恰希玛核电工程安全壳简体钢衬里的埋弧自动焊焊接质量控制

介绍了巴基斯坦恰希玛核电工程（C-2）安全壳钢衬里简体的基本状况，分析了埋弧自动焊产生终端裂纹的原因。防止埋弧自动焊产生终端裂纹，匹配主要工艺参数是消除焊缝宽度窄而余高大的基本控制方法，正确选择焊剂的颗粒度并合理回收使用焊剂是减小气孔及焊缝表面压气／凹坑缺陷的重要途径，通过二次切割可减小翘曲等波浪变形现象。     

压水堆核电厂主管道窄间隙自动焊焊丝研究

根据窄间隙自动焊工艺及主管道母材特点,在ER316L焊材基础上研究与主管道自动焊技术相匹配的专用焊材。通过模拟焊接试验和热裂纹试验验证了自动焊焊材的稳定性、可焊性,并对其焊缝疲劳寿命进行试验。研究结果证明新开发的自动焊焊材与主管道窄间隙自动焊工艺相匹配,焊缝接头综合性能良好。     

大厚度不锈钢焊接质量控制

作者通过理论分析和实验研究,确定了大厚度不锈钢焊缝的最优合金系统(0Cr20Ni10)和最佳铁素体含量(3.5—6.5%),提出了低热输入快速埋弧自动焊方法(q≤1600J/mm,v≥34m/h)和焊缝结晶过程水喷淋冷却措施以及二级快速升温非敏化消除应力热处理制度。通过七个环节的质量控制,焊接质量极为优良。新的材料和工艺经产品焊接实践,证明其技术效果和经济效益是显著的。     

氧化物夹杂与Ni-Cr-Mo-V钢多层焊缝低温冲击韧性变化规律的关系

测试了反应堆压力容器用Ni-Cr-Mo-V钢焊缝的冲击韧性，实验结果表明，当实验温度较低时，同一实验温度下沿盖面焊到焊根方向不同层焊缝样品的冲击吸收能呈下降趋势。通过低温实验样品断口观察到韧窝底部、起裂源、解离断刻面裂纹源存在直径为0.3～2.0 μm的球形氧化物夹杂，导致试样在变形过程中氧化物夹杂与基体分离形成微裂纹，并发展为试样的韧窝、起裂源和解离断刻面裂纹源，由此推断氧化物夹杂是造成焊缝低温失效的主要原因。同时氧化物夹杂的数量沿盖面焊到焊根方向逐渐增多，使得微裂纹形核率逐渐增加，造成焊缝低温冲击韧性沿盖面焊到焊根方向逐渐变差。     

316不锈钢激光焊接中离焦量对热裂纹的影响

采用最大平均功率为500 W的脉冲激光焊机开展了316不锈钢焊接试验,通过测试表面形貌、微观组织、显微硬度及能谱（EDS）等,分析了离焦量对焊缝组织和热裂纹的影响。研究结果表明,在其他焊接参数不变的条件下,离焦量增大时焊缝组织逐渐细化和致密,热裂纹倾向性逐渐减小。焊缝熔深和熔宽均随离焦量的增大而减小,但宽深比增大,当宽深比大于7.5时焊接热裂纹彻底消失。增大离焦量改变了激光能量的分布状态,导致焊缝凝固过程中S、P等元素向熔池表面偏析,消除了焊缝凝固后期液膜及低熔点组织的不利影响,有效控制了脉冲激光焊接316不锈钢热裂纹的产生。     

核电站安全壳钢衬里埋弧自动焊工艺评定

安全壳钢衬里是核电站非常重要的设备，其安装主要是通过焊接的方式。为了提高安全壳钢衬里的焊接施工质量和施工效率，在预制阶段采用埋弧自动焊可以起到很好的效果。而工艺评定是焊接工艺能用于产品焊接的前提，在核电站建设中尤为重要。本文主要介绍对安全壳钢衬里的埋弧自动焊进行工艺评定的要求、步骤和评定的结果。     

海阳AP1000核电工程安全壳电气贯穿件焊缝缺陷分析

海阳AP1000核电工程安全壳电气贯穿件套筒与补强板焊缝,焊接完成后经UT检验,发现存在大量危险性Ⅰ类缺陷,主要为裂纹、未融合、条渣、气孔等类型.通过统计分析,焊接缺陷主要集中在内侧焊缝套筒母材侧融合区,偏向于仰焊位置.本文主要从焊接工艺、施工作业条件等方面对缺陷产生的原因进行分析,得出通过对焊材选用、焊前预热方式、坡口设计、焊接工艺、电气贯穿件安装次序等方面的改进,可以很好的改善电气贯穿件焊接质量,这对后期核电建设具有一定的借鉴意义.     

CLAM钢的钨极氩弧焊及焊接后的结构与性能

利用钨极氩弧焊(TIG)焊接方法对中国自行研制的低活化铁素体/马氏体(CLAM)钢进行焊接试验,分别采用了Y型坡口和双Y型坡口两种焊接工艺。对焊接件各部分的硬度和显微结构进行测试分析,利用透射电镜观测材料的微观形貌并进行析出物相分析,以此对CLAM钢的焊接性能进行初步评价。观察发现,焊缝区没有产生缩孔和裂纹;焊缝区和母材的微观形貌主要为板条马氏体,板条宽度约为600 nm,其析出物均为20~200 nm的M23C6型碳化物;经过焊后热处理,焊缝区、热影响区和母材的硬度之间的差别减小。     

核反应堆主管道负压腔根阀焊缝缺陷分析及处理

核电厂一回路主管道冷却剂流量负压腔根阀通过接管座以焊接的方式与主管道相连接。本文以秦山核电厂30万千瓦机组流量负压腔根阀前焊缝缺陷处理为例,对焊缝裂纹缺陷产生的初步原因以及在线套管密封焊接修复方案的提出、论证、实施的技术难点进行全面阐述。通过对裂纹焊缝形貌、金相组织的观察进一步分析确认焊缝裂纹产生的根本原因,据此采用技术变更手段从根本上解决了结构不足对设备运行造成的影响,避免焊缝裂纹缺陷的产生,保证了机组的安全稳定运行。     

焊后热处理对16MND5钢焊接组织结构与残余应力的影响

16MND5钢广泛应用于核岛承压容器构件,其焊接接头不可避免地会引入高的残余应力,而焊后热处理可有效消减焊接残余应力以克服应力腐蚀裂纹的影响。本工作利用轮廓法和中子衍射技术研究了焊后热处理对16MND5钢焊接残余应力的影响。结果表明,轮廓法与中子衍射测试结果在趋势和数值上取得了较好的一致性,焊后热处理使焊接态的残余应力峰值从约420 MPa降低至约210 MPa。同时,利用金相法和SEM研究了焊后热处理对焊缝区域组织结构的影响。结果表明,焊后热处理主要表现为贝氏体和少量自回火马氏体的焊缝中心组织转变为回火贝氏体和回火马氏体,热处理后的焊缝区晶粒明显长大。     

Measurement of Reverse Transition in Converging Duct Flow

Installation and replacement of many PWR-steam generators are planned inside and outside Japan. The steel plates for steam generators are heavy in thickness, and increase the number of welding passes and prolong the welding time. Electron beam welding (EBW) can greatly reduce the welding period compared with conventional welding methods (narrow-gap gas metal arc welding (GMAW) and submerged arc welding (SAW)). The problems in applying EBW are to prevent weld defects and to improve the toughness of the weld metal. Defect-free welding procedures were successfully established even in thick steel plates. The factors that deteriorate weld-metal (WM) toughness of EBW were investigated. The manufacturing process, which utilizes a new secondary refining process at steelmaking and a high-torque mill at plate mill in actual mass-production, were established. EBW base metal and WM have better properties including fracture toughness than those of conventional welding processes. As a result, an application of EBW to the fabrication of PWR-steam generators has become possible. Large amounts of ASTM A533 Gr B Cl 2 (JIS SQV2B) steel plates in actual PWR-steam generators have come to be produced (more than 1,500 ton) by appling EBW.     

Welding consumables for nuclear power plants

In nuclear power plants, submerged arc welding and covered arc welding have long been employed especially for main weld seams, including the core region of RPV.This paper investigates the mechanical properties of several welding consumables we have developed for industrial plants — that is, welding consumables which lower the phosphorus and copper content of the welded metal, those for plates possessing particularly high tensile strength and those for the narrow gap welding method.Recent data derived from irradiation embrittlement tests show that these welded metals using a non-copper coating are highly effective in minimizing shifts in the transition curve.Welding consumables for A533B C1.2, A543 C1.1 or A508 C1.4 steels have a higher tensile strength than those for A533B C1.1 or A508 C1.3.We have developed submerged arc and covered arc welding consumables to be used with these kinds of steels, and it was confirmed that these consumables possess excellent tensile strength and notch toughness.Our tests also confirmed that the narrow gap SAW and MIG welds are more efficient than the conventional ones. Moreover, the mechanical properties of the welded metals are also excellent.     

Development of new Z-factors for the evaluation of the circumferential surface crack in nuclear pipes

The purpose of this study is to develop new Z-factors to evaluate the behavior of a circumferential surface crack in nuclear pipe. Z-factor is a load multiplier used in the Z-factor method, which is one of the ASME Code Sec. XI's recommendations for the estimation of a surface crack in nuclear pipe. It has been reported that the load carrying capacities predicted from the current ASME Code Z-factors, are not well in agreement with the experimental results for nuclear pipes with a surface crack. In this study, new Z-factors for ferritic base metal, ferritic submerged arc welding (SAW) weld metal, austenitic base metal, and austenitic SAW weld metal are obtained by use of the surface crack for thin pipe (SC.TNP) method based on GE/EPRI method. The desirability of both the SC.TNP method and the new Z-factors is examined using the results from 48 pipe fracture experiments for nuclear pipes with a circumferential surface crack. The results show that the SC.TNP method is good for describing the circumferential surface crack behavior and the new Z-factors are well in agreement with the measured Z-factors for both ferritic and austenitic pipes.     

Studies on A-TIG welding of Low Activation Ferritic/Martensitic (LAFM) steel

Low Activation Ferritic–Martensitic steels (LAFM) are chosen as the candidate material for structural components in fusion reactors. The structural components are generally fabricated by welding processes. Activated Tungsten Inert Gas (A-TIG) welding is an emerging process for welding of thicker components. In the present work, attempt was made to develop A-TIG welding technology for LAFM steel plates of 10 mm thick. Activated flux was developed for LAFM steel by carrying out various bead-on-plate TIG welds without flux and with flux. The optimum flux was identified as one which gave maximum depth of penetration at minimum heat input values. With the optimized flux composition, LAFM steel plate of 10 mm thickness was welded in square butt weld joint configuration using double side welding technique. Optical and Scanning Electron Microscopy was used for characterizing the microstructures. Microhardness measurements were made across the weld cross section for as welded and post weld heat treated samples. Tensile and impact toughness properties were determined. The mechanical properties values obtained in A-TIG weld joint were comparable to that obtained in weld joints of LAFM steel made by Electron beam welding process.     

低锡Zr—4包壳管电子束焊接时发生的合金元素蒸发现象

采用电子探针的波谱分析方法,对国产低锡Ｚｒ－４包壳管的环焊缝试样进行表面成份分析。分析结果表明,从焊缝的外边到内边缘,Ｓｎ,Ｃｒ,Ｆｅ元素的化学成份在统计上呈增大趋势,腐蚀后出现了白色产物的试样表层,其Ｓｎ,Ｃｒ,Ｆｅ元素含量相当程度地降低。这一事实表明,国产低锡Ｚｒ－４包壳管采用电子束焊接时,在一定的焊接规范环焊缝的合金元素存在严重蒸发现象,特别是合金中锡元素的蒸发使其锡元素含量低于０．５％,导     

贯穿件J形坡口焊接残余应力分析

核电站反应堆压力容器（RPV）顶盖控制棒驱动机构（CRDM）管座J形坡口焊缝在一回路高温高压水环境下存在应力腐蚀开裂（SCC）的风险,而焊接残余应力是SCC的主要驱动力。使用二维轴对称模型有限元方法对CRDM中心管座J形坡口进行焊接残余应力分析。为了探索一种简单、高效和保守的方法,研究了热源简化、焊缝形状简化、屈服强度、相变和强化行为对焊接残余应力的影响。结果表明:双椭球热源与均匀热源得到的残余应力结果基本一致;焊缝形状由鱼鳞状简化为方块模型对焊接残余应力结果影响不大,但是与合并焊道的结果相差较大;采用低屈服强度得到的残余应力结果并不保守;在ANSYS软件中,固液相变对残余应力结果影响不大;等向强化模型的结果比随动强化模型的结果保守;在工程上,建议采用均匀热源、方块焊道模型和等向强化模型进行焊接模拟。      

A study on influence of heat input variation on microstructure of reduced activation ferritic martensitic steel weld metal produced by GTAW process

Reduced activation ferritic martensitic (RAFM) steel is a major structural material for test blanket module (TBM) to be incorporated in International Thermonuclear Experimental Reactor (ITER) programme to study the breeding of tritium in fusion reactors. This material has been mainly developed to achieve significant reduction in the induced radioactivity from the structural material used. Fabrication of TBM involves extensive welding, and gas tungsten arc welding (GTAW) process is one of the welding processes being considered for this purpose. In the present work, the effect of heat input on microstructure of indigenously developed RAFM steel weld metal produced by GTAW process has been studied. Autogenous bead-on-plate welding, autogenous butt-welding, butt-welding with filler wire addition, and pulsed welding on RAFMS have been carried out using GTAW process respectively. The weld metal is found to contain δ-ferrite and its volume fraction increased with increase in heat input. This fact suggests that δ-ferrite content in the weld metal is influenced by the cooling rate during welding. It was also observed that the hardness of the weld metal decreased with increase in δ-ferrite content. This paper highlights the effect of heat input and PWHT duration on microstructure and hardness of welds.     

Analysis of welding distortion due to narrow-gap welding of upper port plug

Narrow-gap welding is a low distortion welding process. This process allows very thick plates to be joined using fewer weld passes as compared to conventional V-groove or double V-groove welding. In case of narrow-gap arc welding as the heat input and weld volume is low, it reduces thermal stress leading to reduction of both residual stress and distortion. In this present study the effect of narrow-gap welding was studied on fabrication of a scaled down port plug in the form of a trapezoidal box made of 10 mm thick mild steel (MS) plates using gas tungsten arc welding (GTAW). Inherent strain method was used for numerical prediction of resulting distortions. The numerical results compared well with that of the experimentally measured distortion. The validated numerical scheme was used for prediction of weld induced distortion due to narrow-gap welding of full scale upper port plug made of 60 mm thick SS316LN material as is proposed for use in ITER project. It was observed that it is feasible to fabricate the said port plug keeping the distortions minimum within about 7 mm using GTAW for root pass welding followed by SMAW for filler runs.     

Creep rupture strength of activated-TIG welded 316L(N) stainless steel

316L(N) stainless steel plates were joined using activated-tungsten inert gas (A-TIG) welding and conventional TIG welding process. Creep rupture behavior of 316L(N) base metal, and weld joints made by A-TIG and conventional TIG welding process were investigated at 923 K over a stress range of 160-280 MPa. Creep test results showed that the enhancement in creep rupture strength of weld joint fabricated by A-TIG welding process over conventional TIG welding process. Both the weld joints fractured in the weld metal. Microstructural observation showed lower δ-ferrite content, alignment of columnar grain with δ-ferrite along applied stress direction and less strength disparity between columnar and equiaxed grains of weld metal in A-TIG joint than in MP-TIG joint. These had been attributed to initiate less creep cavitation in weld metal of A-TIG joint leading to improvement in creep rupture strength.