涡旋式空调压缩机专用环缝焊机及工艺研究

针对生产线上涡旋式空调压缩机环缝焊接的特定条件和工艺要求,我们研制了一种由PLC控制的专用环缝自动焊接设备。该设备的焊机主体具有垂直和倾斜45°两位性,焊台调速采用数字集成化电路,收弧采用定位、定时搭接并返烧。工艺试验表明,本专用环缝MAG自动焊接系统完全能满足其环缝焊接工艺和焊接质量的要求,是一种高效率低成本的焊接自动化装置。可快速推广应用到其他筒体、管子的环缝焊接。     

等离子纵缝焊机在不锈钢容器制造工艺中的应用

在不锈钢容器制造中，平板拼接和筒体的纵缝焊接采用等离子纵缝焊机焊接工艺，可大大改善产品的焊接质量，提高焊接生产效率。     

Φ9800mm焦炭塔的设计与制造要点

介绍了目前国内最大直径达Φ9800 mm的焦炭塔的设计、制造所采用的技术。设计上主要采用了低S,P含量的钢板,采用整体锻造的过渡段和背带式保温以及特殊结构的急冷油四通。在制造过程中采用合理的焊接工艺,选用合适的焊接材料,制定合理的热处理工艺,确保了国内最大焦炭塔一次制造成功。     

风电塔筒法兰外翻变形的控制工艺

介绍了风电塔筒结构及塔筒法兰设计要求,阐述了风电塔筒法兰与筒体焊接的传统工艺及存在的问题,针对焊后法兰出现外翻变形的现象,在设计塔筒法兰时,采用了预留焊接反变形量的方法,对风电塔筒制造工艺进行了改进,通过试验表明,改进后的工艺简单实用、可操作性强,具有一定的推广价值。     

风电塔筒法兰外翻变形的控制工艺

介绍了风电塔筒结构及塔筒法兰设计要求,阐述了风电塔筒法兰与筒体焊接的传统工艺及存在的问题,针对焊后法兰出现外翻变形的现象,在设计塔筒法兰时,采用了预留焊接反变形量的方法,对风电塔筒制造工艺进行了改进,通过试验表明,改进后的工艺简单实用、可操作性强,具有一定的推广价值.     

CO2气体保护焊在风电场塔架制作中的应用

本文介绍了CO2气体保护焊在宁夏贺兰山风电场塔架制作过程中,根据焊接工艺评定,制定焊接工艺规程,对塔架筒体纵缝、环缝焊接缺陷进行了成功的补焊,经检验合格并取得了较好的经济效益。     

20g中厚板埋弧自动焊焊接接头冷弯开裂的试验研究

我厂长期采用埋弧自动焊工艺焊接20g中厚板,制造锅炉、压力容器的筒体等受压元件。代表筒体焊接质量的焊接试板均能通过《蒸汽锅炉安全监察规程》及《压力容器安全监察规程》所规定的各项性能。产品焊接接头质量一直很稳定。但是,今年以来,在焊接工艺     

大型Cr-Mo钢焦炭塔焊接返修技术

分析Cr-Mo钢焦炭塔的特点和技术进展,指出焦炭塔发生开裂的主要原因是热机械疲劳造成的;针对Cr-Mo钢焦炭塔的焊接特点,从焊接材料选择、焊接返修工艺和焊后热处理等方面分析焦炭塔的焊接返修技术,给出了具体的返修工艺,并对回火焊道技术的应用进行了探讨。     

埋弧自动焊在风电塔筒生产中的应用

通过对风电塔筒特征与埋弧焊适用范围对比分析,选定采用埋弧自动焊方法对风电塔筒焊接。通过对埋弧自动焊焊接材料、焊接设备选配,焊接工艺参数的确定、焊接变形预控措施等进行研究,确定了合理的焊接工艺,既满足了风电塔筒高精度质量要求,又提高了生产效率,具有一定实际指导意义。     

风力发电塔筒大容量接地线装置创新设计

通过对风电塔筒环缝焊接接地使用工况分析,结合分析现有焊缝焊接接地装置存在的弊端,研制出适合风力发电塔筒焊接大容量接地线装置,有铝板式和石墨型两种结构,装置结构简单,使用方便,增大了接地线有效接触面积,保证了焊接质量,有效降低了质量缺陷。     

φ800mm鲁奇式加压气化炉壳体的焊接

介绍了先进的鲁奇炉代表型MARK#Ⅳ/4型φ3 800 mm鲁奇式加压气化炉壳体的焊接工艺及相关要求。根据产品的结构特点确定试验方案,在试验的基础上针对产品制造过程中的一些疑难问题进行方案论证和工艺攻关。制订了科学合理的焊接工艺方案,采取一系列措施保证产品质量和控制焊接变形,实现壳体纵环缝焊接采用窄间隙埋弧焊自动跟踪压道焊工艺。成功地解决了鲁奇式φ3 800 mm加压气化炉壳体焊接在质量性能、控制焊接变形等方面存在的难题,获得了满意的焊接效果。该项目的研制成功为承制大型疲劳容器和耐高温、高压的机械传动设备积累了宝贵的经验。     

T91钢高温过热器管屏拼缝焊接变形的工艺控制

在国产循环化床锅炉屏式过热器膜式壁管屏中使用了T91钢材料,由于其焊接性能差,在组合场管屏拼缝焊接过程中,出现了焊接变形。通过工程实践,采用电阻加热方式,焊前预热温度为320～360℃,分段退焊法焊接,管屏拼缝焊接采用槽钢固定管排的方法,高温过热器管屏拼缝焊后变形基本得到控制,提供了适用于类似T91钢膜式壁拼缝焊接的控制变形措施。     

Quantity analysis for welding performance in manufacturing processes

Welded bond quality is a very important working aspect for the manufacturing and construction industries. A product is affected by quality of welding. A set of evaluation methods for welding operators is proposed in this paper, based on a theoretical analysis, to assure the quality of product. A new index using a categorical quantity expression to evaluate the welding performance is proposed. The mathematical relationship of welding performance, number of bad welds and the maximum tolerable number of bad welds are derived. Then, the best estimators and the deviations of this index are statistically inferred. Finally, a procedure and criteria are proposed to evaluate the performance of a welding operator. This evaluation method can be used in decision-making for the selection of a welding operator. Besides, it can also be used as an analytical tool to evaluate and improve the welding ability of a welding technician and the welding performance of a welding operator.     

Application of submerged arc welding technology with cold wire addition for drum shell long seam butt welds of pressure vessel components

Submerged arc welding is most widely used method for welding thick section in down hand position being a highly economical method for fabrication. As products must meet more stringent requirement of quality, requiring more flexible processes to reduce cost, further improvements is studied. Quality control aspects are also becoming more important to meet regulation and monitoring and control of welding processes, and the standardized testing of joints will meet all the requirements. This paper describes the experimental work carried out to study the effect of process parameters and weld metal property of thick section welds in SA 299 material using cold wire addition technology in tandem submerged arc welding for boiler drum shell fabrication. Improved results of mechanical and metallurgical properties obtained in this study are reported.     

MSR管子管板封口焊

通过对MSR管子管板封口焊的研究,介绍了焊接工艺设计与试验过程。自动钨极氩弧焊在管子管板封口焊缝的成功运用,改善了焊接质量,提高了工作效率。     

压力容器接管与壳体装焊的质量控制

分析了压力容器接管与壳体组装结构对压力容器安全运行的影响。论述了接管与壳体组装与焊接过程中质量控制的重要性及质量控制要素。最终获得能够满足使用要求的接管与壳体焊接接头。     

核级阀门焊接质量控制

阐述了核级阀门承压焊接的质量控制,介绍了产品焊接工艺评定和工艺规程的实施方法,给出了产品施焊中对施工现场、设备及产品检验的具体要求。     

Automatic Detection of Spills and Gas Pockets upon Ultrasonic Checking of Welds in Zirconium Fuel Claddings

The problem of automating detection of flaws (gas pockets and spills) in welds obtained by electron-beam welding, using the ultrasonic echo method which is implemented by slanted introduction of ultrasonic waves into a thin zirconium fuel shell, is considered. Algorithms for automatic detection of flaws and evaluation of their relative dimensions are proposed. Experimental results confirming the efficiency of the algorithms proposed are reported.     

Optimization of Inconel 718 alloy welds in an activated GTA welding via Taguchi method, gray relational analysis, and a neural network

The purpose of this work is to optimize the weld bead geometry of Inconel 718 alloy gas tungsten arc (GTA) welds that are coated with activating flux before welding. In order to obtain the optimal welding parameters with multiple quality characteristics (QCs) such as penetration and depth-to-width ratio (DWR) of weld bead, the Taguchi method (TM), gray relational analysis (GRA), and a neural network (NN) are employed in this work. The TM is first used to construct a database for the NN. The GRA is adopted to solve the problem of multiple QCs. The gray relational grade (GRG) obtained from the GRA is used as the output of the backpropagation (BP) NN. Then, a NN with the Levenberg–Marquardt BP (LMBP) algorithm is used to provide the nonlinear relationship between welding parameters and GRG of each specimen. The optimal parameters of the activated GTA welding process are determined by simulating parameters using a well-trained BPNN model. The experimental procedure of the proposed approach not only improves the DWR of weld bead but also increases the penetration of Inconel 718 alloy welds.     

大型焦炭塔的设计与制造

以某炼油厂的焦炭塔为实例,结合焦炭塔的低周热疲劳工况,对选材、结构设计、焊接、热处理、无损检测及压力实验等主要工艺过程进行了论述和总结。在制造焦炭塔容器时选用具有抗高温蠕变,抗高温硫腐蚀以及对裂纹敏感性小的材料,在裙座与塔体的连接处采用整体锻焊型结构,可有效降低低周热疲劳引起的裙座与塔体连接焊缝的应力。