CN107598342B - Welding manufacturing method for integral bottle-shaped shaft of large pumped storage generator - Google Patents
Welding manufacturing method for integral bottle-shaped shaft of large pumped storage generator Download PDFInfo
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Abstract
The invention discloses a welding manufacturing method of an integral bottle-shaped shaft of a large pumped storage generator, wherein the welding position between every two bottle-shaped shaft sections to be welded is processed into a narrow gap groove with arc-shaped transition at the joint; assembling the bottle-shaped shaft sections processed in the step 1 according to a placement position relationship, aligning narrow gap grooves of two adjacent bottle-shaped shaft sections to form a to-be-welded narrow gap slope welding line with an arc-shaped transition region, wherein the opening of the narrow gap slope welding line faces to the outer side of the bottle-shaped shaft section; and (3) performing single-side welding on the narrow-gap slope formed by the bottle-shaped shaft sections assembled in the step (2) by adopting narrow-gap automatic argon arc welding equipment, firstly welding the arc-shaped transition part to the designed thickness, and then welding the groove until the groove is filled.
Description
Technical Field
The invention relates to the technical field of radio frequency microwave circuits, in particular to a method for welding and manufacturing an integral bottle-shaped shaft of a large pumped storage generator.
Background
The inner diameter of the whole bottle-shaped shaft of the large pumped storage generator is smaller than or equal to 600mm, the original main shaft is in a three-section structure and a two-section structure, the space of an inner cavity is small, the self weight is large, the whole bottle-shaped shaft needs to be installed in a segmented mode during welding, lifting, alignment and fine welding are involved, and the process is complex.
In the prior art, for example, chinese patent publication No. CN1657211A, publication time 24/8/2005 entitled "method and apparatus for welding with rotating arc and narrow gap driven by hollow shaft motor", and a method and apparatus for welding with rotating arc and narrow gap belong to the field of welding technology. The device comprises a welding cable connector, a hollow shaft motor part, an electric brush feed mechanism, a nozzle mechanism and a speed measuring mechanism consisting of a grating and an optical coupler. The welding device is characterized in that a hollow shaft motor is adopted to directly drive a conductive rod to drive a straight conductive nozzle which can extend into a gap to move, a single compression spring is adopted to enable an electric brush to be in close sliding fit with a flange table surface of the conductive rod, and a cable fixedly connected to the electric brush and a connecting head are in conductive connection to realize welding feed, so that the end part of a welding wire which passes through a central hole of the hollow shaft of the motor and the conductive rod and is sent out from an eccentric hole of the conductive nozzle generates rotating electric arc, and meanwhile, different forms of nozzle mechanisms are matched to realize narrow gap welding of the rotating. The invention has strong practicability, low implementation cost and good use effect; the device has simple and compact structural design, small motor driving power, long service life of the electric brush, low operation noise and convenient maintenance.
Then, as disclosed in the chinese invention utility model patent document having publication No. CN204934934U, publication time of 2016, 1, 6 days, and name "a large roller seal welding tool", a large roller seal welding tool is disclosed, which comprises a clamping and rotating mechanism for clamping and rotating a roller, and a first welding mechanism and a second welding mechanism for welding two ends of the roller, respectively; the clamping and rotating mechanism comprises a first clamping seat and a second clamping seat which are oppositely arranged; a clamping oil cylinder coaxial with the rolling shaft is arranged on the first clamping seat, and the free end of a piston rod of the clamping oil cylinder faces the second clamping seat and is provided with a first thimble capable of freely rotating; a second thimble which is coaxial with the rolling shaft and can rotate is arranged on the second clamping seat, and one end of the second thimble is arranged on the second clamping seat and is connected with a rotating motor; the first welding mechanism comprises a first welding gun, a first horizontal sliding seat and a first horizontal sliding block; the second welding mechanism includes a second welding gun.
However, the technical solutions are all improved from the structure of the welding equipment, and still do not solve the problems of sectional assembly, welding back chipping and inner cavity processing in the welding process of the large-size integral bottle-shaped shaft.
Disclosure of Invention
The invention aims to provide a method for welding and manufacturing an integral bottle-shaped shaft of a large pumped storage generator, which adopts the compound welding of narrow-gap automatic argon arc welding and narrow-gap automatic submerged arc welding to realize the single-side welding and double-side forming of a root welding line, does not back gouge the inner side of the welding line, does not process an inner cavity and realizes the successful welding and manufacturing of the integral bottle-shaped shaft with small inner diameter.
The purpose of the invention is realized by the following technical scheme:
a welding manufacturing method of an integral bottle-shaped shaft of a generator is characterized by comprising the following steps:
step 1, processing the welding positions of bottle-shaped shaft sections to be welded into narrow gap grooves with arc-shaped transition at the joint;
step 2, pairing the bottle-shaped shaft sections processed in the step 1 according to a placement position relationship, aligning narrow gap grooves of two adjacent bottle-shaped shaft sections to form a to-be-welded narrow gap groove welding seam with an arc transition area, wherein an opening of the narrow gap groove welding seam faces to the outer side of the bottle-shaped shaft section;
and 3, firstly, carrying out single-side welding on a narrow-gap groove weld formed by the bottle-shaped shaft sections paired in the step 2 by adopting narrow-gap automatic argon arc welding equipment, welding the circular arc transition part to the designed thickness, and then carrying out narrow-gap automatic submerged arc welding on the groove until the groove is filled.
In the step 1, the narrow gap groove with circular arc transition is a slope-shaped opening from the inner wall to the outer wall at the edge of the welding end of the bottle-shaped shaft section, and two circular arc bending transitions are arranged at positions close to the inner wall.
And 2, when the narrow gap grooves of two adjacent bottle-shaped shaft sections are aligned, the inner walls of the two adjacent bottle-shaped shaft sections are spliced and leveled, and an opening of the narrow gap groove is formed between the edges of the outer walls.
The seam allowance gap of the circular arc transition area is not more than 3mm, and the seam allowance thickness of the narrow gap is not more than 4 mm.
In the step 3, the welding is performed in a three-layer protective gas environment, wherein the protective gas is 99.99% Ar, the protective flow of the first layer gas is 15L/min, the protective flow of the second layer gas is 30L/min, and the protective flow of the third layer gas is 12L/min.
In the step 3, during welding, the narrow-gap automatic argon arc welding equipment has peak current 230A, base value current 190A, welding voltage 11-14V, welding speed 40 mm/min and wire feeding speed 50 mm/min.
In the step 3, the welding is performed by adopting an up-and-down asymmetric swing orbital transfer welding process, a welding head of the narrow-gap automatic argon arc welding equipment firstly welds a first circle according to a swing mode with an up-swing angle of 25 degrees and a down-swing angle of 10 degrees, then orbital transfer welds a next circle according to a swing mode with an up-swing angle of 10 degrees and a down-swing angle of 25 degrees, one-time asymmetric swing orbital transfer welding is completed, and then the asymmetric swing orbital transfer welding is repeated until the welding is completed.
And welding head welding rotation 363 degrees of the narrow-gap automatic argon arc welding equipment is regarded as finishing one circle, welding current is attenuated to 60A at the 363-degree position, the welding head is stopped in swinging and welding wire feeding is stopped, the welding head enters a track changing area, track changing is finished by welding 3 degrees to a lower layer weld bead at a normal welding speed, the welding current and the welding wire feeding are recovered after the track changing is finished, and the next circle of welding is continued.
In the step 3, when the arc-shaped transition part is welded to the designed thickness, the assembled bottle-shaped shaft sections are vertically placed on the rotary table, the narrow-gap automatic argon arc welding equipment is aligned to the arc-shaped transition part, and the rotary table drives the assembled bottle-shaped shaft sections to realize annular welding.
In the step 3, when the groove is welded, all the bottle-shaped shaft sections are paired and the arc transition part is welded, the formed bottle-shaped shaft is horizontally placed on the roller frame, the narrow-gap automatic submerged arc welding is aligned to the groove part, and the roller frame drives the bottle-shaped shaft to rotate to realize annular welding.
The invention has the following beneficial effects:
the invention provides a method for welding and manufacturing an integral bottle-shaped shaft of a large pumped storage generator, which is characterized in that the edge of a welding part of a bottle-shaped shaft section to be welded is processed into a narrow gap groove with circular arc transition, so that the later-stage narrow gap welding operation can be conveniently realized, the welding difficulty is reduced, meanwhile, the welding from the inside after assembling can be avoided by controlling the ramp direction of the narrow gap groove, the problem that the integral bottle-shaped shaft of the large pumped storage generator is small in inner diameter and cannot be used for back chipping of a welding seam at the inner side is solved, the single-side welding and double-side forming can be realized by adopting the mode of the narrow gap automatic argon arc welding and the narrow gap automatic submerged arc welding, the back chipping of the welding seam at the inner side is avoided, the narrow gap groove design with the unique circular arc transition of double R is adopted, the narrow gap automatic argon arc welding is firstly adopted for welding, the groove is welded to, the invention changes the original main shaft structure form, and adopts the narrow-gap automatic argon arc welding and the narrow-gap automatic submerged arc welding to weld three sections of main shafts into a whole, thereby realizing the manufacture of the integral shaft (avoiding the assembly installation by multiple sections), reducing the weight of the unit and effectively improving the critical rotating speed of the rotating shaft.
The invention provides a method for welding and manufacturing an integral bottle-shaped shaft of a large pumped storage generator, which is characterized in that a groove type is designed according to the size of the bottle-shaped shaft, wherein a joint of a buried arc section and an argon arc welding section adopts double-R transition, and the groove type after narrow-gap automatic argon arc welding meets the narrow-gap automatic submerged arc welding groove type; the spigot which is processed together during groove processing is used for positioning, so that the assembly precision is ensured; narrow gap automatic argon arc welding: firstly, the first section and the second section are vertically assembled on a rotating tire through a bottle-shaped shaft, narrow-gap automatic argon arc welding is adopted, the groove at the root of the welding realizes the double-sided forming of single-sided welding, and the groove is welded to the designed thickness.
The manufacturing method of the integral bottle-shaped shaft welding manufacturing method of the large pumped storage generator provided by the invention has the advantages that the tungsten electrode of the welding seam of the first and lower fusion lines of the narrow-gap automatic argon arc welding does not need to swing, and the tungsten electrode serving as the welding head needs to swing when the fusion line is welded; the tungsten electrode adopts an up-and-down asymmetric swinging technology: the upper-layer welding bead is welded at an upper swing angle of 25 degrees and the lower swing angle of 10 degrees, rail change is carried out at a 363-degree position, namely the tungsten electrode starts to change the rail from the upper-layer welding bead to the lower-layer welding bead, the welding current is attenuated to 60A at the 363-degree position, the tungsten electrode stops swinging and welding wire feeding is stopped, the welding wire enters a rail change area, rail change is completed at a normal welding speed by welding the lower-layer welding bead for 3 degrees, and the welding current and the welding wire feeding are recovered after the rail change is finished; the swinging up angle of the tungsten electrode is 10 degrees, the swinging down angle is 25 degrees, the lower welding bead is welded, and the lower welding bead is welded to 363 degrees and then is changed into a rail again; realizes no joint in the welding process, and the arc striking and arc closing areas of the upper and lower layers of welding beads on each layer are staggered by 6 degrees.
Drawings
FIG. 1 is a schematic diagram of a preferred embodiment of the assembly and splicing of the bottle-shaped shaft sections of the present invention;
FIG. 2 is a schematic view of a preferred embodiment of a narrow gap groove weld of the present invention;
FIG. 3 is a schematic view of a preferred embodiment of the assembled bottle-shaped shaft segments of the present invention in a vertical position;
FIG. 4 is a schematic diagram of a preferred embodiment of the present invention in which the assembled bottle-shaped shaft segments are horizontally disposed.
Fig. 5 is a schematic diagram of welding orbital transfer according to the invention.
Detailed Description
The technical solutions for achieving the objects of the present invention are further illustrated by the following specific examples, which should be construed as including but not limited to the following examples.
Example 1
Referring to fig. 1 to 5, a method for manufacturing a generator by welding an integral bottle-shaped shaft comprises the following steps:
step 1, processing the welding positions of bottle-shaped shaft sections to be welded into narrow gap grooves with arc-shaped transition at the joint;
step 2, pairing the bottle-shaped shaft sections processed in the step 1 according to a placement position relationship, aligning narrow gap grooves of two adjacent bottle-shaped shaft sections to form a to-be-welded narrow gap groove welding seam with an arc transition area, wherein an opening of the narrow gap groove welding seam faces to the outer side of the bottle-shaped shaft section;
and 3, performing single-side welding on the narrow-gap groove weld formed by the bottle-shaped shaft sections paired in the step 2 by adopting narrow-gap automatic argon arc welding equipment, firstly welding the circular arc transition part to the designed thickness, and then performing narrow-gap automatic submerged arc welding on the groove until the groove is filled.
This is one of the most basic embodiments of the present invention. The edge of the welding position of the bottle-shaped shaft section to be welded is processed into a narrow gap groove with circular arc transition, so that the later-stage narrow gap welding operation can be conveniently realized, the welding difficulty is reduced, meanwhile, the welding is also required to be carried out from the inside after the assembly is avoided by controlling the ramp direction of the narrow gap groove, the problem of the manufacturing technology of the integral bottle-shaped shaft welding of the large-sized pumped storage generator with small inner diameter and the inner side incapable of weld seam back chipping is solved, the double-side forming of single-side welding is realized by adopting the mode of the composite welding of the narrow gap automatic argon arc welding and the narrow gap automatic submerged arc welding, the back chipping is not carried out on the inner side weld seam, the narrow gap groove design of the circular arc transition with unique double R is adopted, firstly, the narrow gap automatic argon arc welding gun is adopted for welding, the groove is welded to the designed thickness, then the narrow gap submerged arc welding is, the invention changes the original main shaft structure form, and adopts narrow-gap automatic argon arc welding and narrow-gap automatic submerged arc welding to weld three sections of main shafts into a whole, thereby realizing the manufacture of the integral shaft (avoiding the assembly installation by multiple sections) of the large-scale pumped storage generator, realizing the weight reduction of the unit and effectively improving the critical rotating speed of the rotating shaft.
Example 2
Referring to fig. 1 to 5, a method for manufacturing a generator by welding an integral bottle-shaped shaft comprises the following steps:
step 1, processing the welding positions of bottle-shaped shaft sections to be welded into narrow gap grooves with arc-shaped transition at the joint;
step 2, pairing the bottle-shaped shaft sections processed in the step 1 according to a placement position relationship, aligning narrow gap grooves of two adjacent bottle-shaped shaft sections to form a to-be-welded narrow gap groove welding seam with an arc transition area, wherein an opening of the narrow gap groove welding seam faces to the outer side of the bottle-shaped shaft section;
step 3, performing single-side welding on a narrow-gap groove weld formed by the bottle-shaped shaft sections paired in the step 2 by adopting narrow-gap automatic argon arc welding equipment, firstly welding the arc-shaped transition part to the designed thickness, and then performing narrow-gap automatic submerged arc welding on the groove until the groove is filled;
in the step 1, the narrow gap groove with circular arc transition is a slope-shaped opening from the inner wall to the outer wall at the edge of the welding end of the bottle-shaped shaft section, and two circular arc bending transitions are arranged at positions close to the inner wall;
step 2, when the narrow gap grooves of two adjacent bottle-shaped shaft sections are aligned, the inner walls of the two adjacent bottle-shaped shaft sections are spliced and leveled, and an opening of the narrow gap groove is formed between the edges of the outer walls;
the seam allowance gap of the circular arc transition area is not more than 3mm, and the seam allowance thickness of the narrow gap is not more than 4 mm.
This is a preferred embodiment of the invention. The edge of the welding position of the bottle-shaped shaft section to be welded is processed into a narrow gap groove with circular arc transition, so that the later-stage narrow gap welding operation can be conveniently realized, the welding difficulty is reduced, meanwhile, the welding is also required to be carried out from the inside after the assembly is avoided by controlling the ramp direction of the narrow gap groove, the problem of the manufacturing technology of the integral bottle-shaped shaft welding of the large-sized pumped storage generator with small inner diameter and the inner side incapable of weld seam back chipping is solved, the double-side forming of single-side welding is realized by adopting the mode of the composite welding of the narrow gap automatic argon arc welding and the narrow gap automatic submerged arc welding, the back chipping is not carried out on the inner side weld seam, the narrow gap groove design of the circular arc transition with unique double R is adopted, firstly, the narrow gap automatic argon arc welding gun is adopted for welding, the groove is welded to the designed thickness, then the narrow gap submerged arc welding is, the invention changes the original main shaft structure form, and adopts narrow-gap automatic argon arc welding and narrow-gap automatic submerged arc welding to weld three sections of main shafts into a whole, thereby realizing the manufacture of the integral shaft (avoiding the assembly installation by multiple sections) of the large-scale pumped storage generator, realizing the weight reduction of the unit and effectively improving the critical rotating speed of the rotating shaft; designing a groove type according to the size of the bottle-shaped shaft, wherein the joint of the submerged arc section and the argon arc welding section adopts double-R transition, and ensuring that the groove type after the narrow-gap automatic argon arc welding meets the narrow-gap automatic submerged arc welding groove type; the spigot which is processed together during groove processing is used for positioning, so that the assembly precision is ensured; narrow gap automatic argon arc welding: firstly, the first section and the second section are vertically assembled on a rotating tire through a bottle-shaped shaft, narrow-gap automatic argon arc welding is adopted, the groove at the root of the welding realizes the double-sided forming of single-sided welding, and the groove is welded to the designed thickness.
Example 3
Referring to fig. 1 to 5, a method for manufacturing a generator by welding an integral bottle-shaped shaft comprises the following steps:
step 1, processing the welding positions of bottle-shaped shaft sections to be welded into narrow gap grooves with arc-shaped transition at the joint;
step 2, pairing the bottle-shaped shaft sections processed in the step 1 according to a placement position relationship, aligning narrow gap grooves of two adjacent bottle-shaped shaft sections to form a to-be-welded narrow gap groove welding seam with an arc transition area, wherein an opening of the narrow gap groove welding seam faces to the outer side of the bottle-shaped shaft section;
step 3, performing single-side welding on a narrow-gap groove weld formed by the bottle-shaped shaft sections paired in the step 2 by adopting narrow-gap automatic argon arc welding equipment, firstly welding the arc-shaped transition part to the designed thickness, and then performing narrow-gap automatic submerged arc welding on the groove until the groove is filled;
in the step 1, the narrow gap groove with circular arc transition is a slope-shaped opening from the inner wall to the outer wall at the edge of the welding end of the bottle-shaped shaft section, and two circular arc transition bends are arranged at positions close to the inner wall;
step 2, when the narrow gap grooves of two adjacent bottle-shaped shaft sections are aligned, the inner walls of the two adjacent bottle-shaped shaft sections are spliced and leveled, and an opening of the narrow gap groove is formed between the edges of the outer walls;
the thickness of the weld joint of the circular arc transition area is not more than 3mm, and the thickness of the weld joint of the narrow gap groove is not more than 4 mm;
in the step 3, welding is performed in a three-layer protective gas environment, wherein the protective gas is 99.99% Ar, the protective flow of the first layer gas is 15L/min, the protective flow of the second layer gas is 30L/min, and the protective flow of the third layer gas is 12L/min;
in the step 3, during welding, the narrow-gap automatic argon arc welding equipment has peak current 230A, base value current 190A, welding voltage 11-14V, welding speed 40 mm/min and wire feeding speed 50 mm/min;
in the step 3, the welding is performed by adopting an up-and-down asymmetric swing orbital transfer welding process, a welding head of the narrow-gap automatic argon arc welding equipment firstly welds a first circle according to a swing mode with an up-swing angle of 25 degrees and a down-swing angle of 10 degrees, then orbital transfer welds a next circle according to a swing mode with an up-swing angle of 10 degrees and a down-swing angle of 25 degrees, one-time asymmetric swing orbital transfer welding is completed, and then the asymmetric swing orbital transfer welding is repeated until the welding is completed;
welding head welding rotation 363 DEG of the narrow-gap automatic argon arc welding equipment is regarded as completing one circle, welding current is attenuated to 60A at the position of 363 DEG, the welding head is stopped in swinging and welding wire feeding is stopped, the welding head enters a track changing area, track changing is completed for 3 DEG of lower-layer welding bead welding at normal welding speed, welding current and welding wire feeding are recovered after track changing is finished, and next circle of welding is continued;
in the step 3, when the arc-shaped transition part is welded to the designed thickness, the assembled bottle-shaped shaft sections are vertically placed on a rotary table, the narrow-gap automatic argon arc welding equipment is aligned to the arc-shaped transition part, and the rotary table drives the assembled bottle-shaped shaft sections to realize annular welding;
in the step 3, when the groove is welded, all the bottle-shaped shaft sections are paired and the arc transition part is welded, the formed bottle-shaped shaft is horizontally placed on the roller frame, the narrow-gap automatic submerged arc welding equipment is aligned to the groove part, and the roller frame drives the bottle-shaped shaft to rotate to realize annular welding.
This is a preferred embodiment of the invention. The edge of the welding position of the bottle-shaped shaft section to be welded is processed into a narrow gap groove with circular arc transition, so that the later-stage narrow gap welding operation can be conveniently realized, the welding difficulty is reduced, meanwhile, the welding is also required to be carried out from the inside after the assembly is avoided by controlling the ramp direction of the narrow gap groove, the problem of the manufacturing technology of the integral bottle-shaped shaft welding of the large-sized pumped storage generator with small inner diameter and the inner side incapable of weld seam back chipping is solved, the double-side forming of single-side welding is realized by adopting the mode of the composite welding of the narrow gap automatic argon arc welding and the narrow gap automatic submerged arc welding, the back chipping is not carried out on the inner side weld seam, the narrow gap groove design of the circular arc transition with unique double R is adopted, firstly, the narrow gap automatic argon arc welding gun is adopted for welding, the groove is welded to the designed thickness, then the narrow gap submerged arc welding is, the invention changes the original main shaft structure form, and adopts narrow-gap automatic argon arc welding and narrow-gap automatic submerged arc welding to weld three sections of main shafts into a whole, thereby realizing the manufacture of the integral shaft (avoiding the assembly installation by multiple sections) of the large-scale pumped storage generator, realizing the weight reduction of the unit and effectively improving the critical rotating speed of the rotating shaft; designing a groove type according to the size of the bottle-shaped shaft, wherein the joint of the submerged arc section and the argon arc welding section adopts double-R transition, and ensuring that the groove type after the narrow-gap automatic argon arc welding meets the narrow-gap automatic submerged arc welding groove type; the spigot which is processed together during groove processing is used for positioning, so that the assembly precision is ensured; narrow gap automatic argon arc welding: performing cylindrical shaft vertical assembly on the first section, the second section and the third section which are subjected to narrow-gap automatic argon arc welding on a rotating tire, adopting narrow-gap automatic argon arc welding, realizing single-side welding and double-side forming of a welding root groove, and welding the groove to the designed thickness; the first and lower fusion lines welded by the narrow-gap automatic argon arc welding have no need of swinging tungsten electrode, and the tungsten electrode as a welding head is required to swing when the fusion line is welded; the tungsten electrode adopts an up-and-down asymmetric swinging technology: the upper-layer welding bead is welded at an upper swing angle of 25 degrees and the lower swing angle of 10 degrees, rail change is carried out at a 363-degree position, namely the tungsten electrode starts to change the rail from the upper-layer welding bead to the lower-layer welding bead, the welding current is attenuated to 60A at the 363-degree position, the tungsten electrode stops swinging and welding wire feeding is stopped, the welding wire enters a rail change area, rail change is completed at a normal welding speed by welding the lower-layer welding bead for 3 degrees, and the welding current and the welding wire feeding are recovered after the rail change is finished; the swinging up angle of the tungsten electrode is 10 degrees, the swinging down angle is 25 degrees, the lower welding bead is welded, and the lower welding bead is welded to 363 degrees and then is changed into a rail again; realizes no joint in the welding process, and the arc striking and arc closing areas of the upper and lower layers of welding beads on each layer are staggered by 6 degrees.
Example 4
Referring to fig. 1 to 5, a method for manufacturing a generator by welding an integral bottle-shaped shaft comprises the following steps:
(a) dividing the integral bottle-shaped shaft of the generator into three sections, processing the three sections of shafts to be welded into double-R circular arc transition groove-shaped grooves and assembling the grooves;
(b) the whole bottle-shaped shaft of the motor is vertically arranged, the rotating tire drives the bottle-shaped shaft to rotate, the root groove is transversely welded by adopting narrow-gap automatic argon arc welding equipment, single-side welding and double-side forming are carried out, and the groove is welded to the designed thickness;
(c) the whole bottle-shaped shaft of the motor is horizontally placed, the roller carrier drives the bottle-shaped shaft to rotate, and the narrow-gap automatic submerged arc welding equipment is adopted to perform flat welding on the root groove to fill the groove.
A groove type suitable for realizing the double-sided forming of the root weld seam by the narrow-gap automatic argon arc welding and the narrow-gap automatic submerged arc welding is designed.
The thickness of the welding line of the seam allowance area is not more than 4mm, and the seam allowance gap is not more than 3 mm. The peak current 230A, the base current 190A, the welding voltage 11-14V, the welding speed 40 mm/min and the wire feeding speed 50 mm/min.
Three layers of protective gas are adopted, the protective gas is 99.99% Ar, the protective flow of the first layer of gas is 15L/min, the protective flow of the second layer of gas is 30L/min, and the protective flow of the third layer of gas is 12L/min.
The upper welding bead is welded at an upper swing angle of 25 degrees and the lower swing angle of 10 degrees by adopting an up-down asymmetric swing technology, the rail is changed at a 363-degree position, namely the tungsten electrode is changed from the upper welding bead to the lower welding bead, the welding current is attenuated to 60A at the 363-degree position, the tungsten electrode is swung and stopped, the welding wire feeding is stopped, the welding wire enters a rail changing area, the rail is changed at a normal welding speed for 3 degrees by welding the lower welding bead, and the welding current and the welding wire feeding are recovered after the rail changing. The swinging angle of the tungsten electrode is 10 degrees, the swinging angle of the tungsten electrode is 25 degrees, the lower welding bead is welded, and the lower welding bead is welded to 363 degrees and then is changed into a rail again. Realizes no joint in the welding process, and the arc striking and arc closing areas of the upper and lower layers of welding beads on each layer are staggered by 6 degrees.
After the narrow-gap automatic argon arc welding is cleaned, the groove size is checked to meet the requirements on the basis of the narrow-gap automatic argon arc welding, and then the narrow-gap automatic submerged arc welding is adopted for flat welding.
The tungsten electrode of the welding seam of the first and lower fusion lines does not need to swing, and the tungsten electrode needs to swing when the fusion line is welded.
Example 5
Taking an ASTM a668D pumped storage generator shaft as an example, the welding manufacturing technology of the integral bottle-shaped shaft of the large pumped storage generator is specifically described as follows:
(1) base material: ASTM A668D forging, bore diameter 600mm, weld thickness 200mm, total length 9862mm, weight 65 tons.
(2) Narrow gap automatic argon arc welding material: welding wire phi 1.2AWS ER 70S-G; 99.99% Ar protective gas.
(3) Welding materials for narrow-gap automatic submerged arc welding: welding wire phi 4.0AWS EM 12K; flux F7P6-EM 12K.
(4) double-R arc transition groove type grooves (R1 =8mm, R2=11 mm).
(5) Surface cleaning: and cleaning oil stain, water, oxide and the like in the groove and the range of 50mm on two sides before welding.
(6) The welding position of the narrow-gap automatic argon arc welding is as follows: transverse welding; welding position of narrow gap automatic submerged arc welding: and (7) flat welding.
(7) If the burning loss of the tungsten electrode is found in the narrow-gap automatic argon arc welding process, the tungsten electrode needs to be replaced in time, and under the normal condition, the tungsten electrode is replaced once within 2 hours.
(8) And (3) appearance inspection: the welding seam is formed by welding one side and two sides, and the surface of the root part of the welding seam is well formed.
(9) Flaw detection inspection: UT and MT flaw detection is defect-free.
(10) And (3) testing welding evaluation mechanical properties: and if the strength of the base material is greater than the lower limit value of the base material strength, the test result is qualified.
(11) Welding evaluation bending test: the test sample is subjected to a bending test according to the standard to reach 180 degrees, no crack is found, and the test result is qualified.
Further, as (1) the base material: ASTM A668E forging, bore diameter 580mm, weld thickness 330mm, total length 9934mm, weight 114 tons.
(2) Narrow gap automatic argon arc welding material: welding wire phi 1.2AWS ER 70S-G; 99.99% Ar protective gas.
(3) Welding materials for narrow-gap automatic submerged arc welding: welding wire phi 4.0AWS EM 12K; flux F7P6-EM 12K.
(4) double-R arc transition groove type grooves (R1 =7.8mm, R2=11 mm).
(5) Surface cleaning: and cleaning oil stain, water, oxide and the like in the groove and the range of 50mm on two sides before welding.
(6) The welding position of the narrow-gap automatic argon arc welding is as follows: transverse welding; welding position of narrow gap automatic submerged arc welding: and (7) flat welding.
(7) If the burning loss of the tungsten electrode is found in the narrow-gap automatic argon arc welding process, the tungsten electrode needs to be replaced in time, and under the normal condition, the tungsten electrode is replaced once within 2 hours.
(8) And (3) appearance inspection: the welding seam is formed by welding one side and two sides, and the surface of the root part of the welding seam is well formed.
(9) Flaw detection inspection: UT and MT flaw detection is defect-free.
(10) And (3) testing welding evaluation mechanical properties: and if the strength of the base material is greater than the lower limit value of the base material strength, the test result is qualified.
(11) Welding evaluation bending test: the test sample is subjected to a bending test according to the standard to reach 180 degrees, no crack is found, and the test result is qualified.
Claims (8)
1. A method for manufacturing a large pumped storage generator by welding an integral bottle-shaped shaft is characterized by comprising the following steps:
step 1, processing the welding positions of bottle-shaped shaft sections to be welded into narrow gap grooves with arc-shaped transition at the joint;
step 2, pairing the bottle-shaped shaft sections processed in the step 1 according to a placement position relationship, aligning narrow gap grooves of two adjacent bottle-shaped shaft sections to form a to-be-welded narrow gap groove welding seam with an arc transition area, wherein an opening of the narrow gap groove welding seam faces to the outer side of the bottle-shaped shaft section;
step 3, firstly, carrying out single-side welding on a narrow-gap groove weld formed by the bottle-shaped shaft sections paired in the step 2 by adopting narrow-gap automatic argon arc welding equipment, and welding a part of the circular arc transition area to the designed thickness; then, carrying out narrow-gap automatic submerged arc welding on the groove until the groove is filled;
adopting narrow-gap automatic argon arc welding equipment to carry out single-side welding, namely adopting an up-and-down asymmetric swing orbital transfer welding process, wherein a welding head of the narrow-gap automatic argon arc welding equipment firstly welds a first circle according to a swing mode with an up-swing angle of 25 degrees and a down-swing angle of 10 degrees, then orbital transfer welds a next circle according to a swing mode with an up-swing angle of 10 degrees and a down-swing angle of 25 degrees, completes one-time asymmetric swing orbital transfer welding, and then repeats the asymmetric swing orbital transfer welding until the welding is completed;
and welding head welding rotation 363 degrees of the narrow-gap automatic argon arc welding equipment is regarded as finishing one circle, welding current is attenuated to 60A at the 363-degree position, the welding head is stopped in swinging and welding wire feeding is stopped, the welding head enters a track changing area, track changing is finished by welding 3 degrees to a lower layer weld bead at a normal welding speed, the welding current and the welding wire feeding are recovered after the track changing is finished, and the next circle of welding is continued.
2. The method for manufacturing the integral bottle-shaped shaft of the large pumped storage generator in the welding mode according to claim 1, wherein the method comprises the following steps: in the step 1, the narrow gap groove with circular arc transition is a slope-shaped opening from the inner wall to the outer wall at the edge of the welding end of the bottle-shaped shaft section, and two circular arc bending transitions are arranged at positions close to the inner wall.
3. The method for manufacturing the integral bottle-shaped shaft of the large pumped storage generator in the welding mode according to claim 1, wherein the method comprises the following steps: and 2, when the narrow gap grooves of two adjacent bottle-shaped shaft sections are aligned, the inner walls of the two adjacent bottle-shaped shaft sections are spliced and leveled, and an opening of the narrow gap groove is formed between the edges of the outer walls.
4. The method for manufacturing the integral bottle-shaped shaft of the large pumped storage generator in the welding mode according to claim 1 or 2, wherein the method comprises the following steps: the seam allowance gap of the circular arc transition area is not more than 3mm, and the seam allowance thickness of the narrow gap is not more than 4 mm.
5. The method for manufacturing the integral bottle-shaped shaft of the large pumped storage generator in the welding mode according to claim 1, wherein the method comprises the following steps: in the step 3, the single-side welding is carried out by adopting narrow-gap automatic argon arc welding equipment in a three-layer protective gas environment, wherein the protective gas is 99.99% Ar, the protective flow of the first layer gas is 15L/min, the protective flow of the second layer gas is 30L/min, and the protective flow of the third layer gas is 12L/min.
6. The method for manufacturing the integral bottle-shaped shaft of the large pumped storage generator in the welding mode according to claim 1, wherein the method comprises the following steps: in the step 3, during welding, the narrow-gap automatic argon arc welding equipment has peak current 230A, base value current 190A, welding voltage 11-14V, welding speed 40 mm/min and wire feeding speed 50 mm/min.
7. The method for manufacturing the integral bottle-shaped shaft of the large pumped storage generator in the welding mode according to claim 1, wherein the method comprises the following steps: in the step 3, when the part of the circular arc transition area is welded to the designed thickness, the bottle-shaped shaft sections after being assembled are vertically placed on the rotary table, the narrow-gap automatic argon arc welding equipment is aligned to the part of the circular arc transition area, and the rotary table drives the bottle-shaped shaft sections after being assembled to realize annular welding.
8. The method for manufacturing the integral bottle-shaped shaft of the large pumped storage generator in the welding mode according to claim 1 or 7, wherein the method comprises the following steps: in the step 3, when the groove is welded, all the bottle-shaped shaft sections are paired and the arc transition region is welded, the formed bottle-shaped shaft is horizontally placed on the roller frame, the narrow-gap automatic submerged arc welding equipment is aligned to the groove part, and the roller frame drives the bottle-shaped shaft to rotate to realize annular welding.
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| CN114951902B (en) * | 2022-04-27 | 2023-11-17 | 大连船舶重工集团有限公司 | Construction method suitable for welding seam of reactor body of nuclear power station reactor |
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