The hydraulic turbine wear-resisting cast-weld construction stator and preparation method thereof
Technical field
The present invention relates to the hydraulic turbine wear-resisting cast-weld construction stator and preparation method thereof, be applied to control inside spiral case
Swiftly flowing water flows to annular water flow amount and the annular hydrostatic energy of rotary wheel of water turbine wheel blade around rotary wheel of water turbine.
Background technology
Guide vanes of water turbine is the key component of turbine gate mechanism;Turbine gate mechanism passes through array at rotary wheel of water turbine
On the one hand the numerous guide vanes of water turbine circularizing distribution around control to flow to the total water current amount of rotary wheel of water turbine wheel blade, the opposing party
Face forms annular momentum, and the kinetic energy of snail shell-side fluid is converted into the static energy flowing to runner blade.Turbine gate mechanism is also
Hydraulic turbine shut-off function in emergency situations is realized by stator.
During hydraulic turbine operation, the voltage signal of electrical network the auxiliary device speed regulator being automatically fed to turbine-generator units enters
Action is made, and rotates folding by stator, controls hydraulic turbine discharge or normal shutdown, so stator general work state can be ceaselessly
Slow rotation, its axle journal rotating support level easily weares and teares.Stator rotates the abrasion of support level and then directly influences the hydraulic turbine
The motility of water distributor operation, sealing, it is related to turbine efficiency and the performance of hydraulic turbine stable operation.Except guide vane teunnion axle
Neck is frayed can be affected outside hydraulic turbine operation performance, and the rostral face of diffuser, caudal face, upper surface and lower surface are subject in current
Silt particle constantly washes away and easy to wear, if do not have the sealing function to current when stator normal shutdown, unit will
Orderly closedown.So rotating the vertical sideways wearability of support level, the both ends of the surface of diffuser and diffuser two often determine water
Turbine overhaul life or even the service life of the hydraulic turbine.
Improving the traditional method of stator wearability is that the method workload is big at easy-wearing surface paving weldering high-abrasive material;Welding
Time produce substantial amounts of heat energy and make guide vane teunnion flexural deformation, need weld layer enlarged in thickness or to guide vane teunnion alignment repeatedly, add
Manufacturing cost.Guide vanes of water turbine is generally steel-casting, and material is ordinary carbon steel or rustless steel.Common sand mold cast steel low cost, casting
Often there is burning into sand, pore, the defect such as loose in steel part stator, and stator is Precision Machining part, and manufacturing procedure is many, and the cycle is long,
Casting flaw occurs during polish, the allowance left when the stress deformation amount produced during repair welding is commonly greater than polish, this
Sample result in workpiece cannot repair welding and scrap.Cast stainless steel stator mostly uses refine to cast, and has higher wearability, but
Casting technique is complicated, and material is precious metal, and manufacturing cost is high.
Summary of the invention
The wear-resisting cast-weld construction of the hydraulic turbine that it is an object of the invention to provide a kind of high-wear resistance, that Financial cost is low is led
Leaf.The present invention also will provide a kind of method making the described hydraulic turbine wear-resisting cast-weld construction stator.
The technical scheme is that the hydraulic turbine wear-resisting cast-weld construction stator, including diffuser and guide vane teunnion;
It is characterized in that:
I () diffuser is by casting carbon steel diffuser body, rustless steel upper head plate, rustless steel bottom plate, rustless steel tailgate group
Become;Described casting carbon steel diffuser body band body upper surface, body lower surface, body caudal face, body rostral face;Described
Welding angle, the periphery upper surface of falling body, body upper surface;Welding angle, the periphery lower surface of falling body, described body lower surface;Described body
Welding angle, the dual-side caudal of falling body face, caudal face;Format body rostral face, described body rostral face weld filler groove;
(ii) guide vane teunnion is by casting carbon steel guide vane teunnion body, upper axle journal coating, middle axle journal coating, lower axle journal coating, axis
The shoulder collar, lower shaft shoulder collar composition;Described casting carbon steel guide vane teunnion body includes axle under body upper shaft, body axis, body;Institute
State axle journal surfacing on body upper shaft band;Axle journal surfacing in described body axis band;Axle leukorrhagia axle journal surfacing under described body;
(iii) body axis one end is connected with body upper shaft one, and other end one vertical with body upper surface is connected;This
Under body, axle one end one vertical with body lower surface is connected;
(iv) opening inversed taper platform shape plug welding hole I inside rustless steel upper head plate and body axis passes hole, described body axis is worn
The via inner edge axis of falling body connects angle through eyelet welding;
V opening axle under inversed taper platform shape plug welding hole II and body inside () rustless steel bottom plate and pass hole, under described body, axle is worn
Under the body of via inner edge, axle connects angle through eyelet welding;
(vi) rustless steel tailgate connects end both sides band rustless steel tailgate and connects welding angle, end both sides;
(vii) rustless steel upper head plate is combined mutually with body upper surface, by inversed taper platform shape plug welding hole I soldering stainless steel material
Rustless steel upper head plate is welded together with body upper surface, by body upper surface welding welded corner joint stainless steel material by stainless
Steel upper head plate periphery welds together with body upper surface periphery;Welded corner joint stainless steel material is connect through eyelet welding by body axis
Middle axle journal periphery is welded together with rustless steel upper head plate;
(viii) rustless steel bottom plate is combined mutually with body lower surface, by inversed taper platform shape plug welding hole II soldering stainless steel material
Rustless steel bottom plate is welded together by material with body lower surface, will not by body lower surface welding welded corner joint stainless steel material
Rust steel bottom plate periphery welds together with body lower surface periphery;Stainless through the welding welded corner joint of inner edge, hole by axle under body
Lower axle journal periphery is welded together by Steel material with rustless steel bottom plate;
(ix) rustless steel tailgate welds welded corner joint not by rustless steel tailgate connection welding angle, end both sides and body caudal face
Rust Steel material welds together with body caudal face;
Stainless steel material is filled by welding in the weld filler groove of (x) body rostral face;
(xi) by brush nickel plating or electrodeposited chromium, upper axle journal coating is deposited in upper axle journal surfacing;By brush nickel plating or
Middle axle journal coating is deposited in middle axle journal surfacing by electrodeposited chromium;By brush nickel plating or plating, lower axle journal coating is deposited on lower axle
In neck surfacing.
A kind of method of the hydraulic turbine wear-resisting cast-weld construction stator that make high-wear resistance, that Financial cost is low, its feature
It is to comprise the following steps:
One of step: make casting carbon steel stator body, rustless steel upper head plate, rustless steel bottom plate, rustless steel tailgate;System
The shaft shoulder collar, the lower shaft shoulder collar in work;
Described casting carbon steel stator body is formed with casting carbon steel guide vane teunnion body by casting carbon steel diffuser body;
Described casting carbon steel diffuser body band body upper surface, body lower surface, body caudal face, body rostral face;
Welding angle, the periphery upper surface of falling body, described body upper surface;Welding angle, the periphery lower surface of falling body, described body lower surface;Institute
State welding angle, the dual-side caudal of falling body face, body caudal face;Format body rostral face, described body rostral face weld filler groove;
Described casting carbon steel guide vane teunnion body includes axle under body upper shaft, body axis, body;On described body upper shaft band
Axle journal surfacing;Axle journal surfacing in described body axis band;Axle leukorrhagia axle journal surfacing under described body;
Body axis one end is connected with body upper shaft one, and other end one vertical with body upper surface is connected;Under body
Axle one end one vertical with body lower surface is connected;
Described rustless steel upper head plate, opens inversed taper platform shape plug welding hole I inside rustless steel upper head plate and body axis passes hole, institute
State body axis and connect angle through inner edge, the hole axis of falling body through eyelet welding;
Described rustless steel bottom plate, opens axle under inversed taper platform shape plug welding hole II and body and passes hole inside rustless steel bottom plate,
Under described body, axle connects angle through axle under the body of inner edge, hole through eyelet welding;
Described rustless steel tailgate, rustless steel tailgate connects end both sides band rustless steel tailgate and connects welding angle, end both sides;
The two of step: the welding on welding angle or plug welding hole of employing stainless steel electrode or welding wire will cast carbon steel stator originally
Body, rustless steel upper head plate, rustless steel bottom plate, rustless steel tailgate assemble and weld together and obtain assembly;
The three of step: step 2 gained assembly is made annealing treatment, annealing regulation parameter: temperature rise speed is little be equal to 80 DEG C/
H, is incubated 3-4h at 565 DEG C to 585 DEG C, then cools to room temperature with the furnace;
The four of step: use surface brush plating nickel or electrodeposited chromium, in upper axle journal surfacing, middle axle journal surfacing, lower axle journal surfacing
Generate nickel plating or the upper axle journal coating of chromium plating, middle axle journal coating, lower axle journal coating;
The five of step: the middle shaft shoulder collar is enclosed within outside middle axle journal coating by hot cover process interference fit, and overlaps to axis root
Portion;The lower shaft shoulder collar is enclosed within outside lower axle journal coating by hot cover process interference fit, and overlaps to lower axle root.
The method of the described hydraulic turbine wear-resisting cast-weld construction stator, is characterized in that nickel plating thickness 0.1~0.2mm or chromium plating thickness
0.05~0.10mm.
The method of the described hydraulic turbine wear-resisting cast-weld construction stator, is characterized in that upper axle journal surfacing, middle axle journal surfacing, lower axle journal
Surfacing all arranges cylindrical grinding process before and after surface brush plating nickel or electrodeposited chromium.
The method of the described hydraulic turbine wear-resisting cast-weld construction stator, is characterized in that hot cover process uses oil to boil shaft shoulder set in heating
Ring or the lower shaft shoulder collar;Heating-up temperature is 200 DEG C~250 DEG C, is inserted in the outer or lower axle journal coating of axis neck coating after being incubated 2 hours
Outward.
Present invention have the advantage that
1, high abrasion cost performance.There is stainless anti-wear performance, lead relative to starting from cast steel from cast steel stator base
Leaf, cost only carries about 15%, is but avoided that in the course of processing and causes making cast steel stator failure because mending (paving) weldering and cause
The technical problem that cast steel stator base substrate is scrapped;Make price relative to pure rustless steel and be then generally reduced more than 50%.
2, only with spot welding, wire bonding;Sweating heat melt is little, surface brush plating or plating low temperature, the middle shaft shoulder collar, the lower shaft shoulder
The heating-up temperature of collar hot cover process is low, and the thermally-induced stress deformation of whole manufacturing process is little, it is therefore prevented that hot jacket causes guide vane teunnion
Deformation;Ensure that the yield rate of making.
3, it is inserted in axis and lower axle in rustless steel upper head plate, rustless steel bottom plate after the middle shaft shoulder collar, the lower shaft shoulder collar, makes
The hole dimension supplying axis or lower axle to pass that rustless steel upper head plate, rustless steel bottom plate plate Middle face are opened is less.Tip plate configurations
Need to not divide half making because its hole size is too big, thus end plate processing technology simple in construction, make easily.
4, annealing temperature is less than austenitic stainless steel sensitive temperature, it is ensured that rustless steel intrinsic corrosiom resistance energy, eliminates
Residual stress in Welding Structure, makes stator overall structure stable mechanical property.
As long as 5, stator cast-weld construction assembles rustless steel upper head plate and rustless steel bottom plate to be inserted in respectively and casts carbon steel and lead
On rachis body, and making two end plates outer rim align with casting carbon steel diffuser body external surface, point welds, then executes welding comprehensively i.e.
Can;Rustless steel tailgate uses the wire bonding attachment structure connecting welding angle, end both sides;Wire bonding in the weld filler groove of body rostral face
Stainless steel material, process for assembling and welding is simple.
6, casting carbon steel stator body uses ordinary carbon steel material to make, and Financial cost is effectively reduced.
Accompanying drawing explanation
Accompanying drawing 1 is that the present invention casts carbon steel stator body structural representation from direction at a glance.
In figure, 1 is upper axle journal surfacing, and 3 is middle axle journal surfacing, and 5 is body rostral face weld filler groove, and 7 is the plating of lower axle journal
Face, 9 is welding angle, body caudal face, and 11 is welding angle, body upper surface, and 13 is body upper surface.
Fig. 2 is the structural representation that the present invention casts that carbon steel stator body is seen from direction two.
In figure, 1 is upper axle journal surfacing, and 3 is middle axle journal surfacing, and 13 is body upper surface, and 11 is welding angle, body upper surface, 7
Being lower axle journal surfacing, 9 is welding angle, body caudal face.
Fig. 3 is the structural representation that the present invention casts that carbon steel stator body is seen from direction three.
In figure, 1 is upper axle journal surfacing, and 3 is middle axle journal surfacing, and 5 is body rostral face weld filler groove, and 15 is body lower end
Face, 7 is lower axle journal surfacing, and 17 is welding angle, body lower surface, and 9 is welding angle, body caudal face.
Fig. 4 is the structural representation that the present invention casts that carbon steel stator body is seen from direction four.
In figure, 1 is upper axle journal surfacing, and 3 is middle axle journal surfacing, and 9 is welding angle, body caudal face, and 15 is body lower surface, 7
Being lower axle journal surfacing, 17 is welding angle, body lower surface.
Fig. 5 is the structural representation that the present invention casts that carbon steel stator body is seen from direction five.
In figure, 1 is upper axle journal surfacing, and 3 is middle axle journal surfacing, and 7 is lower axle journal surfacing, and 9 is welding angle, body caudal face, 11
Being welding angle, body upper surface, 13 is body upper surface.
Fig. 6 is rustless steel top end plate structure schematic diagram.
In figure, 20 is inversed taper platform shape plug welding hole I, and 21 is that body axis passes inverse bonding angle, inner edge, hole, and 23 is that body axis passes
Hole
Fig. 7 is rustless steel bottom plate structural representation.
In figure, 25 is inversed taper platform shape plug welding hole II, and 27 is that under body, axle is through welding angle, inner edge, hole, and 29 is that under body, axle is worn
Via.
Fig. 8 be stainless be steel tail-board structure schematic diagram.
Fig. 9 is the enlarged drawing of Fig. 8 amplifier section.
In figure, 30 is that rustless steel tailgate connects welding angle, end both sides
Figure 10 is rustless steel weldment and the casting combined structural representation seen from direction six of carbon steel stator body.
In figure, 41 is body upper shaft, and 1 is upper axle journal surfacing, and 43 is body axis, and 3 is middle axle journal surfacing, and 45 is rustless steel
Upper head plate, 47 is rustless steel tailgate, and 48 is axle under body, and 49 is rustless steel bottom plate, and 5 is body rostral face weld filler groove,
51 is casting carbon steel diffuser body.
Figure 11 is rustless steel weldment and the casting combined structural representation seen from direction seven of carbon steel stator body.
In figure, 48 is axle under body, and 49 is rustless steel bottom plate, and 51 is casting carbon steel diffuser body, and 3 is the plating of middle axle journal
Face, 1 is upper axle journal surfacing, and 45 is rustless steel upper head plate, and 47 is rustless steel tailgate, and 7 is lower axle journal surfacing.
Figure 12 is that embodiment casts carbon steel stator body manuscript.
Figure 13 is that the present invention makes middle-size and small-size Guide Vanes in Francis Turbine manufacturing cost synopsis.
Detailed description of the invention
The hydraulic turbine wear-resisting cast-weld construction stator, including diffuser and guide vane teunnion;The improvements of the present invention are:
(i) diffuser by cast carbon steel diffuser body (51), rustless steel upper head plate (45), rustless steel bottom plate (49),
Rustless steel tailgate (47) forms.Casting ordinary carbon steel can be selected for material ZG230-450, ZG20MnSi etc..Corrosion resistant plate can be selected for
Material 0Cr18Ni9,1Cr18Ni9Ti.
Described casting carbon steel diffuser body band body upper surface (13), body lower surface (15), body caudal face, body
Rostral face;Welding angle, the periphery upper surface of falling body, described body upper surface (11);The periphery lower end of falling body, described body lower surface
Welding angle, face (17);Described welding angle, the dual-side caudal of falling body face, body caudal face (9);Described body rostral face format body head
Side weld filler groove (5).
(ii) guide vane teunnion is by casting carbon steel guide vane teunnion body, upper axle journal coating, middle axle journal coating, lower axle journal coating, axis
The shoulder collar, lower shaft shoulder collar composition;Described casting carbon steel guide vane teunnion body includes body upper shaft (41), body axis (43), basis
Axle (48) under body;Axle journal surfacing (1) on described body upper shaft band;Axle journal surfacing (3) in described body axis band;Under described body
Axle leukorrhagia axle journal surfacing (7).Upper axle journal coating, middle axle journal coating, the thickness nickel plating thickness 0.1 of the lower each coating of axle journal coating~
0.2mm or chromium plating thickness 0.05~0.10mm.The middle shaft shoulder collar, the lower shaft shoulder collar select stainless steel material to make, and high 12 to 15
Millimeter, wall thickness 6 to 8 millimeters, interior draw ratio each coating external diameter is less than 0.1 millimeter, to obtain plating with middle axle journal coating or lower axle journal
Small-gap suture fiting effect between Ceng.
(iii) body axis one end is connected with body upper shaft one, other end one vertical with body upper surface (13) phase
Even;Under body, axle one end one vertical with body lower surface (15) is connected.Casting carbon steel guide vane teunnion body and casting carbon steel stator
Body body composition casting carbon steel stator body.Casting carbon steel stator body makes by the following method:
The first, casting casting carbon steel stator body foundry goods, casting annealing.The second, milling guide vane teunnion both ends of the surface.
3rd, on the basis of stator profile, guide vane teunnion two ends centre bore processing line is drawn.(during line first with red steel paper or
3240 epoxy plates make diffuser molded line basic pattern, and line centre bore is made at model center)
4th, stator body two ends centre bore is bored.Then go out to cast carbon steel diffuser body and casting by following working procedure processing
Make the above-mentioned technical characteristic that carbon steel guide vane teunnion body is carried:
5th, carbon steel stator body manuscript turning foundry goods guide vane teunnion and foundry goods diffuser both ends of the surface are cast by Figure 12.
6th, on the basis of foundry goods guide vane teunnion, stator profile processing line is marked.First with red steel paper or 3240 epoxies during line
Plate makes diffuser profile face mold, and the endoporus of model coordinates with the lower axle journal small-gap suture of guide vane teunnion, and fit clearance is the least
In 0.1mm.
7th, the planing of carbon steel stator body manuscript or milling diffuser profile are cast by Figure 12, including body rostral face
The body caudal face that weld filler groove (5) coordinates with rustless steel tailgate weld angle (9) (as use planing diffuser profile, its
The diameter of axle to increase because planing with face of passing through the mutually part of diffuser profile together with milling pass through face operation mutually).
Welding angle, body upper surface (11) the body lower surface of the 8th, milling (or with air-arc cutting) diffuser two end periphery
Welding angle (17).Welding angle angle typically uses 45 degree.
(iv) internal inversed taper platform shape plug welding hole I (20) and the body axis opened of rustless steel upper head plate (45) is through hole, described
Body axis connects angle (21) through inner edge, the hole axis of falling body through eyelet welding.
V () rustless steel bottom plate (49) inside is opened axle under inversed taper platform shape plug welding hole II (25) and body and is passed hole (29), institute
State axle under body and connect angle (27) through axle under the body of inner edge, hole through eyelet welding.
Rustless steel upper head plate and the making of rustless steel bottom plate, can be carried out by following operation: the first, CNC Plasma Cutting
Blanking or laser blanking.If plasma cutting blanking by hand, then line, plasma cutting is used (during line, first to use red steel paper
Or 3240 epoxy plate manufacturing terminal template line basic patterns).Rustless steel upper head plate and rustless steel bottom plate, selecting thickness is 10 millimeters
Stainless steel materials.The second, smoothing stator end plate two plane.3rd, guide vane teunnion mating holes and plug welding hole line are drawn.4th, brill is led
Rachis mating holes and plug welding hole.
(vi) rustless steel tailgate connects end both sides band rustless steel tailgate and connects welding angle, end both sides (30).Its manufacturing process is
Blanking, smooth, rule, external surface of planing.
Following assembling is used to form the stator assembly blank with following vii~x structure with welding procedure:
The first, the guide vane teunnion of casting carbon steel stator body is inserted on fitter's bench with holes or assembling plate, will not
Rust steel upper head plate (45) endoporus and end face are positioned at casting carbon steel guide vane teunnion body and the body upper surface of casting carbon steel diffuser
On, and rotate end plate so that it is profile and body upper surface perimeter alignment.After accurate positioning, spot welding is firm.Casting carbon steel stator is originally
Above work step tack-weld rustless steel bottom plate (49) is repeated after body tune.
The second, firm with the butt welding in casting carbon steel stator body caudal face spot welding after neat for rustless steel tailgate.
3rd, welding on each welding angle, wlding uses stainless steel electrode or welding wire.At body rostral face weld filler groove
(5) upper built-up welding rustless steel.
(vii) rustless steel upper head plate (45) is combined mutually with body upper surface (13), is welded by inversed taper platform shape plug welding hole I (20)
Connect stainless steel material to weld together in rustless steel upper head plate plate with body upper surface, by welding angle, body upper surface (11)
Rustless steel upper head plate periphery is welded together by soldering stainless steel material with body upper surface periphery;By body axis through hole
Middle axle journal periphery is welded together by welding angle (21) soldering stainless steel material with rustless steel upper head plate.
(viii) rustless steel bottom plate (49) is combined mutually with body lower surface (15), by inversed taper platform shape plug welding hole II (25)
Soldering stainless steel material welds together in rustless steel bottom plate plate with body lower surface, by welding angle, body lower surface
(17) rustless steel bottom plate periphery is welded together by soldering stainless steel material with body lower surface periphery;Worn by axle under body
Lower axle journal periphery is welded together by welding angle, via inner edge (27) soldering stainless steel material with rustless steel bottom plate;
(ix) rustless steel tailgate (47) connects welding angle, end both sides (30) and the welding of body caudal face by rustless steel tailgate
Angle (9) soldering stainless steel material welds together with body caudal face;
Stainless steel material is filled by welding in (x) body rostral face weld filler groove (5).
Above-mentioned stator assembly blank is made half finish turning machining.Each engagement journal stay allowance for finish 0.3 to
0.4mm.The not made allowance turning of non-engagement journal is to whole processing dimension.With prefabricated diffuser profile face mold, mark stator
Build face processing line and stator facade sealing surface processing line.The V-block of workbench it is positioned with the middle axle journal of stator and lower axle journal
On, by processing line planing diffuser profile.Or numerical control milling diffuser profile (diffuser profile can be omitted and draw processing line operation).
Relief grinding also polishes diffuser profile, with the accuracy of diffuser profile model check and correction molded line.Profile model is positioned to lead with endoporus
Under leaf at axle journal.Repairing center hole, Double Tops point positions, and the upper, middle and lower axle journal of grinding stator, its grinding the most finally adds Chinese musical scale
2 times of sizes of the very little thickness deducting monolateral Brush Plating or electrodeposited coating, axle journal surfacing, middle axle journal surfacing and the plating of lower axle journal in formation
Face.
After completing above-mentioned half finish turning machining, can pass through stator upper, middle and lower axle journal surfacing upper surface brush plating nickel (or electricity
Chromium plating).Top layer nickel plating (or chromium) hardness is up to (more than HR65), and brush plating nickel THICKNESS CONTROL is at 0.1 to 0.2mm, electrodeposited chromium thickness
Controlling at 0.05 to 0.10mm, thickness is the thickest, less economical and coating is easy to fall off, and thickness is the least, and the guide vane teunnion wearing layer life-span is short.
Stator assembly blank after half finish turning machining has the structure of following xi after surface brush plating nickel or electrodeposited chromium.
(xi) by brush nickel plating or electrodeposited chromium, upper axle journal coating is deposited on upper axle journal surfacing (1);Pass through Brush Plating
Middle axle journal coating is deposited on middle axle journal surfacing (3) by nickel or electrodeposited chromium;By brush nickel plating or plating, lower axle journal coating is sunk
Amass on lower axle journal surfacing (7).
In finish turning machining hot jacket, the shaft shoulder collar, the lower shaft shoulder collar make the generation of processing workpiece have following xii structure
Finished product.Double Tops point positions, finish turning diffuser both ends of the surface and the axle journal coordinated with guide vane lever.Double Tops point positions, and checks diffuser
Both ends of the surface jerk value in permissible value, the upper, middle and lower axle journal of grinding stator, it is ensured that its position of related features.With the middle axle journal of stator and
Lower axle journal is positioned on workbench V-block, respectively centering stator head facade sealing surface and outlet edge facade processing line, milling respectively
Cut facade sealing surface at two, it is ensured that its position degree requirement.Shaft shoulder set and lower shaft shoulder set on hot jacket, shaft shoulder set uses little with guide vane teunnion
Interference fit, oil boils the method for heating shaft shoulder set, heating-up temperature 200 DEG C to 250 DEG C, is incubated 2 hours.Owing to the magnitude of interference is little, axle
Shoulder set heating-up temperature is low, so hot jacket also will not cause the deformation of main shaft after main shaft polish.In addition to stainless steel surfaces, all
Surface is coated with antirust oil, gets rusty protecting metal surface.
(xii) in, the shaft shoulder collar is enclosed within outside middle axle journal coating to axis root by interference fit;The lower shaft shoulder collar passes through
It is outer to lower axle root that interference fit is enclosed within lower axle journal coating.
A kind of method of the hydraulic turbine wear-resisting cast-weld construction stator that make high-wear resistance, that Financial cost is low, including with
Lower step:
One of step: make casting carbon steel stator body, rustless steel upper head plate (45), rustless steel bottom plate (49), stainless
Steel tailgate (47);The shaft shoulder collar, the lower shaft shoulder collar in making;
Described casting carbon steel stator body by cast carbon steel diffuser body (51) and casting carbon steel guide vane teunnion body form;
Described casting carbon steel diffuser body (51) band body upper surface (13), body lower surface (15), body caudal face,
Body rostral face;Welding angle, the periphery upper surface of falling body, described body upper surface (11);Described body lower surface periphery falls body
Welding angle, lower surface (17);Described welding angle, the dual-side caudal of falling body face, body caudal face (9);Described body rostral face format
Body rostral face weld filler groove (5);
Described casting carbon steel guide vane teunnion body includes axle (48) under body upper shaft (41), body axis (43), body;Described
Axle journal surfacing (1) on body upper shaft band;Axle journal surfacing (3) in described body axis band;Axle leukorrhagia axle journal surfacing under described body
(7);
Body axis one end is connected with body upper shaft one, and other end one vertical with body upper surface (13) is connected;This
Under body, axle one end one vertical with body lower surface (15) is connected;
Described rustless steel upper head plate (45), opens inversed taper platform shape plug welding hole I (20) and body axis inside rustless steel upper head plate
Through hole, described body axis connects angle (21) through inner edge, the hole axis of falling body through eyelet welding;
Described rustless steel bottom plate (49), opens axle under inversed taper platform shape plug welding hole II (25) and body inside rustless steel bottom plate
Through hole (29), under described body, axle connects angle (27) through axle under the body of inner edge, hole through eyelet welding;
Described rustless steel tailgate, rustless steel tailgate connects end both sides band rustless steel tailgate and connects welding angle, end both sides (30);
The two of step: the welding on welding angle or plug welding hole of employing stainless steel electrode or welding wire will cast carbon steel stator originally
Body, rustless steel upper head plate, rustless steel bottom plate, rustless steel tailgate assemble and weld together and obtain assembly;
The three of step: step 2 gained assembly is made annealing treatment, annealing regulation parameter: temperature rise speed is little be equal to 80 DEG C/
H, is incubated 3-4h at 565 DEG C to 585 DEG C, is then cooled to room temperature with stove.
The four of step: use surface brush plating nickel or electrodeposited chromium, at upper axle journal surfacing (1), middle axle journal surfacing (3), lower axle journal
Surfacing (7) is upper generates nickel plating or the upper axle journal coating of chromium plating, middle axle journal coating, lower axle journal coating.Nickel plating thickness 0.1~0.2mm
Or chromium plating thickness 0.05~0.10mm.Upper axle journal surfacing (1), middle axle journal surfacing (3), lower axle journal surfacing (7) are at surface brush plating nickel
Or before and after electrodeposited chromium, all arrange cylindrical grinding process.
The five of step: the middle shaft shoulder collar is enclosed within outside middle axle journal coating by hot cover process interference fit, and overlaps to axis root
Portion;The lower shaft shoulder collar is enclosed within outside lower axle journal coating by hot cover process interference fit, and overlaps to lower axle root.Hot cover process uses
Oil boils the shaft shoulder collar or the lower shaft shoulder collar in heating;Heating-up temperature is 200 DEG C~250 DEG C, is inserted in the plating of axis neck after being incubated 2 hours
Outside the outer or lower axle journal coating of layer.
The present invention uses cast-weld construction to make stator, and its Financial cost situation compared with block cast rustless steel stator sees Figure 13
" certain serial middle-size and small-size Guide Vanes in Francis Turbine manufacturing cost synopsis (separate unit) ".From table it appeared that:
Rotary wheel of water turbine diameter 1500 millimeters, (56688.08-266686.91)/56688.08 × 100%=can be saved
52.9%
Rotary wheel of water turbine diameter 2000 millimeters, (134371.73-60089.58)/134371.73 × 100% can be saved
=55.3%
Rotary wheel of water turbine diameter 3000 millimeters, (453504.60-187240.75)/453504.60 × 100% can be saved
=58.7%
Rotary wheel of water turbine diameter 4000 millimeters, can save (1074973.88-418935.35)/1074973.88 ×
100%=61.0%
Rotary wheel of water turbine diameter 5000 millimeters, can save (2099558.36-791976.01)/2099558.36 ×
100%=62.3%
Save Financial cost more than 50%, and along with the increase of hydraulic turbine generated output is cost-effective more significantly.Also
May be used for the renovation of frayed serious casting carbon steel stator, shorten stator fabrication cycle and the time of shutdown maintenance stator,
Reduce stator cost of manufacture further, there is good economic benefit and social benefit.