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1、Introduction on Welding Technology of Elevated Temperature Rotor汽轮机高温转子焊接技术简介2013-09-04Contents目录Background of elevated temperature welded rotor高温焊接转子背景介绍01Construction design结构设计02Welding technology development焊接工艺技术开发03Conclusion小结0405USC Dual-reheat Steam Turbine designed by STP上汽自主设计的超超临界 620二次再
2、热汽轮机1. BackgroundIP module of USC Double-reheat Steam Turbine超超临界二次再热汽轮机中压模块1. BackgroundIP 620 Rotor of USC Double-reheat Steam Turbine超超临界二次再热汽轮机 620中压转子1. Backgrounddifficult to forge锻造难度大Long period锻造周期长High price大锻件价格高SoWelded Rotor is an option开发焊接转子是一个好选择Material/锻件材料： FB2Forging weight /锻件重量
3、 ： 53tMax OD/最大外径 ： 1180mm 2. Construction Design1. Material： dissimilar steels异种钢材料对接，中间为 FB2钢，两侧为 CrMoV钢。2. Welds position 应力低 ,温度相对低 -Lower stress and temperature焊接可达性 -Welding accessability可检测性 -Detectability2. Construction DesignDistribution of temperature温度云图Distribution of mises stress应力云图3.
4、Welding Technology DevelopmentFB2CrMoVTechnical Challenges1Difference in tempering temperature of the two materials两种母材的性能热处理回火温度不同2Difference in chemical composition and mechanical properties两种母材化学成分和力学性能差异较大3Carbon migration and segregation两种材料由于 Cr含量差异较大，会产生碳迁移。GoalProperties of weld joint meet t
5、he requirement of service condition .焊接接头性能满足服役条件。weld metal can balance the requirement of two parent metals.选择合适焊缝金属匹配两侧母材。3. Welding Technology DevelopmentTwo solution were tested分两种方案进行测试1Weld FB2 to CrMoV directlyFB2直接与 CrMoV焊接2Weld FB2 with buffer layerThen weld buffer layer to CrMoV在 FB2上堆焊过渡
6、层再与 CrMoV焊接The comparison test results show that weld joint Without buffer layer has better mechanical properties两个方案测试结果对比发现，无过渡层力学性能更优，主要是过渡层焊缝经历两次焊后热处理，强度下降明显。better3. Welding Technology Developmentelding processWelding pr焊接方法Mock-up 模拟件Outer diameter：900mm 圆环外径Depth of weld：135mm 焊缝深度TIG氩弧焊SAW埋弧
7、焊+3. Welding Technology DevelopmentPWHT焊后热处理No excessive heat affected zone hardness焊接热影响区没有硬度过高点。No unacceptable softening at the weld fusion lines焊接熔合线附近没有软化层。NDT无损检测UT： Good detectability of weld and HAZ焊缝和热影响区的超声波可探性较好。UT&RT ： No unacceptable defect超声波和射线检测均未发现超标缺陷。3. Welding Technology Developm
8、entScope ofTesting检测项目Long-Term properties Still ongoing长时测试项目仍在进行Hardness硬度Bend弯曲FATT50韧脆转变温度LCF低周疲劳Creep蠕变da/dN疲劳裂纹扩展速率Kth疲劳裂纹扩展门槛值Macrostructure宏观金相Creep-rupture持久强度Microstructure微观金相J-integralJ积分HCF高周疲劳Tensile拉伸Charpy-V冲击RT室温RT&RT室温和高温3. Welding Technology DevelopmentMacrostructure 宏观金相(1)Cross
9、Section of Weld 焊缝横截面FB2 Side FB2侧金相图CrMoV SideCrMoV侧金相图3. Welding Technology DevelopmentTensile 拉伸(2)Yield strengthtensile strength0123测试母材、焊接接头在室温和高温下的屈服强度和抗拉强度。Tensile tests on base metal and welding joint at RT and elevated temperature respectively3. Welding Technology DevelopmentCharpy-V（ RT） &
10、 FATT50 室温冲击和韧脆转变温度(3)FB2-HAZ Weld CrMoV-HAZAkv/J0123测试焊缝及两母材室温下的冲击功，焊缝的韧脆转变温度Impact energy and fracture appearance transition temperature3. Welding Technology DevelopmentHardness 硬度(4)FB2 FB2-HAZ Weld CrMoV-HAZ CrMoVHV10/TIGHV10/1HV10/2HV10/31023456测试两母材、焊缝及两侧热影响区，氩弧焊和埋弧焊焊缝的硬度Hardness distributions
11、 across the joint in transverse and depth 无硬度过高区域也没有明显软化区域Neither excessive hardness nor softening area123TIG3. Welding Technology DevelopmentBend 弯曲(5)整个焊接接头区域无开裂No open discontinuity across the joints3. Welding Technology DevelopmentCreep-rupture 持久强度(6)3. Welding Technology DevelopmentHCF 高周疲劳(7)
12、焊接接头室温&470Weld joint RT&470应力比 R=-1，循环次数 N 5 1073. Welding Technology DevelopmentCreep 蠕变(8)分区悬臂梁小试样cantilever beam焊缝470测试结果Weld metal at 470已经获得焊缝470本构方程Norton-Bailey constitutive equations on Weld metal at 470is available取样图中包括母材 ,焊缝和热影响区Base metal ,Weld metal and HAZ3. Welding Technology Developm
13、entCreep 蠕变(8)全焊缝试样Full-penetration weld接头小试样Weld joint以上两种试样的蠕变测试正在进行。Test ongoing4. Conclusion1. Weld FB2 to CrMoV without buffer layer is a feasible solution.不用过渡层，直接将 FB2与 CrMoV钢焊接起来是可行的。From test data we got：2. Weld joint that meets the requirement of service condition can be acquired with appropriate weld metal、 welding process and Post Weld Heat Treatment（ PWHT）通过选择合适的焊接材料、焊接工艺及焊后热处理工艺可以获得满足服役条件的焊接接头。3. Solution without buffer layer is more convenient for production. This solution has advantage in efficiency and economy.不用过渡层的方案更方便生产。该方案在效率和经济性上更具优势。
