CN115255575B - Submerged arc welding manufacturing method for primary stud of hydraulic generator - Google Patents
Submerged arc welding manufacturing method for primary stud of hydraulic generator Download PDFInfo
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- CN115255575B CN115255575B CN202210974944.3A CN202210974944A CN115255575B CN 115255575 B CN115255575 B CN 115255575B CN 202210974944 A CN202210974944 A CN 202210974944A CN 115255575 B CN115255575 B CN 115255575B
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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
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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
- B23K9/235—Preliminary treatment
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- 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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Abstract
The application discloses a submerged arc welding manufacturing method of a main stud of a hydraulic generator, belongs to the field of welding manufacturing of the main stud of the hydraulic generator, solves the problems of low production efficiency, difficult welding deformation control, difficult welding quality guarantee, high welding cost and repeated turning of the main stud and the auxiliary stud of the hydraulic generator, adopts a rolling tire and a triangular backing plate to realize the repeated turning submerged arc welding of the main stud of the hydraulic generator, effectively controls the welding deformation of the main stud and the auxiliary stud by adopting a reverse deformation method and a square control verticality mode, obviously improves the production efficiency by arranging reasonable welding technological parameters, improving the groove form and other measures, shortens the production and manufacturing period, saves the welding cost and effectively ensures the internal quality and the forming quality of a welding seam.
Description
Technical Field
The application belongs to the field of welding and manufacturing of main studs of a giant hydraulic generator, and particularly relates to a submerged arc welding and manufacturing method of main studs of a hydraulic generator.
Background
The disc-type rotor bracket of the oblique support arm is a key component of the giant hydroelectric generating set, and is formed by assembling and welding a rotor center body, an outer circle component, a main upright rib and an auxiliary upright rib, wherein a plurality of layers of magnetic yokes are overlapped on the outer circle of the auxiliary upright rib, and magnetic poles are hung on the outer circle of the magnetic yokes, so that the component with the largest weight in the whole generator is formed. With the increase of the capacity of the unit, the volume and the weight of the rotor are very huge, the outside diameter of the stream ferry rotor is 13.7 m, the whole height is about 3.49 m, the weight is 1600 tons, the diameter of the white crane beach rotor is about 1.65 m, the whole height is 3.9 m, the weight reaches 2300 more tons surprisingly, and the complex is very strict in installation and manufacturing requirements.
The diameter of the rotor support is generally more than 10m, the height is more than 3m, the rotor support is split-welded into a rotor center body, a rotor excircle assembly, a primary stud and a secondary stud split-welding structure in a factory, the split parts are sent to a construction site and then welded into a whole, in order to ensure smooth performance of a magnetic yoke lamination, the requirements on manufacturing quality, mounting and processing precision of split-welding parts of the primary stud and the secondary stud are extremely high, the straightness of the split-welding parts of the primary stud and the secondary stud with the height of 3m is required to be within 0.30mm, and meanwhile, the whole rotor is subjected to great centrifugal force in the high-speed rotation process due to the fact that the weights of the rotor support, the magnetic yoke and the magnetic poles are large, and welding lines of the primary stud and the secondary stud are subjected to great centrifugal force, so that higher requirements on welding deformation control and internal quality of the primary stud and the secondary stud are provided.
The number of the main studs and the auxiliary studs of the disc type rotor support of the inclined support arm is large, the number is generally 24-28, the length is more than 3m, the maximum length can reach 3.6m, the groove is in a K-shaped groove, the welding workload is large, the conventional welding mode mostly adopts CO2 manual gas shielded arc welding, and narrow-gap submerged arc welding is also less.
Because the auxiliary stud has large thickness and large welding filling quantity, the CO2 manual gas shielded welding is adopted, the welding efficiency is low, the production period is not easy to ensure, the welding deformation is difficult to control, the welding quality is not easy to ensure, and the welding repair is easy to occur.
For narrow-gap submerged arc welding, in the actual welding process, the submerged arc welding can only be implemented by adopting large submerged arc welding equipment with an operating frame, the number of the large submerged arc welding equipment with the operating frame is rare, the large occupied area of the site can affect the welding of other parts, due to high cladding efficiency and large heat input of the submerged arc welding, the welding deformation which is in a wave shape after secondary stud welding often occurs is difficult to control, the straightness requirement cannot be met, meanwhile, the secondary stud groove form is K-shaped when the original design is adopted, the filling quantity of groove welding wires is large, the welding deformation is large, and the welding cost is high.
In the actual production process, the two traditional welding modes all need repeated turn-over welding, and the production efficiency can be greatly influenced.
Disclosure of Invention
The application solves the problems of low production efficiency, difficult welding deformation control, difficult welding quality guarantee, high welding cost and repeated turning over of the welding of the primary stud and the secondary stud in order to overcome the defects of the prior art, and further provides a submerged arc welding manufacturing method of the primary stud of the hydraulic generator; the method is realized by the following steps:
step one: the method comprises the steps of installing a rolling tire, positioning and welding a primary stud and a secondary stud, wherein the front rolling tire and the rear rolling tire are respectively arranged on a front guide rail and a rear guide rail, the left side and the right side of the rolling tire are respectively fixed by a first stop block, the primary stud is positioned and welded in a groove of the rolling tire, the secondary stud is positioned and welded on the primary stud, and arc-shaped lacing wires are welded between the side elevation of a small groove of the secondary stud and the plane of the primary stud;
step two: the method comprises the steps of performing bottom sealing welding on the root part of a small groove, rotating a rolling tire anticlockwise until a secondary stud is in an approximately horizontal state, enabling the small groove side to face upwards, preheating a to-be-welded area of a primary stud and the secondary stud, and performing bottom sealing welding on the root part of the small groove by adopting gas shielded welding;
step three: performing backing welding on the large groove side, rotating the rolling tire clockwise until the auxiliary stud is in an approximately horizontal state, enabling the large groove side to face upwards, welding a second stop block on the auxiliary stud, arranging a triangular backing plate on the auxiliary stud along the length direction, paving a submerged arc welding trolley and a track on the triangular backing plate, preheating the welding areas of the main stud and the auxiliary stud to a preset temperature, performing backing welding by submerged arc welding, and controlling the welding thickness to be 3-5 mm;
step four: filling and welding the side of the large groove, namely filling and welding the side of the large groove to the height of 20-30 mm, and controlling the perpendicularity of the auxiliary stud and the main stud to be 5-10 mm/m by adopting a square;
step five: the method comprises the steps of back gouging on the side of a small groove, rotating a rolling tire anticlockwise until a secondary stud is in an approximately horizontal state, enabling the side of the small groove to face upwards, back gouging a root back-sealing weld joint on the side of the small groove and a backing weld joint on the side of a large groove, polishing to expose metallic luster after back gouging, and then performing PT flaw detection to ensure that defects at the root of the weld joint are removed completely and arc-shaped lacing wires are removed simultaneously;
step six: backing welding on the side of the small groove, preheating the to-be-welded areas of the primary stud and the secondary stud to a preset temperature, welding a third stop block on the secondary stud, arranging the triangular backing plate on the secondary stud along the length direction, paving a submerged arc welding trolley and a track on the triangular backing plate, and backing welding on the side of the small groove by submerged arc welding;
step seven: filling welding on the small groove side, adopting submerged arc welding to fill welding on the small groove side of the auxiliary stud, and detecting and controlling the perpendicularity of the auxiliary stud and the main stud within the range of 3-5 mm/m by using a square;
step eight: repeatedly turning over and filling and welding, clockwise rotating the rolling tire until the auxiliary stud is in an approximately horizontal state, enabling the large groove side to face upwards, filling and welding the large groove side, controlling the perpendicularity of the auxiliary stud and the main stud to be between 0 and 2mm/m by adopting a square, anticlockwise rotating the rolling tire until the auxiliary stud is in an approximately horizontal state, enabling the small groove side to face upwards, filling and welding the small groove side, controlling the perpendicularity of the auxiliary stud and the main stud to be between 0 and 2mm/m by adopting the square, and repeatedly turning over and filling and welding until the auxiliary stud is in a full welding state;
step nine: and (3) carrying out transition and cover surface welding by rotating the rolling tire clockwise until the auxiliary stud is in an approximately horizontal state, enabling the side of the large groove to face upwards, carrying out transition and cover surface welding on the side of the large groove, controlling the perpendicularity of the auxiliary stud and the main stud to be between 0 and 2mm/m by adopting a square, rotating the rolling tire anticlockwise until the auxiliary stud is in an approximately horizontal state, enabling the side of the small groove to face upwards, carrying out transition and cover surface welding on the side of the small groove, controlling the perpendicularity of the auxiliary stud and the main stud to be between 0 and 2mm/m by adopting the square, and repeatedly turning over until the welding seam welding angle welding is completed.
In the method for manufacturing the primary stud submerged arc welding of the hydraulic generator, the rolling tire in the first step is formed by welding three parts of an arc section, a groove and a horizontal section in a grouping mode, and the material is a Q345B steel plate.
In the method for manufacturing the primary stud of the hydraulic generator by submerged arc welding, the primary stud and the secondary stud in the first step are made of Q345B steel plates.
In the method for manufacturing the primary stud submerged-arc welding of the hydraulic generator, welding wires used for the positioning welding in the first step and the small groove side root sealing welding in the second step are phi 1.2mm ER50-6.
In the hydraulic generator main stud submerged arc welding manufacturing method, the large groove side priming welding in the third step, the large groove side filling welding in the fourth step, the small and medium groove side priming welding in the sixth step, the small and medium groove 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 the welding wires and the welding flux used are phi 4mm H08MnA and 10-60 mesh HJ431 respectively.
In the method for manufacturing the primary stud submerged arc welding of the hydraulic generator, the welding specifications of the positioning welding in the first step and the small groove side root back cover welding in the second step are as follows: current 210-280A, voltage 22-29V, welding speed 180-350 mm/min, shielding gas component: 78% Ar+22% CO 2 Flow rate: 12-20L/min.
In the method for manufacturing the primary stud submerged arc welding of the hydraulic generator, the welding specification of the large groove side backing welding 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 method for manufacturing the primary stud submerged arc welding of the hydraulic generator, the welding specifications of the large groove side filling welding in the fourth step, the small groove side filling welding 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.
In the method for manufacturing the primary stud submerged arc welding of the hydraulic generator, the welding specification of the backing welding of the side of the small and medium grooves in the step six is as follows: the current is 700-750A, the voltage is 36-40V, and the welding speed is 250-330 mm/min.
In the method for manufacturing the primary stud submerged arc welding of the hydraulic generator, welding specifications of transition and cover surface welding in the step nine are as follows: the current is 650-700A, the voltage is 34-38V, and the welding speed is 330-420 mm/min.
In the method for manufacturing the primary stud submerged arc welding of the hydraulic generator, welding specifications of transition and cover surface welding in the step nine are as follows: the current is 500-600A, the voltage is 36-40, and the welding speed is 420-500 mm/min.
In the method for manufacturing the primary stud of the hydraulic generator by submerged arc welding, the large groove and the small groove of the secondary stud are in the form of broken line transition grooves.
Compared with the prior art, the application has the following beneficial effects:
1) The rolling tire and the triangular backing plate are adopted to realize submerged arc welding manufacture of the main stud of the giant hydraulic generator, so that the production efficiency can be effectively improved, and the production and manufacturing period can be obviously shortened.
2) The application solves the problem of repeated turning of the primary 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 method of controlling verticality by using the reverse deformation method and the square effectively controls the welding deformation of the main stud and the stud, and reasonable welding specifications are set at different welding stages of backing welding, filling welding, transition and cover welding, so that the internal quality and the forming quality of the welding seam are effectively ensured.
4) The groove form of the auxiliary stud is changed from the original K-shaped groove to a groove in a broken line transition form, so that the filling quantity of welding wires is reduced, and the welding cost is effectively saved.
Drawings
FIG. 1 is a schematic front view of a station for positioning and welding a rolling tire, a primary stud and a secondary stud in the application;
FIG. 2 is a schematic left view of a station for positioning and welding a rolling tire, a primary stud and a secondary stud in the application;
FIG. 3 is a schematic diagram of a welding station of the small groove side root back-sealing welding of the application;
FIG. 4 is a schematic diagram of a welding station for primary and secondary stud large groove side backing welding in the present application;
FIG. 5 is a schematic view of the installation position of a second stop, a triangular backing plate, a track and a submerged arc welding trolley in the application;
FIG. 6 is a schematic diagram of a welding station for filler welding of the large groove sides of a primary stud and a secondary stud in the application;
FIG. 7 is a schematic diagram of a welding station for back chipping and backing welding of a primary stud and a secondary stud small groove side in the application;
FIG. 8 is a schematic diagram of a welding station for the filler welding of the primary and secondary bead small groove sides in the present application;
FIG. 9 is a schematic diagram of a welding station after the primary and secondary studs are repeatedly turned over and welded;
FIG. 10 is a schematic diagram of a welding station after the transition between the primary stud and the secondary stud and the cover surface welding are completed;
FIG. 11 is a schematic view of a tire according to the present application;
fig. 12 is a schematic view of a secondary stud fold line groove in the present application.
The figure indicates: 1-rolling tire, 2-primary stud, 3-secondary stud, 4-guide rail, 5-first stop block, 6-arc lacing wire, 7-small groove, 8-large groove, 9-second stop block, 10-triangular baffle plate, 11-submerged arc welding trolley, 12-track, 13-third stop block, 14-arc section, 15-groove and 16-horizontal section.
Detailed Description
The application is further described below with reference to the accompanying drawings. The following examples are only for more clearly illustrating the technical aspects of the present application, and are not intended to limit the scope of the present application.
The embodiment provides a submerged arc welding manufacturing method of a primary stud of a hydraulic generator, which is realized by the following steps:
step one: the positioning welding of the rolling tire 1, the primary stud 2 and the secondary stud 3 is carried out, as shown in fig. 1 and 2, the front rolling tire 1 and the rear rolling tire 1 are respectively arranged on the front guide rail 4 and the rear guide rail 4, the left side and the right side of the front rolling tire are respectively fixed by the first stop blocks 5, the primary stud 2 is positioned and welded in the groove 15 of the rolling tire 1, the secondary stud 3 is positioned and welded on the primary stud 2, and the arc-shaped lacing wire 6 is welded between the side elevation of the small groove 7 of the secondary stud 3 and the plane of the primary stud 2; in the step, the main stud 2 is positioned and welded in the groove 15 of the rolling tire 1, so that the gravity centers of the rolling tire 1, the main stud 2 and the auxiliary stud 3 are positioned below the whole structure, which is similar to a tumbler principle, on one hand, the repeated turning over is easier, on the other hand, the whole structure is prevented from toppling over, and the use safety is improved. The arc lacing wire 6 is used for preventing the auxiliary stud 3 from being excessively deformed during backing welding and filling welding of the large groove 8 side.
Step two: the bottom sealing welding of the root of the small groove 7 is carried out, as shown in fig. 3, the rolling tire 1 is rotated anticlockwise until the auxiliary stud 3 is in an approximately horizontal state, the small groove 7 is upwards, the areas to be welded of the main stud 2 and the auxiliary stud 3 are preheated, and the bottom sealing welding of the root of the small groove 7 is carried out by adopting gas shielded welding; the purpose of this step is to prevent flux from leaking from the back of the weld during the backing weld on the large groove 8 side, in preparation for the backing weld on the large groove 8 side.
Step three: the large groove 8 side is subjected to backing welding, as shown in fig. 4, the rolling tire 1 is rotated clockwise until the auxiliary stud 3 is in an approximately horizontal state, the large groove 8 side is upwards, as shown in fig. 5, a second stop block 9 is welded on the auxiliary stud 3, a triangular backing plate 10 is arranged on the auxiliary stud 3 along the length direction, meanwhile, a submerged arc welding trolley 11 and a track 12 are paved on the triangular backing plate 10, after the welding areas of the main stud 2 and the auxiliary stud 3 are preheated to a preset temperature, backing welding is performed by adopting submerged arc welding, and the welding thickness is controlled to be 3-5 mm; the secondary backing welding is carried out in a mode of small welding standard fast carriage, and the purpose is to increase the welding thickness of the backing layer and prevent the backing layer from being broken down during filling welding of the large groove 8 side.
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 until the height is 20-30 mm, and controlling the perpendicularity between the auxiliary stud and the main stud to be 5-10 mm/m by adopting a square; in the step, the side of the large groove 8 is filled and welded to the height of 20-30 mm, meanwhile, the purpose of controlling the perpendicularity of the auxiliary stud 3 and the main stud 2 to be between 5-10 mm/m is to prevent the weld joint strength from being insufficient due to the fact that the weld joint section is reduced after the back gouging of the side weld joint of the small groove 7, and the weld joint root is cracked due to the release of stress parts when preheating is carried out, meanwhile, the auxiliary stud 3 is pre-deformed towards the side of the large groove 8 after being cooled by adopting an inverse deformation method, a proper margin is reserved for the deformation of the side of the small groove 7 in the subsequent backing welding and filling welding, and the deformation of the auxiliary stud 3 in the whole welding process can be controlled more effectively.
Step five: the back gouging of the side of the small groove 7 is carried out, as shown in fig. 7, the rolling tire 1 is rotated anticlockwise until the auxiliary stud 3 is in an approximately horizontal state, the side of the small groove 7 faces upwards, the back gouging is carried out on the root back-sealing welding seam of the side of the small groove 7 and the bottoming welding seam of the side of the large groove 8, the metal luster is exposed after the back gouging, then PT flaw detection is carried out to ensure that the defects of the root parts of the welding seams are cleared completely, and meanwhile, the arc-shaped lacing wires 6 are cleared; in the step, the root part may have defects such as air holes and microcracks, and the purpose of back chipping is to remove the defects affecting the joint performance, ensure the internal quality of the weld root part during subsequent welding, and improve the flaw detection qualification rate during final cross inspection of the weld.
Step six: welding the side of the small groove 7, as shown in fig. 7, preheating the to-be-welded areas of the primary stud 2 and the secondary stud 3 to a preset temperature, welding a third stop block 13 on the secondary stud 3, arranging a triangular backing plate 10 on the secondary stud 3 along the length direction, paving a submerged arc welding trolley 11 and a track 12 on the triangular backing plate 10, and performing backing welding on the side of the small groove 7 by submerged arc welding; the purpose of adopting single-pass heavy-current welding in the step is to ensure thorough penetration of the root and the welding seams at the two sides.
Step seven: filling welding of the small groove 7 side, as shown in fig. 8, performing filling welding of the small groove 7 side of the auxiliary stud 3 by submerged arc welding, and detecting and controlling the perpendicularity between the auxiliary stud 3 and the main stud 2 within a range of 3-5 mm/m by using a right angle ruler; the method adopts the reverse deformation method to lead the auxiliary stud 3 to be deformed in advance towards the small groove 7 side after cooling, so that a proper margin is reserved for the deformation towards the large groove 8 side in the subsequent large groove 8 side filling welding, and the more strict the reverse deformation requirements for the repeated turning-over filling welding, transition and cover surface welding stages of the large groove 8 side and the small groove 7 side are, the more effective the deformation of the auxiliary stud 3 in the whole welding process can be controlled.
Step eight: the filling welding is repeatedly turned over, as shown in fig. 9, the rolling tire 1 is rotated clockwise until the auxiliary stud 3 is in an approximately horizontal state, the side of the large groove 8 faces upwards, the side of the large groove 8 is filled and welded, a square is adopted to control the perpendicularity between the auxiliary stud 3 and the main stud 2 to be 0-2 mm/m, the rolling tire 1 is rotated anticlockwise until the auxiliary stud 3 is in an approximately horizontal state, the side of the small groove 7 faces upwards, the side of the small groove 7 is filled and welded, the square is adopted to control the perpendicularity between the auxiliary stud 3 and the main stud 2 to be 2-3 mm, and the filling welding is repeatedly turned over until the state is reached; in the step, normal standard welding is adopted, the welding current is amplified, the welding speed is slowed down to ensure the fusion of two sides of the groove, and meanwhile, the welding quantity is continuously reduced, and the perpendicularity is controlled to be within 2mm/m and is controlled to be 0mm/m, so that the welding deformation of the auxiliary stud 3 is more favorably controlled.
Step nine: the transition and cover welding is carried out, as shown in fig. 10, the rolling tire 1 is rotated clockwise to the auxiliary stud 3 to be in an approximately horizontal state, the side of the large groove 8 faces upwards, the side of the large groove 8 is subjected to the transition and cover welding, the right angle ruler is adopted to control the perpendicularity between the auxiliary stud 3 and the main stud 2 to be between 0 and 2mm, the rolling tire 1 is rotated anticlockwise to the auxiliary stud 3 to be in an approximately horizontal state, the side of the small groove 7 faces upwards, the side of the small groove 7 is subjected to the transition and cover welding, the right angle ruler is adopted to control the perpendicularity between the auxiliary stud 3 and the main stud 2 to be between 0 and 2mm, and the welding is repeatedly turned over until the welding of a weld joint welding angle is completed; in the step, the normal standard welding is adopted firstly, the welding current is amplified, the welding speed is slowed down to ensure the fusion with the side wall, meanwhile, the welding quantity is continuously reduced, the perpendicularity is controlled to be within 2mm/m and is controlled to be 0mm/m, so that the welding deformation of the auxiliary stud 3 is more favorably controlled, the small standard welding of a small current quick carriage is adopted in the final cover welding, the welding seam transition and the cover quality are improved, the undercut defect is avoided, and the welding seam appearance is attractive.
Further, as shown in fig. 11, in the first step, the rolling tire 1 is formed by welding three parts of an arc section 14, a groove 15 and a horizontal section 16, and the material is a Q345B steel plate;
further, in the first step, the primary stud 2 and the secondary stud 3 are made of Q345B steel plates;
further, welding wires used for the positioning welding in the first step and the bottom sealing welding of the side root part of the small groove 7 in the second step are phi 1.2mm ER50-6;
further, the welding of the side priming of the large groove 8 in the third step, the welding of the side filling of the large groove 8 in the fourth step, the welding of the side priming of the small groove 7 in the sixth step, the welding of the side filling of the small groove 7 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 the welding wires and the welding flux used are phi 4mm H08MnA and 10-60 mesh HJ431 respectively; the control of the preheating temperature and the interlayer temperature in the step is mainly used for preventing the generation of cold cracks and hot cracks in the welding of the thick steel plate and ensuring the quality of welding seams.
Further, the welding specifications of the tack welding in the first step and the small groove 7 side root sealing welding in the second step are as follows: current 210-280A, voltage 22-29V, welding speed 180-350 mm/min, shielding gas component: 78% Ar+22% CO 2 Flow rate: 12-20L/min;
further, the welding specification of the large groove 8 side backing welding 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 bottoming welding of the large groove 8 side is key, and the welding is generally carried out by adopting a small standard, so that the welding quality is guaranteed.
Further, the welding specifications of the large groove 8 side filling welding in the fourth step, the small groove 7 filling welding 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; in the step, the filling welding is performed by adopting a large standard, which is beneficial to improving the metal cladding efficiency and the production efficiency.
Further, the welding specification of the side bottoming welding of the small and medium grooves 7 in the step six 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-scale welding in the step is to ensure thorough penetration of the root and the welding seams at two sides.
Further, the welding specification of the transition and cover welding in the step nine is as follows: the current is 650-700A, the voltage is 34-38V, and the welding speed is 330-420 mm/min; in the step, the submerged arc transition and the cover surface welding are welded by adopting large specifications, so that the metal cladding efficiency is improved, and the production efficiency is improved.
Further, the welding specification of the last transition welding and cover welding in the step nine 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 final welding of submerged arc transition and cover surface welding adopts small-specification rapid welding, which is favorable for controlling undercut defects and leading the welding seam to be formed attractive.
Further, as shown in fig. 12, the large groove 8 and the small groove 7 of the auxiliary stud 3 are in the form of broken line transition grooves; in the step, the original K-shaped groove of the auxiliary stud 3 is changed into a broken line transition groove, so that the welding wire filling quantity is reduced, and the production and manufacturing cost is saved.
The present application is merely illustrative of the present application and not limited to the scope thereof, and those skilled in the art can make modifications thereto without departing from the spirit of the application.
Claims (9)
1. A submerged arc welding manufacturing method of a primary stud of a hydraulic generator is characterized by comprising the following steps of: the method is realized by the following steps:
step one: the method comprises the steps of installing a rolling tire (1), positioning and welding a primary vertical rib (2) and a secondary vertical rib (3), arranging the front rolling tire (1) and the rear rolling tire on a front guide rail (4) and a rear guide rail (4) respectively, fixing the front rolling tire and the rear rolling tire by using first stop blocks (5) respectively at the left side and the right side, positioning and welding the primary vertical rib (2) in a groove (15) of the rolling tire (1), positioning and welding the secondary vertical rib (3) on the primary vertical rib (2), and welding an arc-shaped lacing wire (6) between the side vertical surface of a small groove (7) of the secondary vertical rib (3) and the plane of the primary vertical rib (2);
step two: the method comprises the steps of performing bottom sealing welding on the root part of the small groove (7), rotating a rolling tire (1) anticlockwise until a secondary vertical rib (3) is in an approximately horizontal state, enabling the side of the small groove (7) to face upwards, preheating the to-be-welded areas of the primary vertical rib (2) and the secondary vertical rib (3), and performing bottom sealing welding on the root part of the small groove (7) by adopting gas shielded welding;
step three: performing backing welding on the side of the large groove (8), rotating the rolling tire (1) clockwise until the auxiliary stud (3) is in an approximately horizontal state, enabling the side of the large groove (8) to face upwards, welding a second stop block (9) on the auxiliary stud (3), arranging a triangular base plate (10) on the auxiliary stud (3) along the length direction, simultaneously paving a submerged arc welding trolley (11) and a track (12) on the triangular base plate (10), preheating a region to be welded of the main stud (2) and the auxiliary stud (3) to a preset temperature, and performing backing welding by submerged arc welding, wherein the welding thickness is controlled to be 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 perpendicularity of the auxiliary stud (3) and the main stud (2) to be 5-10 mm/m by adopting a square;
step five: the method comprises the steps of performing back gouging on the side of a small groove (7), rotating a rolling tire (1) anticlockwise until a secondary stud (3) is in an approximately horizontal state, enabling the side of the small groove (7) to face upwards, performing back gouging on a root back-sealing welding line on the side of the small groove (7) and a bottoming welding line on the side of a large groove (8), polishing after back gouging to expose metallic luster, performing PT flaw detection to ensure that defects at the root of the welding line are cleared completely, and simultaneously clearing an arc-shaped lacing wire (6);
step six: welding the side of a small groove (7), preheating the to-be-welded areas of a primary stud (2) and a secondary stud (3) to a preset temperature, welding a third stop block (13) on the secondary stud (3), arranging a triangular backing plate (10) on the secondary stud (3) along the length direction, paving a submerged arc welding trolley (11) and a track (12) on the triangular backing plate (10), and performing backing welding on the side of the small groove (7) by submerged arc welding;
step seven: filling welding the side of the small groove (7), adopting submerged arc welding to fill welding the side of the small groove (7) of the auxiliary stud (3), and detecting and controlling the verticality of the auxiliary stud (3) and the main stud (2) to be in the range of 3-5 mm/m by using a right angle ruler;
step eight: repeatedly turning over and filling and welding, clockwise rotating the rolling tire (1) until the auxiliary stud (3) is 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), controlling the perpendicularity between the auxiliary stud (3) and the main stud (2) to be 0-2 mm/m by adopting a square, anticlockwise rotating the rolling tire (1) until the auxiliary stud (3) is 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), controlling the perpendicularity between the auxiliary stud (3) and the main stud (2) to be 0-2 mm/m by adopting the square, and repeatedly turning over and filling and welding until the welding is in a full state;
step nine: and (3) carrying out transition and cover surface welding, namely rotating the rolling tire (1) clockwise until the auxiliary stud (3) is in an approximately horizontal state, enabling the side of the large groove (8) to face upwards, carrying out transition and cover surface welding on the side of the large groove (8), controlling the perpendicularity of the auxiliary stud (3) and the main stud (2) to be between 0 and 2mm/m by adopting a square, rotating the rolling tire (1) anticlockwise until the auxiliary stud (3) is in an approximately horizontal state, enabling the side of the small groove (7) to face upwards, carrying out transition and cover surface welding on the side of the small groove (7), controlling the perpendicularity of the auxiliary stud (3) and the main stud (2) to be between 0 and 2mm/m by adopting the square, and repeatedly turning over until the welding of a welding seam welding angle is completed.
2. The method for manufacturing the primary stud submerged arc welding of the hydraulic generator according to claim 1, wherein the method comprises the following steps: the rolling tire (1) in the first step is formed by welding three parts of an arc-shaped section (14), a groove (15) and a horizontal section (16) in a grouping mode, the material is a Q345B steel plate, and the materials of the primary stud (2) and the secondary stud (3) in the first step are both Q345B steel plates.
3. The method for manufacturing the primary stud submerged arc welding of the hydraulic generator according to claim 1, wherein the method comprises the following steps: welding wires used for the positioning welding in the first step and the small groove side root sealing welding in the second step are phi 1.2mm ER50-6, and welding specifications are as follows: current 210-280A, voltage 22-29V, welding speed 180-350 mm/min, shielding gas component: 78% Ar+22% CO 2 Flow rate: 12-20L/min.
4. The method for manufacturing the primary stud submerged arc welding of the hydraulic generator according to claim 1, wherein the method comprises the following steps: the welding method comprises the steps of welding a large groove (8) side priming in the third step, welding a large groove (8) side filling in the fourth step, welding a small groove (7) side priming in the sixth step, welding a small groove (7) side filling in the seventh step, repeatedly turning over and filling in the eighth step, preheating at the transition stage and the cover surface welding stage in the ninth step at a temperature of not lower than 100 ℃, and preheating at the interlayer temperature of not higher than 260 ℃, wherein the welding wires and the welding fluxes are phi 4mm H08MnA and 10-60 meshes HJ431 respectively.
5. The method for manufacturing the primary stud submerged arc welding of the hydraulic generator according to claim 1, wherein the method comprises the following steps: the welding specification of the large groove (8) side bottoming welding 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 method for manufacturing the primary stud submerged arc welding of the hydraulic generator according to claim 1, wherein the method comprises the following steps of: the welding specifications of the large groove (8) side filling welding in the fourth step, the small groove (7) side filling welding in the seventh step, the repeated turning-over filling welding in the eighth step and the transitional 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 method for manufacturing the primary stud submerged arc welding of the hydraulic generator according to claim 1, wherein the method comprises the following steps: the welding specification of the side priming welding of the small and medium grooves (7) in the step six is as follows: the current is 700-750A, the voltage is 36-40V, and the welding speed is 250-330 mm/min.
8. The method for manufacturing the primary stud submerged arc welding of the hydraulic generator according to claim 1, wherein the method comprises the following steps: the welding specification of the last transition welding and the cover welding in the step nine is as follows: the current is 500-600A, the voltage is 36-40, and the welding speed is 420-500 mm/min.
9. The method for manufacturing the primary stud submerged arc welding of the hydraulic generator according to claim 1, wherein the method comprises the following steps: the large groove (8) and the small groove (7) of the auxiliary stud (3) are in the form of broken line transition grooves.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| 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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| EP2787167B1 (en) * | 2013-04-04 | 2018-12-26 | Ansaldo Energia IP UK Limited | Method for welding rotors for power generation |
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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 |
| 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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