低碳钢管板全位置活性焊接法研究
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摘要
对活性剂在管板全位置焊接中的应用进行了研究。在不开坡口或者倒角的情况下,将活性剂刷涂到角焊缝待焊区域,对壁厚为3mm的低碳钢管板角伸出焊缝施焊,通过试验确定了最佳的焊接工艺参数。分析了活性剂对熔池受力状态的影响,确定了管板各个位置熔池的受力状态与焊接电流之间的对应关系。依据各种焊接位置时熔池受力状态的理论分析和熔深增加机理,综合考虑焊接热积累对焊缝成形的影响,将管板分段,分别以不同的焊接电流、焊接速度,从不同焊接起始点进行焊接,调节工艺规范参数,研究不同焊接条件对焊缝成形的影响。对焊接过程中容易出现的问题作了归纳和总结,确定了最佳的管板全位置焊接工艺方案和工艺参数。根据GB151-1999《管壳式换热器》的要求,对外观符合要求的焊件进行了检测,包括：外观检查、着色渗透探伤试验、拉脱试验、硬度试验等,检验的各项指标符合要求。活性剂在管板全位置焊接中的应用研究,扩大了活性剂的使用范围,突破了管板全位置焊接厚壁管时需开坡口的局限性,减少了角焊缝的焊丝填充量,节约了焊接成本,大幅度提高了焊接效率。
The application of activating fluxes in all-position welding for tube-to-tubesheet was studied.The activating fluxes were deposed on the metal surface by a brusher without the groove preparation or chamfer for the low-carbon steel tube of 3mm thick,the optimal welding parameter is obtained through the experiments. At the same time, we took detailed analysis on the the impact of activating fluxes on the force state of the pool and relation between the force state of the tubesheet in all kinds of locations and the welding current. According to the theoretical analysis on penetration increase mechanism、the force state of the pool in all kinds of locations and welding heat accumulation, we set sections on the tubesheet, adjusting norms of welding process parameters with different starting points of welding、different welding current、and different welding speed,finding the differences between them on affecting the formation of weld,making analysis on the results of the welding results, at last,we obtain the best welding parameters.According to the request of GB151-1999,we test the weld of the work-pieces which meet the requirements of the appearance, including appearance inspection、dye penetrant inspection testing、pull-out force testing and hardness testing. Testing results show that the indicators are in line with relevant standards. By this process, the range of use for activating fluxes can be expanded, the demand of welding wire is decreased, the efficiency of welding is improved substantially, furthermore, the limitation of the need to open groove when the welding of tube-to-tubesheet is broken.
The application of activating fluxes in all-position welding for tube-to-tubesheet was studied.The activating fluxes were deposed on the metal surface by a brusher without the groove preparation or chamfer for the low-carbon steel tube of 3mm thick,the optimal welding parameter is obtained through the experiments. At the same time, we took detailed analysis on the the impact of activating fluxes on the force state of the pool and relation between the force state of the tubesheet in all kinds of locations and the welding current. According to the theoretical analysis on penetration increase mechanism、the force state of the pool in all kinds of locations and welding heat accumulation, we set sections on the tubesheet, adjusting norms of welding process parameters with different starting points of welding、different welding current、and different welding speed,finding the differences between them on affecting the formation of weld,making analysis on the results of the welding results, at last,we obtain the best welding parameters.According to the request of GB151-1999,we test the weld of the work-pieces which meet the requirements of the appearance, including appearance inspection、dye penetrant inspection testing、pull-out force testing and hardness testing. Testing results show that the indicators are in line with relevant standards. By this process, the range of use for activating fluxes can be expanded, the demand of welding wire is decreased, the efficiency of welding is improved substantially, furthermore, the limitation of the need to open groove when the welding of tube-to-tubesheet is broken.
引文
[1]丁玉龙,王娟.管壳式换热器设计相关问题的分析研究.广东化工,2008,35(10)：133-137
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[3]章姚辉,赵军,徐鸿.换热器管板的应力分析和安全评定.化工设备与防腐蚀,2003,(1)：26-28
[4]张晓峰,张小萌.管壳式换热器的腐蚀与防护分析.化工与技术装备,1997,18(1)： 52-55
[5]屈昀丽,张祥泰,邹素芳.浅谈换热器的腐蚀与防护.内蒙古石油化工,2006,(9)：144-146
[6]林虹.管壳式换热器换热管与管板焊接工艺.安装,2002,(4)：14-15
[7]周彦伟,许庆和,奚敏.铁素体不锈钢管子管板焊接工艺研究.电站辅机,2005, (4)：13-15
[8]刘志伟,郑保祯,高忠.换热器管板的全位置自动氩弧焊.石油工程建设,2000,(5)：28-29
[9]黄旭升,段滋华.全位置自动管板焊系统在换热器制造中的应用.科技情报开发与经济,2006,16(2)：277-279
[10]陈国余,董文宁.全位置自动管板焊系统在电建冷凝器制造中的应用.电焊机,2005,35(8)：5-6
[11]蒋文春,巩建鸣,陈虎.换热器管子与管板焊接接头残余应力数值模拟.焊接学报,2006,27(12)：1-4
[12]倪丞舜.换热器与管板焊接结构的比较和选择.化工装备技术,2007,28(1)：42-46
[13]高志平,邬志刚.薄壁管-管板焊接工艺与改进措施.焊接技术,2001,30(6)：58-59
[14]Fan Ding, Zhang Ruihua.Effect of Flux on A-TIG Weldingof Mild Steels. Transaction of JWRI,2001,30(1):35-40
[15]Zhang Ruihua, Fan Ding.Numerical simulation of effects of activating flux on flow patterns and weld penetration in A-TIG welding.Science and Tech nology of welding and Joining,2007,12(1):15-23
[16]Zhang Ruihua, Fan Ding.Electron Beam Welding with ActivatingFlux[J].Tra nsactions of JWRI,2006,35(2):19-22
[17]杨春利.电弧焊基础.哈尔滨工业大学出版社,2003.2
[18]S.Lecontel, P.Paillard, P.Chapelle. Effect of oxide fluxes on activation mec-hanisms of tungsten inert gas process. Science and Technology of Weldin gand Joining,2006,11(4):389-397
[19]刘凤尧,杨春利,林三宝.活性化TIG焊熔深增加机理的研究.金属学报,2003,39(6)：661-665
[20]刘凤尧,杨春利,林三宝.活性化TIG电弧光谱分布的特征.金属学报,2003,39(8)：875-878
[21]张瑞华.活性焊接法及熔深增加机理的数值模拟研究.兰州理工大学博士论文.2005,79-82
[22]张瑞华,樊丁,余淑荣.低碳钢A-TIG焊的活性剂研制.焊接学报,2003,24 (2)：16-18
[23]张瑞华,尹燕,水谷正海等.A-TIG焊接熔池行为的观察.机械工程学报,2009,45(3)：115-118
[24]张瑞华,尹燕,樊丁等.A-TIG焊熔深增加机理的数值模拟.机械工程学报,2008,44(5)：175-180
[25]G.Ruckert,B.Huneau and S.Marya. Workshop validates Success of Penetrati on Flux[J]. Welding Journal,1999,(3):60-63
[26]K.Kamo,M.Toyoda and S.Ito.Application on GTA Welding with Activating Flux to Nuclear Power Plants. The 57th Annual Assembly of the Internatio nal Institute of Welding.Osaka,12 to 14 July,2004:425-441
[27]S.Asai,R.Tsuboi,K.Kamimura. Application of A-TIG Process to Repair Wel ding in Power Plants.The 57th Annual Assembly of the International Instit ute of Welding.Osaka,12 to 14 July,2004:442-453
[28]S.Yokoya and S.Matsunawa.Heat and mass transfer and their effect on pen-etration shape in stationary TIG arc weld pool[J].Transactions of the Japa n Welding Society.1993,24(1):45-47
[29]朱日良.管壳式换热器管板与换热管焊接常见质量问题的防止.化工设备与管道,2005,42(1)：62-63
[30]潘杰军.换热器管-管板角焊缝焊接质量的控制.无损检测,2006,28(1)：53-54
[31]史建涛.换热器管子和管板焊接接头浅见.广州化工,2009,37(6)：168-170
[32]王书伟.换热器壳体焊缝破裂原因与其对策.焊接技术,2004,33(5)：36-37
[33]段成红,钱才富.换热器管子与管板接头拉脱力的研究.北京化工大学学报,2007,34(3)：308-312
[34]陈泽盘,张定久.管板自动脉冲氩弧焊工艺在生产上的应用.电焊机,2001,31(7)：31-32
[35]史莲莲,杜斌.大型反应器管板焊接变形控制.甘肃科技,2008,24(5)：10-12
[36]董文超,陆善平,李殿中等.微量活性组元氧对焊接熔池Marangoni对流和熔池形貌影响的数值模拟.金属学报,2008,44(2)：249-256
[37]张瑞华.活性焊接法及熔深增加机理的数值模拟研究.兰州理工大学博士论文.2005,3-6
[38]X LI, J XIE, Y ZHOU. Effects of oxygen contamination in the argon sh-ielding gas in laser welding of commercially pure titanium thin sheet[J].J ournal of materials science,2005,(40):3437-3443
[39]Gurevich,S.M.,Zamkov,V.N.,Kushmienko,N.A. Increase in the efficiency of penetration of titanium alloys in argonarc welding[J]. Automat. Svarka,199 5,(9):1-4
[40]C.R.Heiple, J.R.Roper. Mechanism for Minor Element Effect on GTA Fusi on Zone Geometry[J]. Welding Journal,1982,61(4):97-102
[41]孙俊生,宋思利,李宁洋.表面活性元素对熔池流场的影响.山东工业大学学报,1999,(8)：311-316
[42]Michael.H,Gareth.A,Taylor.Thermocapillary and Magnetohydrodynamic Effec-ts in Modeling the Thermodynamics of Stationary Welding Processes.The PHOENICS Journal,2000,13(1):99-113
[43]Young-Jac Jung, Joon-Sik Son. Finite Eleme-nt Modeling of GMA Welding Processes. The PHOENICS Journal,2000,13(1):56-69
[44]杨春利,牛尾诚夫,田中学.TIG电弧活性化焊接现象和机理研究(1)—表面 活性剂对不锈钢材料TIG焊熔深的影响.焊接,2000,(4)：16-18
[45]杨春利,牛尾诚夫,田中学.TIG电弧活性化焊接现象和机理研究(2)—活性化TIG焊接中的电弧现象.焊接,2000,(5)：15-18
[46]杨春利,牛尾诚夫,田中学.TIG电弧活性化焊接现象和机理研究(3)—活性化TIG焊接中的熔池表面张力测定.焊接,2000,(6)：11-15
[47]Lu Shang ping, Fujii Hidetoshi, Sugiyama Hiroyuki,Tanaka Manabu. Maran-goni convection and welding penetration in A-TIG welding[J].Trans. JWRI, 2003,32(1):79-82
[48]Welding J. T. Zackaria, A. H. Eraslan, D. K. Aidun and S. A. David. Thr ee-demensional Transient Model for Arc Welding Process[J]. Metall. Trans. 1989,20B(5):645-659
[49]R. T. C. Choo, J. Szekely. Vaporization Kinetics and Surface Temperature in a Mutually Coupled Spot Gas Tungsten Arc Weld and Weld pool[J]. W elding J.1992,71(3):77-93
[50]张万春.GTA全位置管焊设置.电焊机,1996,(4)：42-43
[51]张瑞华,樊丁.低碳钢A-TIG焊活性剂的焊接性.焊接学报,2003,24(1)：85-89
[52]王天先.高压换热器管子管板自动脉冲钨极氩弧焊.电焊机,2007,37(8)：64-67
[53]顾永康,张良成,张仁刚.60万KW核电蒸汽发生器的管子与管板焊接.2001,(2)：33-35
[2]汪东明,高增福,谭笠.国内外换热器管子管板焊接技术综述.压力容器,1995,12(2)：138-143
[3]章姚辉,赵军,徐鸿.换热器管板的应力分析和安全评定.化工设备与防腐蚀,2003,(1)：26-28
[4]张晓峰,张小萌.管壳式换热器的腐蚀与防护分析.化工与技术装备,1997,18(1)： 52-55
[5]屈昀丽,张祥泰,邹素芳.浅谈换热器的腐蚀与防护.内蒙古石油化工,2006,(9)：144-146
[6]林虹.管壳式换热器换热管与管板焊接工艺.安装,2002,(4)：14-15
[7]周彦伟,许庆和,奚敏.铁素体不锈钢管子管板焊接工艺研究.电站辅机,2005, (4)：13-15
[8]刘志伟,郑保祯,高忠.换热器管板的全位置自动氩弧焊.石油工程建设,2000,(5)：28-29
[9]黄旭升,段滋华.全位置自动管板焊系统在换热器制造中的应用.科技情报开发与经济,2006,16(2)：277-279
[10]陈国余,董文宁.全位置自动管板焊系统在电建冷凝器制造中的应用.电焊机,2005,35(8)：5-6
[11]蒋文春,巩建鸣,陈虎.换热器管子与管板焊接接头残余应力数值模拟.焊接学报,2006,27(12)：1-4
[12]倪丞舜.换热器与管板焊接结构的比较和选择.化工装备技术,2007,28(1)：42-46
[13]高志平,邬志刚.薄壁管-管板焊接工艺与改进措施.焊接技术,2001,30(6)：58-59
[14]Fan Ding, Zhang Ruihua.Effect of Flux on A-TIG Weldingof Mild Steels. Transaction of JWRI,2001,30(1):35-40
[15]Zhang Ruihua, Fan Ding.Numerical simulation of effects of activating flux on flow patterns and weld penetration in A-TIG welding.Science and Tech nology of welding and Joining,2007,12(1):15-23
[16]Zhang Ruihua, Fan Ding.Electron Beam Welding with ActivatingFlux[J].Tra nsactions of JWRI,2006,35(2):19-22
[17]杨春利.电弧焊基础.哈尔滨工业大学出版社,2003.2
[18]S.Lecontel, P.Paillard, P.Chapelle. Effect of oxide fluxes on activation mec-hanisms of tungsten inert gas process. Science and Technology of Weldin gand Joining,2006,11(4):389-397
[19]刘凤尧,杨春利,林三宝.活性化TIG焊熔深增加机理的研究.金属学报,2003,39(6)：661-665
[20]刘凤尧,杨春利,林三宝.活性化TIG电弧光谱分布的特征.金属学报,2003,39(8)：875-878
[21]张瑞华.活性焊接法及熔深增加机理的数值模拟研究.兰州理工大学博士论文.2005,79-82
[22]张瑞华,樊丁,余淑荣.低碳钢A-TIG焊的活性剂研制.焊接学报,2003,24 (2)：16-18
[23]张瑞华,尹燕,水谷正海等.A-TIG焊接熔池行为的观察.机械工程学报,2009,45(3)：115-118
[24]张瑞华,尹燕,樊丁等.A-TIG焊熔深增加机理的数值模拟.机械工程学报,2008,44(5)：175-180
[25]G.Ruckert,B.Huneau and S.Marya. Workshop validates Success of Penetrati on Flux[J]. Welding Journal,1999,(3):60-63
[26]K.Kamo,M.Toyoda and S.Ito.Application on GTA Welding with Activating Flux to Nuclear Power Plants. The 57th Annual Assembly of the Internatio nal Institute of Welding.Osaka,12 to 14 July,2004:425-441
[27]S.Asai,R.Tsuboi,K.Kamimura. Application of A-TIG Process to Repair Wel ding in Power Plants.The 57th Annual Assembly of the International Instit ute of Welding.Osaka,12 to 14 July,2004:442-453
[28]S.Yokoya and S.Matsunawa.Heat and mass transfer and their effect on pen-etration shape in stationary TIG arc weld pool[J].Transactions of the Japa n Welding Society.1993,24(1):45-47
[29]朱日良.管壳式换热器管板与换热管焊接常见质量问题的防止.化工设备与管道,2005,42(1)：62-63
[30]潘杰军.换热器管-管板角焊缝焊接质量的控制.无损检测,2006,28(1)：53-54
[31]史建涛.换热器管子和管板焊接接头浅见.广州化工,2009,37(6)：168-170
[32]王书伟.换热器壳体焊缝破裂原因与其对策.焊接技术,2004,33(5)：36-37
[33]段成红,钱才富.换热器管子与管板接头拉脱力的研究.北京化工大学学报,2007,34(3)：308-312
[34]陈泽盘,张定久.管板自动脉冲氩弧焊工艺在生产上的应用.电焊机,2001,31(7)：31-32
[35]史莲莲,杜斌.大型反应器管板焊接变形控制.甘肃科技,2008,24(5)：10-12
[36]董文超,陆善平,李殿中等.微量活性组元氧对焊接熔池Marangoni对流和熔池形貌影响的数值模拟.金属学报,2008,44(2)：249-256
[37]张瑞华.活性焊接法及熔深增加机理的数值模拟研究.兰州理工大学博士论文.2005,3-6
[38]X LI, J XIE, Y ZHOU. Effects of oxygen contamination in the argon sh-ielding gas in laser welding of commercially pure titanium thin sheet[J].J ournal of materials science,2005,(40):3437-3443
[39]Gurevich,S.M.,Zamkov,V.N.,Kushmienko,N.A. Increase in the efficiency of penetration of titanium alloys in argonarc welding[J]. Automat. Svarka,199 5,(9):1-4
[40]C.R.Heiple, J.R.Roper. Mechanism for Minor Element Effect on GTA Fusi on Zone Geometry[J]. Welding Journal,1982,61(4):97-102
[41]孙俊生,宋思利,李宁洋.表面活性元素对熔池流场的影响.山东工业大学学报,1999,(8)：311-316
[42]Michael.H,Gareth.A,Taylor.Thermocapillary and Magnetohydrodynamic Effec-ts in Modeling the Thermodynamics of Stationary Welding Processes.The PHOENICS Journal,2000,13(1):99-113
[43]Young-Jac Jung, Joon-Sik Son. Finite Eleme-nt Modeling of GMA Welding Processes. The PHOENICS Journal,2000,13(1):56-69
[44]杨春利,牛尾诚夫,田中学.TIG电弧活性化焊接现象和机理研究(1)—表面 活性剂对不锈钢材料TIG焊熔深的影响.焊接,2000,(4)：16-18
[45]杨春利,牛尾诚夫,田中学.TIG电弧活性化焊接现象和机理研究(2)—活性化TIG焊接中的电弧现象.焊接,2000,(5)：15-18
[46]杨春利,牛尾诚夫,田中学.TIG电弧活性化焊接现象和机理研究(3)—活性化TIG焊接中的熔池表面张力测定.焊接,2000,(6)：11-15
[47]Lu Shang ping, Fujii Hidetoshi, Sugiyama Hiroyuki,Tanaka Manabu. Maran-goni convection and welding penetration in A-TIG welding[J].Trans. JWRI, 2003,32(1):79-82
[48]Welding J. T. Zackaria, A. H. Eraslan, D. K. Aidun and S. A. David. Thr ee-demensional Transient Model for Arc Welding Process[J]. Metall. Trans. 1989,20B(5):645-659
[49]R. T. C. Choo, J. Szekely. Vaporization Kinetics and Surface Temperature in a Mutually Coupled Spot Gas Tungsten Arc Weld and Weld pool[J]. W elding J.1992,71(3):77-93
[50]张万春.GTA全位置管焊设置.电焊机,1996,(4)：42-43
[51]张瑞华,樊丁.低碳钢A-TIG焊活性剂的焊接性.焊接学报,2003,24(1)：85-89
[52]王天先.高压换热器管子管板自动脉冲钨极氩弧焊.电焊机,2007,37(8)：64-67
[53]顾永康,张良成,张仁刚.60万KW核电蒸汽发生器的管子与管板焊接.2001,(2)：33-35