertical rib, 3-auxiliary vertical rib, 4-guide rail, 5-first stop block, 6-arc lacing wire, 7-small groove, 8-large groove, 9-second stop block, 10-triangular baffle, 11-submerged arc welding trolley, 12-track, 13-third stop block, 14-arc section, 15-groove and 16-horizontal section.
Detailed Description
The present application is further described below with reference to the accompanying drawings. The following examples are only for illustrating the technical solutions of the present invention more clearly, and the protection scope of the present application is not limited thereby.
The embodiment provides a submerged arc welding manufacturing method for a main stud of a hydraulic generator, which is realized by the following steps:
the method comprises the following steps: installing rollers 1, main studs 2 and auxiliary studs 3, and performing tack welding, wherein the front rollers 1 and the rear rollers 1 are respectively arranged on front and rear guide rails 4 and are respectively fixed by first stop blocks 5 at the left side and the right side, the main studs 2 are tack welded in grooves 15 of the rollers 1, the auxiliary studs 3 are tack welded on the main studs 2, and arc-shaped tie bars 6 are welded between the side vertical surfaces of small grooves 7 of the auxiliary studs 3 and the planes of the main studs 2; the main stud 2 is positioned and welded in the groove 15 of the roller 1 in the step, so that the center of gravity of the roller 1, the main stud 2 and the auxiliary stud 3 is positioned below the whole structure, the principle is similar to that of a tumbler, on one hand, repeated turning over is easier, on the other hand, the whole structure is prevented from falling, and the use safety is improved. The arc-shaped lacing wire 6 is used for preventing the welding deformation of the auxiliary stud 3 during the backing welding and filling welding of the side of the large groove 8 from being overlarge.
Step two: performing bottom sealing welding on the lateral root of the small groove 7, namely, rotating the roller 1 anticlockwise until the auxiliary stud 3 is in an approximately horizontal state as shown in fig. 3, enabling the small groove 7 to face upwards, preheating to-be-welded areas of the main stud 2 and the auxiliary stud 3, and performing bottom sealing welding on the lateral root of the small groove 7 by adopting gas shielded welding; the purpose of this step is to prevent the flux from leaking from the back of the weld when backing welding is performed on the side of the large groove 8, and to prepare for backing welding on the side of the large groove 8.
Step three: backing welding is carried out on the side of a large groove 8, as shown in figure 4, the roller 1 is rotated clockwise until an auxiliary vertical rib 3 is in an approximately horizontal state, the side of the large groove 8 faces upwards, as shown in figure 5, a second stop block 9 is welded on the auxiliary vertical rib 3, a triangular cushion plate 10 is arranged on the auxiliary vertical rib 3 along the length direction, a submerged arc welding trolley 11 and a track 12 are laid on the triangular cushion plate 10, after the welding areas of the main vertical rib 2 and the auxiliary vertical rib 3 are preheated to a preset temperature, submerged arc welding is adopted for backing welding, and the welding thickness is controlled according to 3-5 mm; the method adopts a small welding standard fast walking vehicle mode to carry out secondary backing welding, and aims to increase the welding thickness of the backing layer and prevent the backing layer from being punctured when the large groove 8 side is filled and welded.
Step four: filling and welding the side of the large groove 8, as shown in fig. 6, filling and welding the side of the large groove 8 to the height of 20-30 mm, and controlling the verticality of the auxiliary stud and the main stud to be 5-10 mm/m by using a square ruler; in the step, the side of the large groove 8 is subjected to filling welding to the height of 20-30 mm, and the verticality of the auxiliary stud 3 and the main stud 2 is controlled to be 5-10 mm/m, so that the problem that the strength of a welding seam is insufficient due to the fact that the section of the welding seam is reduced after the welding seam on the side of the small groove 7 is back-gouged is solved, and when preheating is performed, the root of the welding seam is cracked due to the fact that the stress part is released, meanwhile, the auxiliary stud 3 is subjected to pre-deformation after being cooled to the side of the large groove 8 by adopting a reverse deformation method, appropriate margin is reserved for the deformation of the subsequent small groove 7 side towards the small groove 7 side during bottoming welding and filling welding, and the deformation of the auxiliary stud 3 in the whole welding process can be effectively controlled.
Step five: back chipping on the side of the small groove 7, as shown in fig. 7, rotating the roller 1 anticlockwise until the auxiliary stud 3 is in an approximately horizontal state, enabling the side of the small groove 7 to face upwards, back chipping a root back-sealing weld on the side of the small groove 7 and a back-chipping weld on the side of the large groove 8, polishing to expose metallic luster after back chipping, and then performing PT flaw detection to ensure that the root defects of the welds are cleared and simultaneously clear the arc-shaped tie bars 6; in the step, as the root possibly has defects such as air holes, microcracks and the like, the purpose of back chipping is to eliminate the defects which affect the performance of the joint, ensure the internal quality of the root of the welding seam during subsequent welding and improve the flaw detection qualification rate during final inspection of the welding seam.
Step six: backing welding is carried out on the side of the small groove 7, as shown in fig. 7, after the areas to be welded of the main vertical ribs 2 and the auxiliary vertical ribs 3 are preheated to a preset temperature, third blocking blocks 13 are welded on the auxiliary vertical ribs 3, the triangular pad 10 is arranged on the auxiliary vertical ribs 3 along the length direction, meanwhile, a submerged arc welding trolley 11 and a track 12 are laid on the triangular pad 10, and backing welding is carried out on the side of the small groove 7 by adopting submerged arc welding; the purpose of adopting single-pass heavy-current welding in the step is to ensure that the welding seams at the root part and the two sides are thoroughly melted through.
Step seven: filling and welding the side of the small groove 7, as shown in figure 8, filling and welding the side of the small groove 7 of the auxiliary vertical rib 3 by adopting submerged arc welding, and detecting and controlling the verticality of the auxiliary vertical rib 3 and the main vertical rib 2 to be within the range of 3-5 mm/m by using a square; the pre-deformation method is adopted in the step, so that the auxiliary stud 3 is pre-deformed towards the small groove 7 side after being cooled, a proper margin is reserved for the subsequent filling welding of the large groove 8 side to the deformation of the large groove 8 side, the pre-deformation requirements of the large groove 8 side and the small groove 7 side in the stages of repeated turning over filling welding, transition and cover surface welding are stricter, and the deformation of the auxiliary stud 3 in the whole welding process can be more effectively controlled.
Step eight: repeatedly turning over, filling and welding, namely as shown in fig. 9, rotating the roller 1 to the auxiliary vertical rib 3 clockwise to be in an approximately horizontal state, enabling the side of the large slope 8 to face upwards, filling and welding the side of the large slope 8, controlling the verticality of the auxiliary vertical rib 3 and the main vertical rib 2 to be 0-2 mm/m by using a square, rotating the roller 1 to the auxiliary vertical rib 3 anticlockwise to be in an approximately horizontal state, enabling the side of the small slope 7 to face upwards, filling and welding the side of the small slope 7, controlling the verticality of the auxiliary vertical rib 3 and the main vertical rib 2 to be 2-3 mm by using a square, and repeatedly turning over, filling and welding until the welding state is full; in the step, normal standard welding is adopted, namely welding current is amplified, welding speed is slowed down to ensure fusion of two sides of the groove, and meanwhile, welding quantity is continuously reduced, and perpendicularity is controlled within 2mm/m until the welding quantity is 0mm/m, so that welding deformation of the auxiliary stud 3 can be controlled more favorably.
Step nine: transition and cover welding, as shown in fig. 10, clockwise rotating the roller 1 to the auxiliary stud 3 to be in an approximately horizontal state, enabling the side of the large groove 8 to face upwards, performing transition and cover welding on the side of the large groove 8, adopting a square to control the verticality of the auxiliary stud 3 and the main stud 2 to be between 0 and 2mm, anticlockwise rotating the roller 1 to the auxiliary stud 3 to be in an approximately horizontal state, enabling the side of the small groove 7 to face upwards, performing transition and cover welding on the side of the small groove 7, adopting a square to control the verticality of the auxiliary stud 3 and the main stud 2 to be between 0 and 2mm, and repeatedly turning over until welding seam welding angle welding is completed; in the step, normal standard welding is firstly adopted, namely welding current is amplified, welding speed is slowed down to ensure fusion with the side wall, meanwhile, welding quantity is continuously reduced, and the verticality is controlled to be within 2mm/m until 0mm/m, so that welding deformation of the auxiliary stud 3 is more favorably controlled, and small standard welding of a small-current fast-moving vehicle is adopted during last facing welding, so that welding seam transition and facing quality are improved, undercut defects are avoided, and the appearance of a welding seam is attractive in appearance.
Further, as shown in fig. 11, in the first step, the rolling tire 1 is formed by assembling and welding an arc-shaped section 14, a groove 15 and a horizontal section 16, and is made of a Q345B steel plate;
furthermore, in the first step, the main vertical ribs 2 and the auxiliary vertical ribs 3 are both made of Q345B steel plates;
furthermore, welding wires used for positioning welding in the step one and sealing bottom welding at the root part at the side of the small groove 7 in the step two are phi 1.2mm ER50-6;
further, backing welding is carried out on the side of the large groove 8 in the third step, filling welding is carried out on the side of the large groove 8 in the fourth step, backing welding is carried out on the side of the small groove 7 in the sixth step, filling welding is carried out on the side of the small groove 7 in the seventh step, filling welding is carried out on the repeated turning over in the eighth step, the preheating temperature in the transition and cover surface welding stages in the ninth step is not lower than 100 ℃, the interlayer temperature is not higher than 260 ℃, and welding wires and welding fluxes are phi 4mm H08MnA and HJ431 with 10-60 meshes respectively; the preheating temperature and the interlayer temperature are controlled in the step mainly to prevent the generation of cold cracks and hot cracks in the thick steel plate welding and ensure the quality of the welding seam.
Further, the welding specifications of the tack welding in the step one and the root back sealing welding at the side of the small groove 7 in the step two are as follows: the current is 210-280A, the voltage is 22-29V, the welding speed is 180-350 mm/min, and the components of the shielding gas are as follows: 78% Ar +22% of 2 Flow rate: 12-20L/min;
further, the welding specification of backing welding at the 8 sides of the middle and large grooves in the third step is as follows: the current is 500-600A, the voltage is 36-40V, and the welding speed is 330-420 mm/min; in the step, the welding of the bottom of the side of the large groove 8 is a key, and the welding is generally carried out by adopting small specifications, so that the welding quality is ensured.
Further, the welding specifications of the filling welding of the side of the large groove 8 in the fourth step, the filling welding of the side 7 of the small groove in the seventh step and the repeated turning over filling welding in the eighth step are as follows: the current is 650-700A, the voltage is 34-38V, and the welding speed is 330-420 mm/min; the filling welding in the step adopts large standard for welding, which is beneficial to improving the metal cladding efficiency and improving the production efficiency.
Further, the welding specification of the backing welding at the side of the small and medium groove 7 in the sixth step is as follows: the current is 700-750A, the voltage is 36-40V, and the welding speed is 250-330 mm/min; the purpose of adopting single-pass large-specification welding in the step is to ensure that the welding seams at the root part and two sides are thoroughly melted through.
Further, the welding specification of the transition and the cover surface welding in the ninth step is as follows: the current is 650 to 700A, the voltage is 34 to 38V, and the welding speed is 330 to 420mm/min; in the step, the submerged arc transition and the cover surface welding are carried out according to large specifications, so that the metal cladding efficiency is improved, and the production efficiency is improved.
Further, the welding specification of the last step of the transition and the cover surface welding in the ninth step is as follows: the current is 500-600A, the voltage is 36-40, and the welding speed is 420-500 mm/min; in the step, the last welding of submerged arc transition and cover surface welding adopts small standard rapid welding, which is beneficial to controlling undercut defects and enables welding seams to be attractive in appearance.
Further, as shown in fig. 12, the large grooves 8 and the small grooves 7 of the auxiliary studs 3 are polygonal transitional grooves; in the step, the original K-shaped groove of the auxiliary stud 3 is changed into a broken line transition-shaped groove, so that the filling amount of the welding wires is reduced, and the production and manufacturing cost is saved.
The present invention is illustrative only and not intended to limit the scope thereof, and those skilled in the art can make modifications to the present invention without departing from the spirit and scope thereof.

Claims (9)

1. A submerged arc welding manufacturing method for a main stud of a hydraulic generator is characterized by comprising the following steps: the method is realized by the following steps:
the method comprises the following steps: installing a roller (1), and performing tack welding on a main stud (2) and an auxiliary stud (3), wherein the front roller (1) and the rear roller (1) are respectively arranged on a front guide rail and a rear guide rail (4), the left side and the right side of the front roller are respectively fixed by a first stop block (5), the main stud (2) is tack welded in a groove (15) of the roller (1), the auxiliary stud (3) is tack welded on the main stud (2), and an arc-shaped lacing wire (6) is welded between the side vertical surface of a small groove (7) of the auxiliary stud (3) and the plane of the main stud (2);
step two: performing bottom sealing welding on the lateral root of the small groove (7), rotating the roller (1) anticlockwise until the auxiliary stud (3) is in an approximately horizontal state, enabling the small groove (7) to be upward in side, preheating to-be-welded areas of the main stud (2) and the auxiliary stud (3), and performing bottom sealing welding on the lateral root of the small groove (7) by adopting gas shielded welding;
step three: backing welding is carried out on the side of a large groove (8), the roller (1) is rotated clockwise until an auxiliary vertical rib (3) is in an approximately horizontal state, the side of the large groove (8) faces upwards, a second stop block (9) is welded on the auxiliary vertical rib (3), a triangular backing plate (10) is arranged on the auxiliary vertical rib (3) along the length direction, a submerged-arc welding trolley (11) and a track (12) are laid on the triangular backing plate (10), after the to-be-welded areas of the main vertical rib (2) and the auxiliary vertical rib (3) are preheated to a preset temperature, submerged-arc welding is adopted for backing welding, and the welding thickness is controlled according to 3-5 mm;
step four: filling and welding the side of the large groove (8), filling and welding the side of the large groove (8) to the height of 20-30 mm, and controlling the verticality of the auxiliary stud (3) and the main stud (2) to be 5-10 mm/m by using a square ruler;
step five: back gouging is carried out on the side of the small groove (7), the roller (1) is rotated anticlockwise until the auxiliary stud (3) is in an approximately horizontal state, the side of the small groove (7) is upward, back gouging is carried out on a bottom sealing welding line on the side of the small groove (7) and a back-gouging welding line on the side of the large groove (8), metal luster is exposed after back gouging through polishing, then PT flaw detection is carried out, the root defect of the welding line is completely removed, and meanwhile, the arc-shaped tie bar (6) is removed;
step six: backing welding is carried out on the side of the small groove (7), after the to-be-welded areas of the main vertical rib (2) and the auxiliary vertical rib (3) are preheated to a preset temperature, a third stop block (13) is welded on the auxiliary vertical rib (3), a triangular backing plate (10) is arranged on the auxiliary vertical rib (3) along the length direction, a submerged arc welding trolley (11) and a track (12) are laid on the triangular backing plate (10), and backing welding is carried out on the side of the small groove (7) by adopting submerged arc welding;
step seven: filling and welding the side of the small groove (7), filling and welding the side of the small groove (7) of the auxiliary vertical rib (3) by adopting submerged arc welding, and detecting and controlling the verticality of the auxiliary vertical rib (3) and the main vertical rib (2) to be within the range of 3-5 mm/m by using a square;
step eight: repeatedly turning over, filling and welding, namely clockwise rotating the roller (1) to the auxiliary vertical rib (3) to be in an approximately horizontal state, enabling the side of the large groove (8) to face upwards, filling and welding the side of the large groove (8), adopting a square to control the verticality of the auxiliary vertical rib (3) and the main vertical rib (2) to be between 0 and 2mm/m, anticlockwise rotating the roller (1) to the auxiliary vertical rib (3) to be in an approximately horizontal state, enabling the side of the small groove (7) to face upwards, filling and welding the side of the small groove (7), adopting a square to control the verticality of the auxiliary vertical rib (3) and the main vertical rib (2) to be between 0 and 2mm/m, and repeatedly turning over, filling and welding until the welding is full;
step nine: transition and cover face welding, clockwise rotation rolls child (1) to vice stud (3) and is in approximate horizontality, make big tang (8) side up, to going on transition and cover face welding big tang (8) side, adopt the square ruler to control the straightness that hangs down of vice stud (3) and main stud (2) between 0 ~ 2mm/m, anticlockwise rotation rolls child (1) to vice stud (3) and is in approximate horizontality, make little tang (7) side up, to little tang (7) side transition and cover face welding, adopt the square ruler to control the straightness that hangs down of vice stud (3) and main stud (2) between 0 ~ 2mm/m, repeatedly stand over until accomplishing welding seam weld corner welding.
2. The submerged arc welding manufacturing method for the main stud of the hydraulic generator according to claim 1, characterized in that: the rolling tire (1) in the first step is formed by assembling and welding an arc section (14), a groove (15) and a horizontal section (16) and is made of a Q345B steel plate, and the main vertical rib (2) and the auxiliary vertical rib (3) in the first step are both made of the Q345B steel plate.
3. The submerged arc welding manufacturing method for the main stud of the hydraulic generator according to claim 1, characterized in that: welding wires used for positioning welding in the step one and sealing bottom welding at the root part of the small groove side in the step two are phi 1.2mm ER50-6, and the welding specification is as follows: the current is 210-280A, the voltage is 22-29V, the welding speed is 180-350 mm/min, and the components of the shielding gas are as follows: 78% Ar +22% of 2 Flow rate: 12 to 20L/min.
4. The submerged arc welding manufacturing method for the main stud of the water turbine generator according to claim 1, characterized by comprising the following steps: the method comprises the steps of step three middle and large groove (8) side backing welding, step four middle and large groove (8) side filling welding, step six middle and small groove (7) side backing welding, step seven middle and small groove (7) side filling welding, step eight repeated turning over filling welding, step nine middle transition and cover surface welding stages preheating temperature is not lower than 100 ℃, interlayer temperature is not higher than 260 ℃, and welding wires and welding fluxes are phi 4mm H08MnA and 10-60 mesh HJ431 respectively.
5. The submerged arc welding manufacturing method for the main stud of the hydraulic generator according to claim 1, characterized in that: the welding specification of the backing welding of the side of the large groove (8) in the third step is as follows: the current is 500-600A, the voltage is 36-40V, and the welding speed is 330-420 mm/min.
6. The submerged arc welding manufacturing method for the main stud of the hydraulic generator according to claim 1 is characterized by comprising the following steps of: filling welding is carried out on the side of a large groove (8) in the fourth step, filling welding is carried out on the side of a small groove (7) in the seventh step, filling welding is carried out by repeatedly turning over in the eighth step, and welding specifications of transition and cover surface welding in the ninth step are as follows: the current is 650-700A, the voltage is 34-38V, and the welding speed is 330-420 mm/min.
7. The submerged arc welding manufacturing method for the main stud of the hydraulic generator according to claim 1, characterized in that: the welding specification of the backing welding at the side of the small and medium groove (7) in the sixth step is as follows: the current is 700-750A, the voltage is 36-40V, and the welding speed is 250-330 mm/min.
8. The submerged arc welding manufacturing method for the main stud of the hydraulic generator according to claim 1, characterized in that: the welding specification of the last step of the transition and the cover surface welding in the ninth step is as follows: the current is 500-600A, the voltage is 36-40, and the welding speed is 420-500 mm/min.
9. The submerged arc welding manufacturing method for the main stud of the water turbine generator according to claim 1, characterized by comprising the following steps: the large groove (8) and the small groove (7) of the auxiliary stud (3) are polygonal transitional grooves.
CN202210974944.3A 2022-08-15 2022-08-15 Submerged arc welding manufacturing method for primary stud of hydraulic generator Active CN115255575B (en)

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Publication number Priority date Publication date Assignee Title
CN103464870A (en) * 2013-09-06 2013-12-25 东方电气集团东方电机有限公司 Method and device for welding water-wheel socket ring
US20140299580A1 (en) * 2013-04-04 2014-10-09 Alstom Technology Ltd. Method for welding rotors for power generation
CN113523510A (en) * 2021-07-21 2021-10-22 哈尔滨电机厂有限责任公司 Double-vehicle submerged arc welding manufacturing method of seven-stud rotor bracket
CN113620159A (en) * 2021-08-12 2021-11-09 哈尔滨电机厂有限责任公司 Welding structure hanger for steam turbine generator base and manufacturing method

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140299580A1 (en) * 2013-04-04 2014-10-09 Alstom Technology Ltd. Method for welding rotors for power generation
CN103464870A (en) * 2013-09-06 2013-12-25 东方电气集团东方电机有限公司 Method and device for welding water-wheel socket ring
CN113523510A (en) * 2021-07-21 2021-10-22 哈尔滨电机厂有限责任公司 Double-vehicle submerged arc welding manufacturing method of seven-stud rotor bracket
CN113620159A (en) * 2021-08-12 2021-11-09 哈尔滨电机厂有限责任公司 Welding structure hanger for steam turbine generator base and manufacturing method

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