CN115319242A - Method for repairing welding defect of valve lip - Google Patents
Method for repairing welding defect of valve lip Download PDFInfo
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- CN115319242A CN115319242A CN202210845284.9A CN202210845284A CN115319242A CN 115319242 A CN115319242 A CN 115319242A CN 202210845284 A CN202210845284 A CN 202210845284A CN 115319242 A CN115319242 A CN 115319242A
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- 238000003466 welding Methods 0.000 title claims abstract description 222
- 238000000034 method Methods 0.000 title claims abstract description 45
- 230000007547 defect Effects 0.000 title claims abstract description 28
- 230000008569 process Effects 0.000 claims abstract description 17
- 230000008439 repair process Effects 0.000 claims abstract description 13
- 239000000463 material Substances 0.000 claims abstract description 8
- 229910000975 Carbon steel Inorganic materials 0.000 claims abstract description 4
- 239000010962 carbon steel Substances 0.000 claims abstract description 4
- 239000011261 inert gas Substances 0.000 claims abstract description 4
- 239000007787 solid Substances 0.000 claims abstract description 4
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims abstract description 4
- 229910052721 tungsten Inorganic materials 0.000 claims abstract description 4
- 239000010937 tungsten Substances 0.000 claims abstract description 4
- 238000007689 inspection Methods 0.000 claims description 14
- 229910000734 martensite Inorganic materials 0.000 claims description 14
- 230000003014 reinforcing effect Effects 0.000 claims description 14
- 238000004458 analytical method Methods 0.000 claims description 9
- 238000011156 evaluation Methods 0.000 claims description 8
- 230000008859 change Effects 0.000 claims description 7
- 230000007704 transition Effects 0.000 claims description 6
- 238000004088 simulation Methods 0.000 claims description 5
- 238000012795 verification Methods 0.000 claims description 4
- 238000005728 strengthening Methods 0.000 abstract description 7
- 238000013461 design Methods 0.000 abstract description 5
- 229910052751 metal Inorganic materials 0.000 abstract description 3
- 239000002184 metal Substances 0.000 abstract description 3
- 238000005498 polishing Methods 0.000 abstract description 3
- 230000002950 deficient Effects 0.000 abstract description 2
- 238000000227 grinding Methods 0.000 abstract description 2
- 238000002955 isolation Methods 0.000 abstract description 2
- 230000002035 prolonged effect Effects 0.000 abstract description 2
- 230000002787 reinforcement Effects 0.000 description 25
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 8
- 230000035515 penetration Effects 0.000 description 5
- 229910052786 argon Inorganic materials 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 238000001816 cooling Methods 0.000 description 3
- 238000007789 sealing Methods 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 238000011282 treatment Methods 0.000 description 3
- 238000005202 decontamination Methods 0.000 description 2
- 230000003588 decontaminative effect Effects 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000009659 non-destructive testing Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000001066 destructive effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 238000011418 maintenance treatment Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 230000008520 organization Effects 0.000 description 1
- 230000003449 preventive effect Effects 0.000 description 1
- 238000005496 tempering Methods 0.000 description 1
- 238000011179 visual inspection Methods 0.000 description 1
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Classifications
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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
- B23K9/16—Arc welding or cutting making use of shielding gas
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Arc Welding In General (AREA)
- Butt Welding And Welding Of Specific Article (AREA)
Abstract
The invention discloses a method for repairing a welding defect of a valve lip, which comprises the following steps: s1, preheating a valve needing to be repaired in lip welding, and keeping the temperature of the valve at 60-80 ℃; s2, taking a solid carbon steel welding wire as a welding material, and performing reinforced welding on a lip welding seam by adopting a TIG (tungsten inert gas) welding method; in the welding process, the welding heat input is controlled to be 1.2 kJ/mm-2.0 kJ/mm, and the ratio of the welding heat input to the outer diameter of the valve where the lip welding seam is located is 17-23. The method for repairing the lip welding defects of the valve effectively improves the performance of original lip welding seam structures on the valve and effectively improves the hardening structures of the original welding seams, thereby reducing the hardness trend of the original welding seams; the method is carried out by reinforced welding repair, the defective metal does not need to be removed, and the workload of on-site polishing, grinding and the like is reduced; the requirements on the valves and related systems for isolation and evacuation are not strict; strengthening the original welding line by strengthening welding, and meeting the requirement of valve design working condition after strengthening welding; the service life of the valve is prolonged.
Description
Technical Field
The invention relates to the technical field of valve welding repair, in particular to a method for repairing a welding defect of a valve lip.
Background
In valve design, the valve bonnet and the valve body are connected together through threads to bear the main load. The end parts of the sealing surfaces of the two are provided with a lip welding seam which mainly plays a sealing role and is also called a sealing seam.
A large number of valves in the nuclear power plant pipeline system all adopt the lip weld seam structure, the weld seam adopts the manual argon arc welding (TIG) without or with filling metal to weld, because the lip weld seam has the characteristics of thin thickness, gap at the root of the weld seam, high welding cooling speed and the like, if the welding operation is improper and the welding parameter range is too large, the defects of crack, incomplete penetration and the like at the root of the weld seam are easy to generate, the welding seam hardness is too high, and the condition of hardening organization exists. According to the RCC-M standard requirements, for a lip welding seam, only liquid penetration inspection is needed to be carried out on a surface to be welded and the surface of a finished welding seam, no volume inspection requirement (limited by structure and size, and volume inspection cannot be carried out during actual manufacturing), the defect conditions of the root part and the inside of the welding seam cannot be detected through the liquid penetration inspection, if the welding process is not controlled properly, the root part of the welding seam easily generates defects such as cracks, incomplete fusion and the like, and a hardening structure possibly occurs in the welding seam and a heat affected zone, so that the welding seam becomes a failure source.
At present, valve lip welding leakage conditions of different degrees appear in operation and maintenance stages of each nuclear power plant unit, and after fundamental reason analysis and investigation, most of leakage causes are performance reduction caused by welding defects existing at the root of an original welding seam or hardening tissues existing in the original welding seam, and leakage is caused by gradual cracking from the root of the welding seam under long-term service. Leakage occurs in the operation stage of the power station, which seriously affects the safe operation of the power plant, causes immeasurable consequences and needs urgent maintenance treatment.
Because the structure is generally used for the valve structure of each system of a power plant and is difficult to adopt other structural forms for large-scale replacement in a short time, an efficient preventive maintenance method for the welding seam of the valve lip welding seam is necessary to repair the tissue defect of the welding seam.
Disclosure of Invention
The invention aims to solve the technical problem of providing an improved method for repairing the welding defect of a valve lip.
The technical scheme adopted by the invention for solving the technical problems is as follows: the method for repairing the welding defect of the valve lip comprises the following steps:
s1, preheating a valve needing to be repaired in lip welding, and keeping the temperature of the valve at 60-80 ℃;
s2, taking a solid carbon steel welding wire as a welding material, and performing reinforced welding on a lip welding seam by adopting a TIG (tungsten inert gas) welding method;
in the welding process, the welding heat input is controlled to be 1.2 kJ/mm-2.0 kJ/mm, and the ratio of the welding heat input to the outer diameter of the valve where the lip welding seam is located is 17-23.
Preferably, in step S2, the welding current is 60A-80A, the welding voltage is 10V-11V, and the welding speed is 20 mm/min-40 mm/min.
Preferably, in step S2, the reinforcement welding forms at least one reinforcement weld.
Preferably, in step S2, the reinforcement welding forms two or more reinforcement welds, and the arc-closing position of the reinforcement welds covers the arc-starting position by at least 15mm.
Preferably, in step S2, the edge of the reinforcing weld formed by reinforcing welding forms a smooth transition with the surface of the valve where the lip weld is located.
Preferably, in step S2, a transition bevel angle between an edge of the reinforcement weld formed by reinforcement welding and the surface of the valve where the lip weld is located is less than or equal to 30 °.
Preferably, the method for repairing the welding defect of the valve lip further comprises the following steps before the step S1:
s0, establishing a model;
step S0 includes the steps of:
s0.1, simulating a welding temperature field of the lip welding seam according to original size data, welding processes and parameters of the lip welding seam, combining a CCT curve of a material, and comparing martensite structure occupation ratios after welding by different welding processes and parameters;
s0.2, determining welding repair parameters according to the welding temperature field analysis of the simulated lip welding seam in combination with a valve where the lip welding seam is located, and verifying martensite ratio change through modeling;
and S0.3, selecting corresponding welding parameters according to martensite change, and performing simulation verification.
Preferably, step S0 further comprises the steps of:
s0.4, lip welding mechanical modeling and evaluation.
Preferably, the method for repairing the welding defect of the valve lip further comprises the following steps:
and S3, carrying out nondestructive inspection on the reinforced welding seam formed by reinforced welding.
The invention has the beneficial effects that: the structure performance of the original lip welding seam on the valve is effectively improved, and the hardening structure of the original welding seam is effectively improved, so that the hardness trend of the original welding seam is reduced; the method is carried out by reinforced welding repair, the defective metal does not need to be removed, and the workload of on-site polishing, grinding and the like is reduced; the requirements on the valves and related systems for isolation and evacuation are not strict; strengthening the original welding seam by strengthening welding, and meeting the requirement of valve design working condition after strengthening welding; the service life of the valve is prolonged.
Drawings
The invention will be further described with reference to the accompanying drawings and examples, in which:
FIG. 1 is a schematic structural view of an embodiment of the present invention after repair of a valve lip weld;
fig. 2 is a schematic structural view of another embodiment of the valve lip weld repair of the present invention.
Detailed Description
For a more clear understanding of the technical features, objects and effects of the present invention, embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
As shown in fig. 1 and 2, the method for repairing the welding defect of the valve lip comprises the following steps:
and S0, modeling formulation.
Modeling, verifying, making and the like are carried out according to the lip welding seam 10 to be repaired so as to obtain the welding mode, parameters and the like of subsequent repair welding.
S1, preheating a valve needing to be repaired in lip welding, and keeping the temperature of the valve at 60-80 ℃.
The purpose of the preheating is primarily to help reduce the subsequent post-weld cooling rate and thereby reduce the risk of producing hardened structures.
Before the preheating treatment, the surface of the lip weld 10 on the valve is also subjected to decontamination treatment, and the decontamination treatment can comprise polishing, cleaning and the like.
And S2, taking a solid carbon steel welding wire as a welding material, and performing reinforced welding on the lip welding seam 10 by adopting a TIG (tungsten inert gas) welding method.
Wherein, the welding material can be selected from ER-70S series.
The welding parameters were as follows: the welding current is 60A-80A, the welding voltage is 10V-11V, and the welding speed is 20 mm/min-40 mm/min. The welding speed is low, and the risk of producing hardened structures is obviously reduced.
The specific choice for the welding current is based on the valve size. For example, for a small size valve, the welding current selects a small value within a range, and the welding speed selects a small value within a range; for a large-size valve, the welding current is selected to be a middle value or a high value in a range, and the welding speed is selected to be a middle value or a high value in a range.
During welding, heat input needs to be controlled, the heat input is too low, the cooling speed is high, hardened structures are generated, the heat input is too high, the plastic deformation is large, and therefore matching is needed according to the outer diameter of the valve. In the embodiment, the welding heat input is controlled to be 1.2 kJ/mm-2.0 kJ/mm, the ratio of the welding heat input to the outer diameter of the valve where the lip welding seam is located is 17-23, and the risk of producing hardening tissues is reduced.
The reinforcement welds form one or more reinforcement welds 20. The strengthening weld 20 is close to the original weld (lip weld 10) penetration to achieve the purpose of changing the hardened structure of all original welds. Fig. 1 shows a schematic structure of one reinforcing weld 20 formed by reinforcement welding, and fig. 2 shows a schematic structure of two reinforcing welds 20 formed by reinforcement welding.
For reinforcement welding to form two or more reinforcement welds 20, the arc ending position of the reinforcement welds 20 covers the arc starting position by at least 15mm.
Further preferably, the reinforcement welds form two reinforcement welds 20. Wherein, the first reinforced welding seam 20 plays a role of tempering and improving a hardened structure for the original welding seam, and simultaneously, the temperature of the workpiece is maintained at 60-80 ℃ after welding, which is equivalent to that the second reinforced welding seam is preheated; the second reinforcement weld 20 again tempers both the original weld and the first reinforcement weld 20.
In addition, the edge of the reinforcement weld 20 formed by the reinforcement welding forms a smooth transition with the surface of the valve where the lip weld 10 is located. Preferably, the transition bevel angle between the edge of the reinforcement weld 20 formed by the reinforcement welding and the valve surface where the lip weld 10 is located is 30 degrees or less.
And S3, checking and testing.
The reinforcement weld 20 completed in step S2 is subjected to nondestructive inspection. The nondestructive inspection comprises the following steps: visual inspection; performing liquid permeation inspection; non-contact coupled ultrasonic inspection. The nondestructive inspection result should meet the acceptance requirements.
And measuring the size after welding to meet the design requirement.
Further, structural integrity analysis (stress analysis, fatigue analysis) is performed on the reinforcing weld 20 in combination with the dimensional information after welding, and the analysis and evaluation results should meet the design requirements.
In addition, for the non-destructive inspection described above: before the reinforcement welding, the surface to be welded (i.e., the surface of the lip weld 10) is also visually inspected; liquid penetration inspection is also respectively carried out before and during the reinforced welding; the above-mentioned inspection results should meet the acceptance requirements.
Further, in the present invention, the modeling formulation of step S0 may specifically include the following steps:
s0.1, modeling and predicting the structure of the welding seam of the lip welding.
And performing nondestructive testing on the lip welding seam 10 according to the original size data of the lip welding seam 10, the original welding process and parameters, a nondestructive testing report and the like to obtain relevant defect information. Through SYSWELD software, a welding temperature field of a simulated lip welding seam is simulated, a CCT curve of a material is combined, and the ratio of martensite structures after welding with different welding heat inputs is compared, wherein the contribution of the welding speed to the heat input is more obvious.
For example, the martensite structure ratio of the lip weld is predicted according to different modeled models, which are divided into a (high current and high welding speed), B (low current and low welding speed) and C (moderate heat input on the basis of B), as shown in table 1 below.
TABLE 1
And S0.2, designing a welding process for reinforcing welding repair and verifying modeling.
According to the welding temperature field analysis of the simulated lip welding seam, the welding repair process parameters are determined by combining a valve where the lip welding seam is located, and the martensite ratio change is verified through modeling.
The welding repair parameters include welding current range, welding speed, preheating, etc. The welding repair parameters of the A/B/C model reinforced welding verified by the simulation test are shown in a table 2,B/C model martensite structure proportion change and are shown in a table 3.
TABLE 2
TABLE 3
| Model (model) | More than 10 percent | More than 20 percent | More than 30 percent | More than 40 percent |
| B | 31.9％ | 20.8％ | 13.9％ | 4.5％ |
| B + preheating | 22％ | 11％ | 6.6％ | 0 |
| C | 12.5％ | 5.5％ | 1.7％ | 0 |
| C + preheating | 6.9％ | 2.2％ | 0 | 0 |
And S0.3, selecting a corresponding welding process and parameters according to the martensite change, and performing simulation verification.
The conclusion was analyzed according to the sysflex software modeling: martensite is generated with high probability after welding, the martensite content is related to the selected welding process, and the reduction of speed, the increase of heat input and the proper preheating are effective means for reducing the martensite content. A new process is established to develop a simulation verification test: the combination of the desired metallographic structure of the weld joint is preferably obtained by influencing multiple dimensions of the structure after welding such as single welding/double welding, slow welding speed/high welding speed, heat input, valve quality and the like, wherein the welding speed is set to be higher than 45mm/min to be high speed, 45-30mm/min to be medium speed, and the welding speed is set to be lower than 30mm/min to be low speed. The results are shown in the following table 4, and the results prove that the hardened weld joint structure obtained at the medium and slow speed is less, and the hardened weld joint structure is used as the optimal structure of the actual welding and is basically consistent with the conclusion of modeling analysis.
TABLE 4 welding process parameter comparison optimization table
And S0.4, performing mechanical modeling evaluation on the lip welding, wherein the evaluation result is that the valve lip welding does not expand and crack in the service life as long as the welding seam structure is normal.
And (3) performing stress field calculation by adopting ANSYS 12.1 modeling, wherein the thickness of a welding seam is 1.5mm, and 11 evaluation paths are selected from the tip of a similar crack formed by the valve body, the valve cover and the welding seam to all directions. And (4) evaluation results: excessive deformation cannot occur; crack-like cracks (Crack-like discontinuity) are formed on the joint surface of the valve body cover, fatigue accumulated use coefficients are far smaller than 1 according to evaluation results, fatigue Crack initiation cannot occur, even if 0.5mm of unfused defect is considered, the Crack expansion amount after the cycle in the service life is small and is 0.0002mm, and the fatigue Crack expansion cannot penetrate through a welding seam.
In the method for repairing the welding defects of the valve lip, manual argon arc welding (TIG) is preferably selected for welding. Compared with automatic argon arc welding, manual argon arc welding is widely applied to nuclear power engineering, has the most important advantages of flexibility, convenience and strong coverage, and is the first-choice welding process for valve lip welding reinforcement welding on the premise of effectively solving the influence of human factors on welding quality.
The above description is only an embodiment of the present invention, and not intended to limit the scope of the present invention, and all modifications of equivalent structures and equivalent processes performed by the present specification and drawings, or directly or indirectly applied to other related technical fields, are included in the scope of the present invention.
Claims (9)
1. A method for repairing a lip welding defect of a valve is characterized by comprising the following steps:
s1, preheating a valve needing to be repaired in lip welding, and keeping the temperature of the valve at 60-80 ℃;
s2, taking a solid carbon steel welding wire as a welding material, and performing reinforced welding on a lip welding seam by adopting a TIG (tungsten inert gas) welding method;
in the welding process, the welding heat input is controlled to be 1.2 kJ/mm-2.0 kJ/mm, and the ratio of the welding heat input to the outer diameter of the valve where the lip welding seam is located is 17-23.
2. The method for repairing the welding defect of the valve lip according to claim 1, wherein in the step S2, the welding current is in a range of 60A-80A, the welding voltage is in a range of 10V-11V, and the welding speed is in a range of 20 mm/min-40 mm/min.
3. The method for repairing the welding defect of the valve lip according to claim 1, wherein in the step S2, at least one reinforcing welding seam is formed by reinforcing welding.
4. The method for repairing the valve lip welding defect according to claim 3, wherein in the step S2, two or more than two reinforcing welding seams are formed by reinforcing welding; the arc closing position of the reinforced welding line covers the arc starting position by at least 15mm.
5. The method for repairing the welding defect of the valve lip according to claim 1, wherein in the step S2, the edge of the reinforcing welding seam formed by reinforcing welding forms a smooth transition with the surface of the valve where the welding seam of the lip welding is located.
6. The method for repairing the valve lip welding defect according to claim 5, wherein in the step S2, a transition oblique angle between the edge of the reinforcing welding seam formed by reinforcing welding and the surface of the valve where the lip welding seam is located is not more than 30 degrees.
7. The method for repairing the welding defect of the valve lip according to any one of claims 1 to 6, wherein the method for repairing the welding defect of the valve lip further comprises the following steps before the step S1:
s0, establishing a model;
step S0 includes the following steps:
s0.1, simulating a welding temperature field of the lip welding seam according to original size data, welding processes and parameters of the lip welding seam, combining a CCT curve of a material, and comparing martensite structure occupation ratios after welding by different welding processes and parameters;
s0.2, determining welding repair parameters according to the welding temperature field analysis of the simulated lip welding seam in combination with a valve where the lip welding seam is located, and verifying martensite ratio change through modeling;
and S0.3, selecting a corresponding welding process and parameters according to martensite change, and performing simulation verification.
8. The valve lip welding defect repairing method according to claim 7, wherein the step S0 further comprises the following steps:
s0.4, lip welding mechanical modeling and evaluation.
9. The method for repairing a valve lip weld defect according to any one of claims 1 to 6, further comprising the steps of:
and S3, carrying out nondestructive inspection on the reinforced welding seam formed by reinforced welding.
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2022
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