1.5MW风力发电机塔架高强连接螺栓断裂研究
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摘要
某1.5 MW风力发电机在运行过程中发生基础环与塔架第一塔节高强连接螺栓断裂失效。利用宏观分析、化学成分分析、力学性能检测、显微组织检测及SEM断口微区分析等试验方法,对断裂的塔架高强连接螺栓进行分析。结果表明:高强螺栓的螺纹根部退刀槽处在脱碳层形成的组织应力及表层材料氢脆的作用下形成沿晶开裂的微裂纹;在风机运行过程中风力冲击载荷、风叶转动产生的冲击载荷及轴向拉应力载荷的叠加作用下,退刀槽处的氢脆微裂纹快速扩展直至整体断裂失效。最后,提出在制造过程中的酸洗工艺后应彻底清理螺栓表面沉积的酸性介质;调质热处理阶段应严格控制热处理炉的碳势等防控措施。
A high strength bolt connecting the base ring with the first tower segment of 1.5 MW wind turbine was broken when the wind turbine was running.The failed bolt was studied by macroscopic examination,chemical composition analysis,mechanical tests test,metallography,fractography,etc.The results show that intergranular microcracks formed in the bolt root relief groove under the action of decarbonization layer microstructure stress and the hydrogen embrittlement of the surface material; under the superposition of the wind shock load,the blade rotation shock load and the axial tensile stress load,the such hydrogen embrittlement microcracks in the relief groove propagated rapidly until the whole fractured and failed.Finally,corresponding suggestions are proposed,such as completely cleaning out the acid after pickling,and strictly carbon potential controlling during heat treatment.
A high strength bolt connecting the base ring with the first tower segment of 1.5 MW wind turbine was broken when the wind turbine was running.The failed bolt was studied by macroscopic examination,chemical composition analysis,mechanical tests test,metallography,fractography,etc.The results show that intergranular microcracks formed in the bolt root relief groove under the action of decarbonization layer microstructure stress and the hydrogen embrittlement of the surface material; under the superposition of the wind shock load,the blade rotation shock load and the axial tensile stress load,the such hydrogen embrittlement microcracks in the relief groove propagated rapidly until the whole fractured and failed.Finally,corresponding suggestions are proposed,such as completely cleaning out the acid after pickling,and strictly carbon potential controlling during heat treatment.
引文
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[2]Chou J S,Tu C W.Failure analysis and risk management of a collapsed large wind turbine tower[J].Engineering Failure Analysis,2011,18(1):295-313.
[3]姚兵印,张志博,马剑民,等.风力发电机组叶片连接高强螺栓的断裂原因分析[J].理化检验-物理分册,2016,52(5):339-344.Yao Bingyin,Zhang Zhibo,Ma Jianmin,et al.Cause analysis on fracture of high-strength bolts for fastening wind turbine blades[J].Physical Testing and Chemical Analysis Part A:Physical Testing,2016,52(5):339-344.
[4]张邦强,谢娟.10.9级高强度螺栓断裂分析[J].大型铸锻件,2009,177(9):15-18.Zhang Bangqiang,Xie Juan.10.9 High strength bolt fracture analysis[J].Heavy Casting and Forging,2009,177(9):15-18.
[5]徐君,陈纪东,李生初,等.风力发电机连接螺栓断裂失效分析[J].工程与试验,2010,50(3):34-37.Xu Jun,Chen Jidong,Li Shengchu,et al.Fracture failure analysis on connecting bolts of wind generator[J].Engineering and Test,2010,50(3):34-37.
[6]张君,温宝峰,赵江涛,等.风力发电机塔筒紧固用高强螺栓断裂失效分析[J].理化检验-物理分册,2014,50(12):933-935.Zhang Jun,Wen Baofeng,Zhao Jiangtao,et al.Failure analysis on fracture of high-strength bolts for fastening wind turbine[J].Physical Testing and Chemical Analysis Part A:Physical Testing,2014,50(12):933-935.
[7]Eliaz N,Shachar A,Tal B,et al.Characteristics of hydrogen embrittlement,stress corrosion cracking and tempered martensite embrittlement in high-strength steels[J].Engineering Failure Analysis,2002(9):167-184.
[8]杨春,钟振前,司红,等.汽车缸盖螺栓断裂原因分析[J].金属热处理,2016,41(11):175-178.Yang Chun,Zhong Zhenqian,Si Hong,et al.Failure analysis of fractured cylinder bolts[J].Heat Treatment of Metals,2016,41(11):175-178.
[9]赵金兰,刘迎来,王长安,等.燃料气撬调压阀用12.9级螺栓断裂失效分析.[J].金属热处理,2016,41(12):192-195.Zhao Jinlan,Liu Yinglai,Wang Changan,et al.Failure analysis of grade 12.9 bolt for fuel gas pressure regulating valve[J].Heat Treatment of Metals,2016,41(12):192-195.
[10]Klemm Michael.Steel cord production from continuous cast-billets at ISPAT HSW[J].Wire Journal International,2004,37(10):76-80.
[11]宋啸虹,将晓东,董雷云,等.新氢压缩机缸盖螺栓断裂机理及对策[J].腐蚀与防护,2017,38(11):894-897.Song Xiaohong,Jiang Xiaodong,Dong Leiyun,et al.Fracture mechanism and countermeasure of cylinder cover bolt in a make-up hydrogen compressor[J].Corrosion and Protection,2017,38(11):894-897.