CN101198768B - 汽轮机用转子及其制造方法 - Google Patents

汽轮机用转子及其制造方法 Download PDF

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CN101198768B
CN101198768B CN2006800212776A CN200680021277A CN101198768B CN 101198768 B CN101198768 B CN 101198768B CN 2006800212776 A CN2006800212776 A CN 2006800212776A CN 200680021277 A CN200680021277 A CN 200680021277A CN 101198768 B CN101198768 B CN 101198768B
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coating
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有川秀行
目幡辉
新井将彦
儿岛庆享
鸟谷初
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    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18After-treatment
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
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    • F05D2220/30Application in turbines
    • F05D2220/31Application in turbines in steam turbines
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F05D2300/00Materials; Properties thereof
    • F05D2300/10Metals, alloys or intermetallic compounds
    • F05D2300/13Refractory metals, i.e. Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, W
    • F05D2300/132Chromium
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Abstract

本发明提供了一种由9~13%Cr系耐热钢构成的汽轮机用转子及其制造方法,该汽轮机用转子无焊接纹裂,也不需要焊后处理,改善了轴颈部的滑动特性。采用高速氧气火焰喷镀法,在由9~13%Cr系耐热钢构成的汽轮机用转子的轴颈部的滑动面上形成低合金钢被覆层,该低合金钢被覆层是由比9~13%Cr系耐热钢滑动特性好的Cr含量在3%以下的低合金钢构成,其任意断面组织中气孔与氧化物合在一起的缺陷面积率为3~15%。

Description

汽轮机用转子及其制造方法
技术领域
本发明涉及由9~13%Cr系耐热钢构成的汽轮机用转子及其制造方法。
背景技术
9~13%Cr系耐热钢(例如,以重量比计具有如下组成的耐热钢:11%Cr-1%Mo-0.6%Ni-0.7%Mn-0.2%V-0.3%Si-0.2%C-0.1%Nb-0.06%N-余量Fe,11%Cr-2.6%W-0.2%Mo-2.5%Co-0.5%Ni-0.5%Mn-0.2%V-0.05%Si-0.1%C-0.1%Nb-0.03%N-0.02%B-余量Fe等)具有优异的高温强度和低温韧性,因而作为汽轮机的高、中压用转子材料被广泛注意,其使用范围不断扩大。但是,在汽轮机中,用滑动轴承来支承高速旋转的涡轮转子,转子材料的滑动特性对轴承部的耐久性有很大影响。
9~13%Cr系耐热钢作为转子材料具有优异的机械性质,但滑动特性差。因此,轴颈部与轴瓦之间容易发生损伤事故(参见非专利文献1)。
特别是,容易产生被称作“钢丝绒(wire wool)损伤”等的损伤形态,即轴颈部的表面好象经过机械加工一样切削出细的条纹,在产生的异物中发现细的螺旋状的线。
据认为,此轴颈部的损伤是由于异物侵入到轴颈部和轴瓦之间所致。特别是9~13%Cr系耐热钢,由于热传导率小,在异物混入时易产生局部烧接。而且,由于Cr含量多,因烧接使温度上升时,易产生Cr碳化物,这会形成另外的异物而促进轴颈部的损伤。
为了防止由9~13%Cr系耐热钢构成的汽轮机用转子的轴颈部的损伤,有人提出在轴颈部堆焊Cr含量少的低合金钢来将其覆盖的方法(参见专利文献1)。
另外,有人提出了一种方法,将堆焊层形成底层和顶层二层,底层用焊接材料使用比顶层用焊接材料强度小、线膨胀系数大的材料,使堆焊被覆层中产生的拉伸残留应力减小(参见专利文献2)。
专利文献1:日本特开昭57-137456号公报
专利文献2:日本特开平06-272503号公报
非专利文献1:金沢他“转子轴颈部的损伤”火力发电,第23卷第5号,昭和47年5月发行,p.536-542
发明内容
以往的方法是,通过堆焊在由9~13%Cr系耐热钢构成的汽轮机用转子的轴颈部上被覆低合金钢,该低合金钢比母材的滑动特性好,Cr含量低。但是,在该以往的方法中,由于9~13%Cr系耐热钢与低合金钢相比,热膨胀率小,所以在堆焊被覆层的表面上会产生拉伸残留应力。
因此,在焊接时、焊后热处理时或者使用时,会有在堆焊部或焊接热影响部等容易产生裂纹的问题。
而且,在用堆焊被覆的方法中,因为焊接时的稀释,母材的9~13%Cr系耐热钢中的Cr熔进堆焊被覆层中,使堆焊被覆层的Cr含量升高。
因此,不得不进行较厚的堆焊,其厚度达到表面不受稀释的影响的程度,这也成为容易产生焊接裂纹的重要原因。
另外,由于需要较厚的堆焊,还需要进行焊后热处理,所以对于生产工艺是不利的,生产成本也提高了。
本发明就是基于这样的背景而完成的,本发明提供了一种由9~13%Cr系耐热钢构成的汽轮机用转子及其制造方法,该汽轮机用转子无焊接裂纹,也不需要焊后热处理,并且改善了轴颈部的滑动特性。
本发明是由9~13%Cr系耐热钢构成的汽轮机用转子,其特征在于,在转子的轴颈部的滑动面上设置有由Cr含量在3%以下的低合金钢构成的被覆层。
采用本发明,可以改善由9~13%Cr系耐热钢构成的汽轮机用转子的轴颈部滑动面的滑动性。
附图说明
图1是表示本发明的涡轮转子的一个例子的示意图。
图2是表示本发明的涡轮转子的加工例子的示意图。
图3是表示本发明中的低合金钢覆膜的断面组织的一个例子的显微镜照片。
图4是表示本发明中的轴承试验机的结构的示意图。
图5是表示本发明中的低合金钢被覆加工过程的一个例子(第一工序)的示意图。
图6是表示本发明中的低合金钢被覆加工过程的一个例子(第二工序)的示意图。
图7是表示本发明中的低合金钢被覆加工过程的一个例子(第三工序)的示意图。
图8是表示轴承试验中的轴瓦温度变化的示意图。
图9是表示按照本发明将低合金钢被覆应用于涡轮转子轴上的高压汽轮机的示意图。
符号说明
1转子,2轴颈部,3轴颈滑动面,4母材,5低合金钢被覆层,10喷镀枪,21电动机旋转轴,22滚动轴承,23轴,24滑动轴承,25试验轴颈部,26台座,31轴径,32坡口加工深度,33倾斜角度,41第1轴承,42第2轴承,43推力轴承,44高压隔板,45高压转动叶片,46高压内部汽缸,47高压外部汽缸,48涡轮转子轴,49主蒸汽入口,50高压蒸汽排气口
具体实施方式
本发明最主要的特征是,采用高速氧气火焰喷镀(HVOF:High VelocityOxy-Fuel)法,在图1所示的由9~13%Cr系耐热钢构成的汽轮机用转子1的轴颈部2的滑动面上形成被覆层,该被覆层由比9~13%Cr系耐热钢滑动特性好、Cr含量在3%以下的低合金钢构成,其任意断面组织中的气孔与氧化物合在一起的缺陷面积率为3~15%。
本发明的由9~13%Cr系耐热钢构成的汽轮机用转子1,为了改善轴颈部2的滑动特性,代替以往在滑动面3上堆焊被覆低合金钢的方法,采用高速氧气火焰喷镀法设置低合金钢被覆层。
与以往的堆焊被覆相比,本发明可以以非常低的热量输入形成低合金钢被覆层。
而且,在高速氧气火焰喷镀法中,是使粉末粒子高速冲击、冲撞对象物来形成被覆层,因而在被覆表面会产生残留压应力。因此,本发明的由9~13%Cr系耐热钢构成的汽轮机用转子,不容易产生低合金钢被覆层的裂纹,还可以省去被覆形成后的热处理。
还有,因为没有稀释的影响,所以可以使低合金钢被覆层的厚度减小。
另外,由于在被覆层内任意断面存在面积率为3~15%的缺陷,所以其优点是,带来润滑油的含油效果,具有更优异的滑动性。
通过使用高速氧气火焰喷镀法这种低热量输入的被覆形成方法,可以使被覆层中无裂纹,也不需要焊后热处理,与以往的堆焊法相比,可以高度可靠并简便地实现改善由9~13%Cr系耐热钢构成的汽轮机用转子的轴颈部滑动特性的目的。
本发明的由9~13%Cr系耐热钢构成的汽轮机用转子1,为了改善轴颈部2的滑动特性,采用高速氧气火焰喷镀法来设置低合金钢被覆层。
作为用于本发明的低合金钢,Cr含量在3%以下为宜。这是因为,Cr含量超过3%的话,会导致滑动性低下,热传导率降低。
具体地说,具有重量比为0.5~2.5%Cr-0.4~1.1%Mo-余量Fe或2.0~2.5%Cr-0.9~1.1%Mo-0.3%以下V-余量Fe等组成的低合金钢,其被覆强度和滑动性的平衡优异,因而优先选用,但本发明并不限于这些成分,本领域的技术人员可以适当地进行选择。
本发明形成的低合金钢被覆层的厚度在0.5~5mm为宜。这是因为,厚度小于0.5mm的薄的低合金钢被覆层,由于异物混入等使低合金钢被覆层受到磨损时,很可能在短时间内就露出作为基材的9~13%Cr系耐热钢,其长时间的耐久性会出现问题。
另一方面,厚度超过5mm的话,作为高速氧气火焰喷镀法的特征的被覆层表面的残留压应力会逐步减小,在被覆层上容易产生裂纹和剥离,因而不可取。
另外,本发明形成的低合金钢被覆层,没有像以往的堆焊那样由焊接引起的稀释的影响,被覆层的厚度本身就是有效厚度,因而被覆层厚度在堆焊的1/2以下就可得到同样的效果。不必要地增加被覆层的厚度,会延长加工的时间,并且也不经济。
此外,本发明形成的低合金钢被覆层,优选的是,在任意断面组织中的气孔和氧化物合在一起的缺陷的面积率为3~15%。
图3中表示本发明形成的低合金钢被覆层的断面组织照片的一个例子。在9~13%Cr系耐热钢母材4上,本发明形成的低合金钢被覆层5的厚度是大约1.5mm。在断面组织照片中,在低合金钢被覆层5中可以看出黑色网状图案。这是由气孔或氧化物构成的喷镀膜中的缺陷,它主要是在用高速氧气火焰喷镀法形成低合金钢被覆层5时,低合金钢喷镀粉末在高速火焰中飞行时被加热,粉末表面上生成的氧化物(主要含有Fe氧化物,Fe以外的微量的合金元素的氧化物)被收入低合金钢被覆层5中而产生的。通过图像分析,求得此缺陷(网状的黑色区域)在被覆层断面内的面积率约为10%。
由于氧化物是多孔质的,气孔就更不用说了,因此这些缺陷在被覆层内起到细微的空隙的作用,可以浸渍、保持润滑油。因而不易发生油膜不连续的情况,具有防止烧接的效果。
不过,如果缺陷率增加的话,虽然润滑油的浸渍、保持效果提高,但被覆层的强度降低,因而在高面压、高圆周速度的滑动条件下,容易产生被覆层的剥离或者在被覆层内产生层间破坏。
因此,缺陷率小于3%时,含油保持效果不充分,相反,超过15%的话,会导致被覆层的强度降低,因而都不可取。
另一方面,被覆层的强度随着缺陷的状态和分布而不同。即,即使缺陷率相同,在不均匀地存在粗大的缺陷以及均一地分布有细小的缺陷两种场合,还是后者的被覆层的强度高。因此,被覆层的结合强度在40MPa以上为宜。被覆层的结合强度小于40MPa时,容易产生被覆层的剥离或者在被覆层内产生层间破坏。
如上所述,在本发明的由9~13%Cr系耐热钢构成的汽轮机用转子中,作为优选使用的低合金钢被覆层,是由Cr含量在3%以下的低合金钢构成的被覆层,最好是被覆层的厚度在0.5~5mm的范围,任意断面组织中的气孔和氧化物合在一起的缺陷的面积率为3~15%,并且,被覆层的结合强度为40MPa以上。
为了形成这样的被覆层,最好是使用高速氧气火焰喷镀法。相对于其他的喷镀法,例如等离子喷镀、火焰喷镀、电弧喷镀等将材料(粉末、线材)高温熔融后喷吹,主要是在基材上急冷凝固而形成覆膜的方法,高速氧气火焰喷镀法的特征是,高速喷吹粉末,主要是利用由其动能所引起的与基材冲撞时的塑性变形来形成被膜。
由于这种成膜原理上的不同,采用高速氧气火焰喷镀法能够将粉末的氧化抑制在较低的程度。
另外,采用将材料熔融、在基材上急冷凝固的其他方法时,在凝固粘结的被膜中产生残留拉应力。而采用高速氧气火焰喷镀法时,是利用使材料高速冲撞基材时的塑性变形,因而在被膜中产生了残留压应力。因此,通过高速氧气火焰喷镀所产生的被膜还具有结合强度和被膜强度优异、不易产生被膜裂纹和剥离等优点。
实施例1
图4中示意地表示了轴承试验机的结构,该轴承试验机是用于评价本发明形成的低合金钢被覆的轴承特性。该装置在由2个滚动轴承22可自由旋转地支承的轴23的一端设置了试验轴颈部25,与滑动轴承24组合,构成试验轴承部。
由润滑油供给机构(图中未示出)给滑动轴承24供油。滑动轴承24被安装在可以利用油压来升降的台座26上。轴23的另一个端部,与电动旋转机(图中未示出)的旋转轴21相连接,利用电动旋转机的旋转使轴23转动。轴承试验按以下所述进行,利用电动旋转机使轴23转动,同时,使台座26升高,给试验轴颈部25和滑动轴承24的滑动面施加适当的面压。
按以下所述的程序,在12%Cr系耐热钢(11%Cr-2.6%W-0.2%Mo-2.5%Co-0.5%Ni-0.5%Mn-0.2%V-0.05%Si-0.1%C-0.1%Nb-0.03%N-0.02%B-余量Fe)制的轴23的试验轴颈部25上形成低合金钢被覆层5。
首先,如图5所示,在试验轴颈部25进行深度32为2mm的坡口加工。坡口加工的两端形成倾斜角度33为30°的倾斜面。
这是为了防止在坡口加工的端部,喷镀被覆层和母材之间产生缺陷,导致结合力降低。倾斜角度(倾斜面的坡度)33优选的是15~45°。符号31为轴径。
接着,将包含坡口加工面的加工范围的表面脱脂、洗净,随后,使用氧化铝粗砂进行喷砂处理,使其表面粗糙。然后,使用低合金钢粉末(1.3%Cr-0.5%Mo-余量Fe,粉末粒径:25~63μm)作为喷镀粉末,利用TAFA公司制造的JP5000型HVOF装置,如图6所示,形成比坡口加工的深度32厚约1mm的低合金钢被覆层5。这里,符号31是轴径,符号33是倾斜角度。
喷镀条件是:燃料(煤油)流量为23L/hr,氧气流量为873L/hr,燃烧压力为0.7MPa,粉末供给量为60g/分,筒长度为100mm(4英寸),喷镀距离为380mm。如图2所示,一面使转子1旋转,一面相对于滑动面3大致平行地移动喷枪10,喷枪10与喷镀表面的相对速度为200~750mm/秒,以此速度进行喷镀。
观察采用相同的喷镀条件对12%Cr系耐热钢试片实施喷镀的低合金钢被覆的断面组织,利用图像分析求得缺陷率约为10%。
另外,按照JIS H8402:2004“喷镀被膜的拉伸粘附强度试验方法”测定拉伸粘附强度时,由于粘接剂破裂,没有得到测定值,但因为粘接剂破裂时的粘附强度约为70MPa,所以被覆层的粘附强度为70MPa以上。
实施喷镀后,如图7所示,通过机械加工、研磨加工进行精加工,使被覆层施工部达到规定的轴径31。这里,符号5是被加工的低合金钢被覆层,符号32是坡口加工的深度,符号33是倾斜角度。
将上述在试验轴颈部25上设有低合金钢被覆层5的12%Cr系耐热钢轴23,组装到图4所示的装置中,进行轴承试验。
为了进行比较,对未设置低合金钢被覆层5的12%Cr系耐热钢轴以及以往的堆焊轴也进行了试验。
试验条件是,在圆周速度为50m/秒、轴承载荷为30kg/cm2的恒定旋转过程中,以1g/分的比例用大约10分钟向供给轴承的润滑油中投入125~300μm的铁粉,强制性地向轴承部中混入异物,调查轴和轴瓦的损伤。另外,测定试验过程中的轴瓦温度。如果由于投入异物,在轴和轴瓦之间产生油膜不连续,润滑受到损害,那么,由于金属之间的摩擦热而使温度上升。因此,轴瓦温度升高越小,滑动性越好。
试验中的轴瓦温度变化如图8所示。在使用设有本发明的低合金钢被覆层的12%Cr系耐热钢轴的试验中,投入异物后,可以看出突发的温度上升,但短时间内就降低,稳定状态的温度约为80℃。另一方面,在使用未设有低合金钢被覆层的12%Cr系耐热钢轴的试验中,投入异物后,温度连续上升,在200℃时稳定。另外,在使用以往的堆焊轴的试验中,投入异物后,短时间内与本发明的设有低合金钢被覆层的12%Cr系耐热钢轴同样,显示出突发的温度上升,随后在短时间内降低,但在试验后半段,与未设有低合金钢被覆层的12%Cr系耐热钢传动轴同样,温度连续上升,最终达到200℃。
目视观察试验后的轴和轴瓦的损伤状况。结果,本发明的设有低合金钢被覆层的12%Cr系耐热钢轴,在轴的滑动面上只发现少许擦伤,几乎没有损伤,但轴瓦有损伤。
另一方面,未设有低合金钢被覆层的12%Cr系耐热钢轴及以往的堆焊轴,在轴的滑动面上产生了一些切削成细的条纹状的损伤,还发现了钢丝绒状的异物。轴瓦也有很明显的损伤。
由以上所述可知,与未设低合金钢被覆层的情况相比,本发明的设有低合金钢被覆层的12%Cr系耐热钢转子能大幅度改善轴承特性。此外还可以看出,与以往的堆焊轴相比,其轴承特性也十分优异。
实施例2
图9中所示的高压汽轮机由12%Cr系耐热钢(11%Cr-2.6%W-0.2%Mo-2.5%Co-0.5%Ni-0.5%Mn-0.2%V-0.05%Si-0.1%C-0.1%Nb-0.03%N-0.02%B-余量Fe)制涡轮转子轴48、高压隔板44、高压转动叶片45、高压内部汽缸46、高压外部汽缸47、主蒸汽入口49、蒸汽排气口50等构成,在设置于该高压汽轮机的涡轮转子轴48上的第1轴承41、第2轴承42、推力轴承43的滑动部位实施本发明的低合金钢被覆。
实施被覆的方法与实施例1相同,首先,在实施被覆的部位进行深度为3mm的坡口加工。坡口加工的两端形成倾斜角度33为30°的倾斜面。接着,将包含坡口加工面的加工范围的表面脱脂洗净,然后,使用氧化铝粗砂进行喷砂处理,使其表面粗糙化。然后,使用低合金钢粉末(1.3%Cr-0.5%Mo-余量Fe,粉末粒径:25~63μm)作为喷镀粉末,利用TAFA公司制造的JP5000型HVOF装置,形成比坡口加工的深度厚约1mm的低合金钢被覆层。
喷镀条件是:燃料(煤油)流量为23L/hr,氧气流量为873L/hr,燃烧压力为0.7MPa,粉末供给量为60g/分,筒长度为100mm(4英寸),喷镀距离为380mm。一面使涡轮转子轴48转动,一面相对于喷镀表面大致平行地移动喷枪,喷枪与喷镀加工面的相对速度为200~750mm/秒,以此速度进行喷涂。喷镀加工后,通过机械加工、研磨加工来进行精加工,使被覆层加工部成为规定的轴径。
使用这样在轴承滑动部上形成本发明的低合金钢被覆层的涡轮转子轴48的高压汽轮机,在运转1年后进行检验时,涡轮转子轴48的轴承滑动部以及轴瓦都是完好的。
工业上的应用性
利用本发明,可以提高支承汽轮机用转子的轴承部的耐久性。

Claims (4)

1.汽轮机用转子,该汽轮机用转子由9~13%Cr系耐热钢构成,其特征在于,在所述转子的轴颈部的滑动面上设置有通过高速氧气火焰喷镀(HVOF:High Velocity Oxy-Fuel)法由Cr含量在3%以下的低合金钢构成的被覆层,所述被覆层在任意断面组织中的气孔和氧化物合在一起的缺陷的面积率为3~15%。
2.根据权利要求1所述的汽轮机用转子,其特征在于,所述的由Cr含量在3%以下的低合金钢构成的被覆层的厚度是0.5~5mm。
3.根据权利要求1或2所述的汽轮机用转子,其特征在于,所述的由Cr含量在3%以下的低合金钢构成的被覆层,并且,所述的由Cr含量在3%以下的低合金钢构成的被覆层的粘结强度为40MPa以上。
4.由9~13%Cr系耐热钢构成的汽轮机用转子的制造方法,其特征在于,在所述转子的轴颈部的滑动面上,采用高速氧气火焰喷镀(HVOF:HighVelocity Oxy-Fuel)法形成由Cr含量在3%以下的低合金钢构成的被覆层,所述被覆层在任意断面组织中的气孔和氧化物合在一起的缺陷的面积率为3~15%,然后,对所述被覆层的表面进行机械加工或者研磨加工,加工成规定的尺寸以及表面粗糙度。
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CN101198768A (zh) 2008-06-11
US8485788B2 (en) 2013-07-16
EP1898048A4 (en) 2009-12-02
JP4584999B2 (ja) 2010-11-24
EP1898048A8 (en) 2008-05-14
JPWO2006134831A1 (ja) 2009-01-08

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