CN117139988A - Honeycomb sealing vacuum brazing process method for aero-modified gas turbine - Google Patents
Honeycomb sealing vacuum brazing process method for aero-modified gas turbine Download PDFInfo
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- CN117139988A CN117139988A CN202311164910.9A CN202311164910A CN117139988A CN 117139988 A CN117139988 A CN 117139988A CN 202311164910 A CN202311164910 A CN 202311164910A CN 117139988 A CN117139988 A CN 117139988A
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
- B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/008—Soldering within a furnace
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/20—Preliminary treatment of work or areas to be soldered, e.g. in respect of a galvanic coating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
- B23K3/08—Auxiliary devices therefor
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
Abstract
The invention relates to a honeycomb seal vacuum brazing process method of an aero-modified gas turbine, which comprises the following specific steps: removing old honeycomb on the honeycomb sealing structural member to obtain a matrix; performing vacuum brazing deformation control treatment on the matrix; and (3) carrying out tissue performance maintaining treatment on the matrix subjected to vacuum brazing deformation control. The invention has the beneficial effects of providing a novel vacuum brazing process, along with reasonable process, high repair efficiency and better repair effect, and solves the problems of honeycomb removal process control, vacuum brazing deformation control, part tissue performance guarantee and the like in the prior art.
Description
Technical Field
The invention relates to the technical field of wear repair of aero-modified gas turbine gas seal honeycomb assemblies, in particular to a method for performing vacuum brazing on aero-modified gas turbine honeycomb seal.
Background
The honeycomb sealing structure is widely adopted in the rotor and static sealing structure of the inner core component of the aero-modified gas turbine, and friction and extrusion are easy to occur between the honeycomb and the rotor component in the working process, so that the honeycomb is worn or deformed. The key to the manufacture of honeycomb seal structures (simply called honeycomb seals) is the connection of the honeycomb to the housing, and the most effective connection method is currently vacuum brazing. The annular honeycomb structure is generally a welded integral structure, and the worn honeycomb cannot be disassembled and can only be repaired by a method of firstly processing and removing the old honeycomb and then brazing the new honeycomb.
With the continuous start and development of aero retrofit gas turbine maintenance projects, a large number of fragile honeycomb structures need to be repaired. The problems of honeycomb removal, vacuum brazing deformation control, part tissue performance guarantee and the like exist in the brazing repair of the honeycomb sealing structural member. Once the honeycomb sealing structural member is deformed after being used, the installation position almost does not allow reprocessing, the honeycomb brazing quality requirement is high, the repair qualification rate is high, and the deep research on the gas turbine honeycomb sealing vacuum brazing technology is very necessary.
Disclosure of Invention
The invention aims to solve the technical problem of the prior art by providing a honeycomb seal vacuum brazing process method for an aero-modified gas turbine.
The technical scheme for solving the technical problems is as follows:
a honeycomb seal vacuum brazing process method for an aero-modified gas turbine comprises the following specific steps:
s1: removing old honeycomb on the honeycomb sealing structural member to obtain a matrix;
s2: performing vacuum brazing deformation control treatment on the matrix;
s3: and (3) carrying out tissue performance maintaining treatment on the matrix subjected to vacuum brazing deformation control.
The beneficial effects of the invention are as follows: the novel vacuum brazing process provided by the invention is reasonable in process, high in repair efficiency and good in repair effect, and solves the problems of honeycomb removal process control, vacuum brazing deformation control, part tissue performance guarantee and the like in the prior art.
On the basis of the technical scheme, the invention can be improved as follows.
Further, the S2 specifically includes:
s21: cutting and welding the honeycomb strips to obtain honeycomb rings, and cutting and shaping the honeycomb rings;
s22: the honeycomb ring is sleeved outside the matrix and vacuum brazing treatment is carried out.
The technical design is reasonable, the honeycomb strips are firstly processed to obtain the honeycomb rings, the honeycomb rings are cut and shaped to the set size, and then the honeycomb rings are sleeved on the base body, so that the honeycomb rings are convenient to maintain and high in efficiency.
Further, before S21, the method further includes: and (3) carrying out fluorescence detection on the matrix to judge whether cracks exist on the matrix, and if the cracks are found, stopping the use.
The technical scheme has the advantages that the surface layer of the matrix can be removed in the old honeycomb removing process, whether the surface of the matrix has cracks or not can be confirmed through fluorescence detection, and the matrix cannot be used when the cracks appear, so that the quality of the matrix is ensured.
Further, between S21 and S22, further includes: and (3) carrying out sand blasting on the brazing surface of the matrix, cleaning the honeycomb ring and the matrix after sand blasting, removing oil stains and rust stains on the surfaces of the matrix and the honeycomb ring, and then carrying out drying treatment on the matrix and the honeycomb ring.
The technical scheme has the beneficial effects that the cleaning is convenient, the oil stains and rust stains on the surfaces of the matrix and the honeycomb ring are effectively removed, and the maintenance quality is ensured.
Further, the substrate is sandblasted by wet sandblasting of 200-800 mesh.
The adoption of the further scheme has the beneficial effects that the smoothness of the brazing surface of the matrix can be increased through wet sand blasting, so that the subsequent operation is facilitated, and the maintenance quality is improved.
Further, the step S21 specifically includes:
s211: cutting two ends of the honeycomb ring to form an oblique angle of 58-62 degrees, and spot welding and splicing the two ends of the cut honeycomb ring to form the honeycomb ring;
s212: positioning the honeycomb ring on the tool ring by resistance welding;
s213: removing the tilted part on the inner side of the honeycomb ring by wire cutting, and separating the honeycomb ring after wire cutting from the tool ring.
The adoption of the further scheme has the advantages that the two ends of the honeycomb ring are cut into an oblique angle shape, so that the contact area of the two ends of the honeycomb ring can be increased, and the stability and the quality of welding are ensured;
in addition, utilize frock ring simulation base member to handle the honeycomb ring, guarantee that follow-up honeycomb ring can laminate completely with the base member, thereby guarantee the quality of maintenance.
Further, the step S22 specifically includes:
s221: pressing the brazing filler metal strip into the honeycomb core cells of the honeycomb ring, and positioning the honeycomb ring on the substrate by spot welding;
s222: uniformly coating the brazing paste on an included angle between the honeycomb ring and the matrix;
s223: and (3) placing the substrate with the fixed honeycomb ring in a vacuum heat treatment furnace for vacuum brazing treatment to obtain a semi-finished product.
The honeycomb ring is fixedly sleeved outside the matrix through the brazing process, and the honeycomb ring is convenient to maintain.
Further, the step S3 specifically includes:
s31: performing aging heat treatment on the semi-finished product by adopting a vacuum heat treatment furnace;
s32: and (3) adopting electric spark equipment to carry out spark erosion through an electrode head, and processing the surface of the honeycomb ring on the semi-finished product to a finished size to obtain a finished product.
The technical design is reasonable, and the damage of the matrix in the vacuum brazing process is restored by the aid of the technical design method, so that the performance of the whole matrix is guaranteed.
Further, between S223 and S31, further includes: and performing leakage detection on the semi-finished product to judge whether the inner side of the honeycomb ring is tightly sealed, and if the inner side of the honeycomb ring is not tightly sealed, performing repair welding until the sealing is tight.
The adoption of the further scheme has the beneficial effects of simple process and reasonable design, and can effectively judge whether the inner side of the honeycomb ring is tightly sealed or not, so that the maintenance quality is ensured.
Further, the S1 specifically includes:
and fixing the honeycomb sealing structural member by adopting a tool, and removing old honeycomb on the honeycomb sealing structural member by machining.
The beneficial effect of adopting above-mentioned further scheme is simple in process, can get rid of the old honeycomb on the honeycomb structure of sealing fast, and removal efficiency is high.
Drawings
FIG. 1 is a process flow diagram of the present invention;
FIG. 2 is a schematic diagram of a tooling for machining a honeycomb on a substrate;
FIG. 3 is a schematic view of the structure of the honeycomb strip of the present invention;
fig. 4 is a schematic view of the structure of the honeycomb strip of the present invention when two ends are welded.
In the drawings, the list of components represented by the various numbers is as follows:
1. a tool; 2. honeycomb strips.
Detailed Description
It should be noted that, without conflict, the embodiments of the present invention and features of the embodiments may be combined with each other.
The invention will be described in detail below with reference to the drawings in connection with embodiments.
Example 1
As shown in fig. 1 to 4, the embodiment provides a honeycomb seal vacuum brazing process method of an aero-modified gas turbine, which comprises the following specific steps:
s1: removing old honeycomb on the honeycomb sealing structural member to obtain a matrix;
s2: performing vacuum brazing deformation control treatment on the matrix;
s3: and (3) carrying out tissue performance maintaining treatment on the matrix subjected to vacuum brazing deformation control.
The embodiment provides a novel vacuum brazing process, which has reasonable process, high repairing efficiency and better repairing effect, and solves the problems of honeycomb removing process control, vacuum brazing deformation control, part organization property guarantee and the like in the prior art.
Example 2
On the basis of embodiment 1, in this embodiment, the S2 specifically includes:
s21: cutting and welding the honeycomb strips 2 to obtain honeycomb rings, and cutting and shaping the honeycomb rings;
s22: the honeycomb ring is sleeved outside the matrix and vacuum brazing treatment is carried out.
The process is reasonable in design, the honeycomb strips are firstly processed to obtain the honeycomb rings, the honeycomb rings are cut and shaped to the set size, and then the honeycomb rings are sleeved on the substrate, so that the process is convenient to maintain and high in efficiency.
Example 3
On the basis of embodiment 2, in this embodiment, before S21, the method further includes: and (3) carrying out fluorescence detection on the matrix to judge whether cracks exist on the matrix, and if the cracks are found, stopping the use.
The surface layer of the matrix can be removed in the old honeycomb removing process, whether the surface of the matrix has cracks or not can be confirmed through fluorescence detection, and the matrix cannot be used when the cracks appear, so that the quality of the matrix is ensured.
The old honeycomb is removed by turning, and the maximum removal amount of the part matrix material is 0.076mm. The residual honeycomb material and the original brazing material are manually polished by using a silicon carbide abrasive wheel, the profile variation is ensured to be 0.05mm per 25.4mm or less after polishing, and smooth transition in unit area is ensured without pits and high points. Turning to remove old honeycomb and polishing to remove stubbles can contact the brazing surface of the part matrix, and crack detection is carried out on the part to be repaired by using OMat653 standard sensitivity fluorescent penetrant. If a crack is found, the system is deactivated.
It should be noted that: the removal of one layer of the substrate is normal but not crack.
Example 4
In this embodiment, on the basis of any one of embodiments 2 to 3, the step of between S21 and S22 further includes: and (3) carrying out sand blasting on the brazing surface of the matrix, cleaning the honeycomb ring and the matrix after sand blasting, removing oil stains and rust stains on the surfaces of the matrix and the honeycomb ring, and then carrying out drying treatment on the matrix and the honeycomb ring.
The cleaning is convenient, the oil stain and rust on the surfaces of the matrix and the honeycomb ring are effectively removed, and the maintenance quality is ensured.
The specific process of the step is as follows: carrying out 500-mesh wet sand blasting (only the matrix can be subjected to sand blasting) on the brazing surface of the matrix of the part to be repaired, wherein the surface roughness after sand blasting is Ra1.1-1.25 mu m, and the standard is the square root value of Ra0.7-2.0 mu m. The substrate and the honeycomb ring are chemically cleaned together to remove greasy dirt and rust on the surface, and the substrate and the honeycomb ring are cleaned together and then dried in an oven (110-130 ℃ for 30min, preferably 120 ℃).
Preferably, in the present embodiment, the cleaning solution used for the chemical cleaning is preferably isopropyl alcohol (C 3 H 8 O) the volume ratio of isopropanol to pure water is 1:10.
Example 5
On the basis of example 4, in this example, a substrate was sandblasted by wet sandblasting of 200 to 800 mesh.
According to the scheme, the smoothness of the brazing surface of the matrix can be increased through wet sand blasting, so that subsequent operation is facilitated, and the maintenance quality is improved.
Preferably, in this embodiment, the substrate is sandblasted, preferably with 500 mesh wet sandblasting.
Example 6
In this embodiment, on the basis of any one of embodiments 2 to 5, the S21 specifically includes:
s211: cutting two ends of the honeycomb ring to form an oblique angle of 58-62 degrees, and spot welding and splicing the two ends of the cut honeycomb ring to form the honeycomb ring;
s212: positioning the honeycomb ring on the tool ring by resistance welding;
s213: removing the tilted part on the inner side of the honeycomb ring by wire cutting, and separating the honeycomb ring after wire cutting from the tool ring.
The process cuts the two ends of the honeycomb ring into an oblique angle shape, so that the contact area of the two ends of the honeycomb ring can be increased, and the stability and quality of welding are ensured;
in addition, utilize frock ring simulation base member to handle the honeycomb ring, guarantee that follow-up honeycomb ring can laminate completely with the base member, thereby guarantee the quality of maintenance.
The specific steps of S211 are as follows: and horizontally clamping one end of the honeycomb belt with the set length onto a special tool for cutting the honeycomb by the sample cutting machine, and starting the cutting machine to cut a 60-degree bevel along the edge of the honeycomb belt core lattice. And then fixing one end to be cut on a special linear cutting tool (the outer diameter phi 496mm of a honeycomb brazing surface of the part to be repaired, the outer diameter phi 494mm of a tool ring) of the part to be repaired by using a C-shaped clamp, forming a honeycomb ring by encircling the tool on the other end, marking a joint overlapping part by using a marker pen, and reversely cutting a 60-degree bevel edge along the edge of the core lattice again by using the marked part as a starting point. Grinding the chamfer surface by using a grinder GD-6025Q to remove burrs and stubbles on the cutting surface of the honeycomb belt. And winding the cut honeycomb belt on a tool to form a ring, and clamping the honeycomb and the tool by using C-shaped clamps at intervals of 10cm from the bevel joint to ensure that the honeycomb and the tool ring are completely attached.
Evaluation of the wound honeycomb ring joint sites: if the honeycomb bevel joint is in the lap joint state, a whole row of honeycomb core lattices are removed by grinding along the cutting direction until the joint positions at the two ends of the honeycomb ring differ by 0.5-1 row of honeycomb core lattices, and the honeycomb bevel joint is in interference fit with the tool ring. The interference is the best data obtained by multiple test comparison; the interference fit is the assembly relation between the honeycomb ring prefabricated by the honeycomb belt and the tool ring, the interference fit in the wire cutting step is the assembly relation between the inner diameter size of the honeycomb ring and the brazing surface of the part matrix after the wire cutting is completed, and the inner diameter size of the honeycomb ring and the brazing surface of the part matrix are different. Because the honeycomb strip is made by stamping thin band plate materials into a trapezoid corrugated plate structure, the multilayer corrugated plates are welded in a superposition mode, the honeycomb strip is weak in rigidity and has certain stretching ductility, the interference fit only involves stretching and does not squeeze, the interference is obtained through multiple test demonstration, the honeycomb is not deformed, the interference of the honeycomb strip is accurately controlled, two or more people are sleeved into the tool ring in parallel in the circumferential direction of the honeycomb ring in a parallel mode during the assembly, and clamping deformation can be avoided.
In addition, the matching surfaces at the two ends of the honeycomb belt joint are visually inspected before spot welding, so that the two matching surfaces can be welded together with minimum gaps. If gaps are formed due to residual burrs and broken stubbles on the matching surfaces, the process returns to the previous step for polishing and trimming. During spot welding, spot welding is firstly carried out on the inner diameter interface of the honeycomb ring, after the leveling of the lap joint surface is confirmed, the resistance welding mode of a DLE-08 intelligent precision cold welding machine is used for spot welding on the lap joint surface, the spot welding power is set to be 18% -20% (the data are based on the DLE-08 intelligent precision cold welding machine in a factory, and the specification of the honeycomb strip core lattice is combined, and a plurality of experiments prove that the too high spot welding power can cause ablation or even breakdown of the honeycomb core lattice, the too low power welding quality is poor, and the spot welding can be carried out after slight bending. After the inner diameter is equidistantly fixed by 4-5 points, spot welding is carried out on 4-5 points of the outer diameter interface of the honeycomb ring, and then spot welding of all surfaces of the inner diameter and the outer diameter of the mating surface is finished.
It should be noted that: because the honeycomb strip has thickness, the inner diameter and the outer diameter refer to the inner diameter and the outer diameter of the end part of the honeycomb strip, and the honeycomb strip is initially positioned by spot welding and then fully welded to form a honeycomb ring.
The specific steps of S212 are as follows: and (3) carrying out chemical cleaning on the special tool for honeycomb and wire cutting before resistance welding (placing the honeycomb ring and the tool ring in an oil removal groove, wherein alkaline solution is filled in the oil removal groove), and removing oil stains and rust on the surface, otherwise, the resistance welding can cause ablation of the honeycomb ring and the tool, and the welding quality is affected. The honeycomb ring is sleeved on an outer ring of the tool, resistance welding is carried out on a honeycomb surface by using double-pulse spot welding (resistance welding refers to a method of using resistance heat generated by current passing through a welding part and a contact part as a heat source to locally heat the welding part and simultaneously pressurize the welding part, the resistance welding power is set to 25%, the pressure is 30KG (the data is according to an in-plant resistance welding machine and is combined with the specification of a honeycomb core lattice, and a plurality of experiments prove that the excessive resistance welding power can cause ablation even breakdown of the honeycomb core lattice, and the excessive pressure can damage the core lattice structure), so that the honeycomb ring is confirmed to be completely fixed on the tool. After the honeycomb ring is sleeved in the tool ring, the circumference is required to be ensured to be in the same horizontal plane, and no deviation exists after the whole circle is cut by linear cutting. Through keeping the frock ring flat on horizontal reference surface, slowly nest the honeycomb ring back into the frock, make the honeycomb ring lower terminal surface laminate completely with horizontal reference surface to this guarantees honeycomb ring level, realizes the assembly location.
The specific steps of S213 are as follows: the wire cutting of the 0.2mm molybdenum wire starts to circularly cut along the outer diameter of the tool ring by increasing 0.8mm from a wire through hole of a special tool (the speed of the molybdenum wire is adjustable between 8 and 10m/s, the precision is 0.05 to 0.08 mm), the edge-raising part of the inner diameter of the honeycomb ring is required to be completely cut off (saddle shape is removed), and finally the inner diameter of the honeycomb ring and the outer diameter of a substrate of a part to be repaired are in interference fit (the outer diameter of a brazing surface of the substrate is phi 496mm, and the outer diameter of the tool ring is phi 494mm and slightly smaller than the outer diameter of the substrate).
Example 7
In this embodiment, on the basis of any one of embodiments 2 to 6, the S22 specifically includes:
s221: pressing the brazing filler metal strip into the honeycomb core cells of the honeycomb ring, and positioning the honeycomb ring on the substrate by spot welding;
s222: uniformly coating the brazing paste on an included angle between the honeycomb ring and the matrix;
s223: and (3) placing the substrate with the fixed honeycomb ring in a vacuum heat treatment furnace for vacuum brazing treatment to obtain a semi-finished product.
The process is convenient to maintain by fixedly sleeving the honeycomb ring outside the matrix through a brazing process.
The specific steps of 221 are as follows: cutting out 2 nickel-based solder strips with the length of 15-20 cm, sequentially tearing the protective films to stack the 2 solder strips with the same length together, tearing off the white protective film at the bottommost surface, laying the white protective film on the inner diameter surface of the honeycomb ring, and keeping the transparent protective film on the top surface. The honeycomb ring with the brazing filler metal strips placed is pre-tightened by using a self-grinding brazing filler metal pressurizing tool in a factory, the honeycomb ring is sleeved on a steel roller at the lower part of the tool, the nylon roller at the upper part is regulated to slowly descend through a lifting knob at the top until the nylon roller contacts the brazing filler metal strips on the surface of the honeycomb ring, a pressurizing button is pressed down, at the moment, the nylon roller applies 2MPa pressure to the contact surface of the honeycomb ring, and the brazing filler metal (soft) strips are completely pressed into honeycomb cells, wherein the standard is that a honeycomb cell matrix is exposed. And rotating the tool clockwise to rotate the hand wheel, sequentially feeding the brazing filler metal strips to the inner diameter surface of the honeycomb ring, coating the area of which the brazing filler metal is pressed by using a preservative film for protection, embedding the brazing filler metal strips in the whole circle by using the method, and finally removing the preservative film. The tool pressure is adjustable, different pressures are applied according to the honeycomb specification and the using amount of the brazing filler metal belt, the brazing filler metal is completely pressed into the honeycomb core lattice by one-time rolling, and the procedure of scraping the redundant brazing filler metal on the honeycomb surface by the operation blade can be omitted through optimization.
The honeycomb ring is sleeved on the brazing surface of the base body of the part to be repaired, and the double-pulse spot welding is used for carrying out resistance welding fixation on the honeycomb surface. The resistance welding is firstly performed by 4 equal-distance spot welding, then by 8 equal-distance spot welding, then by circumferential direction step by step spot welding, and after three parts in front, middle and back in the width direction of the honeycomb surface are sequentially performed by resistance welding, the resistance welding of the next distance is performed. The resistance welding power is 25%, the pressure is 30KG (the state of the upper electrode head should be checked in real time in the spot welding process, and the upper electrode head should be replaced in time after the copper sheet of the electrode head is deformed or blackened, so that the honeycomb surface is prevented from being burnt and ablated due to poor contact). After welding, checking the welding seam by using a feeler gauge of 0.076mm, and when the gap is larger than 0.076mm, carrying out resistance welding positioning on the area, so as to ensure that the gap is smaller than 0.076mm, wherein the gap value is not universal in industry, and the assembly gap is slightly different due to different brazing filler metal components and substrate materials, and the industry universal data is about 0.1 mm. The to-be-repaired component fixed with the honeycomb ring presents a thermal expansion state in a high-temperature environment, the honeycomb ring and the part are different in material and thermal expansion coefficient, and test results show that the assembly gap between the honeycomb ring and the part brazing surface is controlled below 0.076mm, the better the capillary diffusion effect of the brazing filler metal is, the best brazing effect can be obtained, and the smaller the brazing gap is, the better the brazing filler metal is.
Points to be described: in the step S212, the resistance welding positioning is to fix the prefabricated honeycomb ring on a wire cutting tool, so as to facilitate wire cutting in the next working procedure and avoid the honeycomb ring from moving and falling in the cutting process, thereby causing cutting failure. In the step S221, the electric resistance welding positioning is to fix the honeycomb ring after wire cutting with proper interference after cleaning, pressing in the solder strip and other preparation procedures on the part matrix, which belongs to the final step of the preparation work before brazing, and aims to ensure that the assembly gap between the honeycomb ring and the brazing surface of the matrix is less than 0.076mm, thereby being beneficial to the full capillary action of the solder at the melting temperature and achieving the best brazing effect.
The specific steps of 222 are as follows: 3ml of brazing gel adhesive (G-4624) is extracted by using a sterile injector, about 9G of nickel-based brazing metal powder is weighed by using a balance and poured into a cylinder body of the injector, a glass rod is uniformly stirred, the mixture is in a gel state, and when the glass rod is extracted in an optimal state, the brazing paste can be drawn into a wire by 10-15 mm. And extruding the injector, uniformly smearing the brazing paste on the included angle between the honeycomb ring and the part to be repaired, and simultaneously confirming that the paste completely covers the joint of the brazing pin (brazing paste is coated between the honeycomb ring and two sides of the matrix) in the injection process.
Injection volume standard: the volume of the solder paste is 4 times of the joint assembly gap. The uncovered areas are patched until the entire turn of the seam is completely covered.
The specific steps of 223 are as follows: and (3) clamping the to-be-repaired part assembly with the fixed honeycomb ring into a heat treatment orthopedic tool, and slowly placing the whole into a vacuum heat treatment furnace at a uniform speed to ensure that the assembly gap is not changed due to vibration. Brazing is carried out according to the set process steps: and (3) under the vacuum degree of 0.5 micrometer mercury column, slowly heating to 900 ℃ for 40 minutes, keeping the temperature for 60 minutes, quickly heating to 1130 ℃ (the upper limit of the melting temperature of the nickel-based NICROBRAZ 135 solder) when the temperature of the high-temperature alloy part and the heat treatment orthopedic tool reach a constant temperature state (the real-time temperature is measured by using an armoured thermocouple arranged on the surface of the tool), keeping the temperature for 5 minutes, stopping heating, filling inert gas into the furnace chamber of the heat treatment furnace when the temperature in the furnace is reduced to 900 ℃, and quickly cooling to the tapping temperature. The vacuum degree requirement of the existing invention is higher (4 x10-2 Pa), the vacuum degree value of the 1.9 brazing step can be widened to 6x10-2Pa, the brazing requirement is met, and the call of cost reduction and synergy is responded. The step temperature and the heat preservation time of the existing brazing process of the invention are too long, so that the brazing working hour is greatly increased.
Example 8
On the basis of embodiment 7, in this embodiment, the S3 specifically includes:
s31: performing aging heat treatment on the semi-finished product by adopting a vacuum heat treatment furnace;
s32: and (3) adopting electric spark equipment to carry out spark erosion through an electrode head, and processing the surface of the honeycomb ring on the semi-finished product to a finished size to obtain a finished product.
The process is reasonable in design, and the damage of the matrix in the vacuum brazing process is restored to the original state through the process, so that the performance of the whole matrix is ensured.
The specific steps of 31 are as follows: clamping the parts with qualified brazing quality detected and evaluated into a special fixture for heat treatment, integrally and slowly placing the parts into a vacuum heat treatment furnace at a constant speed, ensuring that the assembly state is not changed due to vibration, always keeping the parts horizontal, completely contacting the matching surface with the fixture without gaps, and performing aging heat treatment according to set process steps: heating to 750 ℃ for 240 minutes under the vacuum degree of 0.5 micrometer mercury column, stopping heating, charging inert gas into the heat treatment furnace chamber when the temperature in the furnace is reduced to 700 ℃, and rapidly cooling to the tapping temperature. And after vacuum brazing, the part is subjected to aging heat treatment, so that the structural performance of the part can be effectively recovered.
The specific steps of 32 are as follows: the corresponding fixture is used for installing the part on the fixture, 46 screws are fastened clockwise in opposite directions, the position of the part is adjusted while being locked during fastening, after all the screws are locked, the outer circle of the part is tabulated by using a dial indicator to find out the deformation position, the corresponding fastening screws are loosened, the part is readjusted, the machined surface of the part to be repaired is positioned on the same circle, and the flatness of 0.02mm and the coaxiality of 0.02mm are ensured. And (3) operating an electric spark device to process the honeycomb surface to a finished size through electrode tip discharge corrosion, and cleaning and degreasing, so that the part to be repaired can be converted into a usable state after the part to be repaired is detected to be qualified, and the part to be repaired is transferred to a warehouse for standby.
Example 9
On the basis of embodiment 8, in this embodiment, between S223 and S31, further includes: and performing leakage detection on the semi-finished product to judge whether the inner side of the honeycomb ring is tightly sealed, if the inner side of the honeycomb ring is not tightly sealed, performing repair welding until the sealing is tight, detecting again after each repair welding is completed, and performing repair welding after the detection is unqualified.
The process is simple, the design is reasonable, whether the inner side of the honeycomb ring is sealed tightly can be effectively judged, and the maintenance quality is ensured.
Preferably, in this embodiment, the detection liquid used for the leakage detection is a C12-14-ethoxyl secondary alcohol, and the volume ratio of the C12-14-ethoxyl secondary alcohol to the pure water is 1:100.
The specific steps of leakage detection are as follows: and (3) taking out the part after the furnace temperature is cooled to 80 ℃, placing the part in a special detection tool charging frame for brazing quality, wherein a 1:100 mixed solution of detection liquid and pure water is arranged in a tool groove, lowering the charging frame to completely soak the part in the detection solution until no bubbles are released, lifting the charging frame to separate the part from the liquid level of the detection solution, placing the part detection surface in the charging frame at an angle of 45 degrees upwards, and performing detection by using a black light lamp (ultraviolet light) irradiation after standing for 15 minutes. In the areas with qualified brazing quality, solutions are arranged in each honeycomb core lattice and reflect fluorescence, the areas similar to fish eye bubbles are dull when not successfully brazed, and the brazing filler metal at the bottom of the honeycomb core lattice has no spreading phenomenon. And marking the non-brazed area for final evaluation, and if the final detection result does not meet the acceptance criterion (the brazing rate requirement is more than 80%), performing repair welding, wherein the repair welding times of each repair piece are not more than 2 times until the brazing rate of the honeycomb surface meets the acceptance criterion.
The process steps are different from the prior patent in the point:
(1) The honeycomb ring is fixed on the part by adopting resistance welding without the constraint of a fixture, so that the honeycomb is prevented from being damaged by thermal expansion extrusion during furnace brazing;
(2) The assembly gap between the honeycomb ring and the part is as small as 0.076mm, so that capillary filling of brazing filler metal is facilitated, the brazing quality is improved, and the primary qualification rate is remarkably improved;
(3) The brazing filler metal is pre-buried into the honeycomb core lattice through a special rolling tool, so that energy storage spot welding brazing filler metal is not needed, and the pollution probability of the brazing filler metal is greatly reduced; the working procedure of polishing welding spots is omitted, so that working hours are effectively reduced;
(4) The prior patent needs a transition honeycomb ring, a sector expansion block, a cone and a limiting ring with different expansion coefficients, the clamping mode is complex and complicated, the honeycomb and the parts are easily damaged due to misoperation, and the tooling has strong wrapping property and is not beneficial to heat dissipation of the parts;
(5) Compared with the prior art, the brazing process has the advantages that the steps are more efficient and simpler, the step temperature and the heat preservation time of the brazing process are optimally shortened, the vacuum degree range is wider, and the brazing time is greatly shortened.
Example 10
On the basis of the foregoing embodiments, in this embodiment, the S1 specifically includes:
and fixing the honeycomb sealing structural member by adopting the tool 1, and removing old honeycomb on the honeycomb sealing structural member by machining.
The process is simple, old honeycombs on the honeycomb sealing structural member can be removed rapidly, and the removal efficiency is high.
In the traditional machining and removing process, the old honeycomb cannot be completely removed due to radial displacement of the part caused by deformation of the part due to stress when the part is pressed to a workbench by using a pressing plate directly.
Because the part to be repaired is of a thin-wall annular structure, the turning tool must be capable of controlling the radial deformation of the part, the tool raw material adopts 45# steel with high strength and strong deformation resistance, and the deformation resistance of the tool material is further improved by heat treatment after the machining is finished (the advantages are that the annular workpiece is elliptical when the traditional machining is carried out, 46 screw holes are formed in the tool, and the screw is manually extruded to the workpiece when the workpiece is deformed, so that the workpiece is restored to the original state). After heat treatment, the hardness of the tool is increased, and a vertical grinding machine is adopted to grind and finish the tool to ensure the tolerance requirement of 0.02mm of flatness and 0.02mm of coaxiality. The bolt hole positions of the part to be repaired are fully utilized, 46 screw holes are uniformly distributed and designed on the turning tool (generally, only 6-8 fastening screw holes are needed for positioning the tool), the position of the part is adjusted while locking, after the part is completely locked, the outer circle of the part is tabulated to find out the deformation position, the corresponding fastening screw is loosened, the part is readjusted, the machined surface of the part to be repaired is positioned on the same circle (see figure 1), and the honeycomb on the radial surface can be completely removed by using the tool to clamp the thin-wall annular part, so that the matrix material is reserved maximally.
The vacuum brazing process of the invention comprises the following steps:
(1) Fixing a honeycomb sealing structural member by adopting a tool 1, and removing old honeycomb on the honeycomb sealing structural member by machining;
(2) Performing fluorescence detection on the substrate to judge whether cracks exist on the substrate;
(3) Cutting two ends of the honeycomb ring to form an oblique angle of 58-62 degrees, and spot welding and splicing the two ends of the cut honeycomb ring to form the honeycomb ring;
(4) Positioning the honeycomb ring on the tool ring by resistance welding;
(5) Removing the tilted part on the inner side of the honeycomb ring by wire cutting, and separating the honeycomb ring after wire cutting from the tool ring;
(6) Carrying out sand blasting on the brazing surface of the matrix, cleaning the honeycomb ring and the matrix after sand blasting, removing oil stains and rust stains on the surfaces of the matrix and the honeycomb ring, and drying the matrix and the honeycomb ring;
(7) Pressing the brazing filler metal strip into the honeycomb core cells of the honeycomb ring, and positioning the honeycomb ring on the substrate by spot welding;
(8) Uniformly coating the brazing paste on an included angle between the honeycomb ring and the matrix;
(9) Placing the substrate with the fixed honeycomb ring into a vacuum heat treatment furnace for vacuum brazing treatment to obtain a semi-finished product;
(10) Performing leakage detection on the semi-finished product to judge whether the inner side of the honeycomb ring is tightly sealed;
(11) Performing aging heat treatment on the semi-finished product by adopting a vacuum heat treatment furnace;
(12) And (3) adopting electric spark equipment to carry out spark erosion through an electrode head, and processing the surface of the honeycomb ring on the semi-finished product to a finished size to obtain a finished product.
The beneficial effects of the invention are as follows:
there are four key factors in the vacuum brazing of gas turbine honeycomb seal assemblies: surface finish of brazing surface, brazing filler metal amount, assembly gap and brazing temperature.
(1) Surface finish of brazing surface
The surface finish of the brazing surface comprises the cleanliness, roughness and flatness of the brazing surface of the substrate of the part to be repaired. In the trial repair, the base body and the honeycomb belt are chemically cleaned, so that the oil removal and decontamination effects are realized; and (3) sand blasting is carried out on the brazing surface of the matrix, the surface roughness is controlled to be between Ra0.84 and 1.41 mu m in a standard interval, if the roughness is larger than a standard value, the positioning of the honeycomb belt resistance welding is not facilitated, the assembly gap is too large, and if the roughness is smaller than the standard value, the brazing surface of the matrix is too smooth, and the diffusion of the brazing filler metal under the capillary action is not facilitated. The flatness of the honeycomb surface can be effectively controlled by the constraint of the clamp, and the brazing clearance is ensured to meet the requirements.
(2) Amount of solder
The dosage of the ribbon-shaped brazing filler metal pressed into the honeycomb core cell surface and the brazing filler metal paste coated with the brazing filler metal feet must be accurately controlled, if the brazing filler metal is excessive in the brazing process, the honeycomb core cell is corroded, the filling size exceeds 25% of the height of the honeycomb, and the honeycomb core cell is seriously or even fully filled, so that the brazing filler metal does not meet the acceptance requirement; if the brazing filler metal is insufficient, brazing failure is caused.
(3) Assembly gap
In the study of the honeycomb seal vacuum brazing technology, the assembly gap is not equivalent to the brazing gap. The to-be-repaired component fixed with the honeycomb ring presents a thermal expansion state in a high-temperature environment, the honeycomb ring and the part are different in material and thermal expansion coefficient, and test results show that the assembly gap between the honeycomb ring and the part brazing surface is controlled below 0.076mm, and the better the capillary diffusion effect of the brazing filler metal is, the best brazing effect can be obtained.
(4) Brazing temperature
The brazing temperature and the heat preservation time of the vacuum furnace are also critical, in trial repair, the heat radiation heating is low, the heat preservation is carried out until the temperature in the hearth is uniform, the components to be repaired and the brazing filler metal are fully preheated, the temperature is quickly increased to reach the melting temperature of the brazing filler metal, and the proper heat preservation time is set. The heat preservation time is linearly changed along with the brazing temperature, and the upper limit of the melting temperature of the brazing filler metal is taken at the brazing temperature, so that the heat preservation time is not too long, otherwise, the brazing filler metal is scattered wantonly, and the brazing filler metal on the brazing surface is insufficient.
It should be noted that, the operation process, the technical parameters and the like involved in each specific processing step of the method related to the present invention are not specifically described, and are executed according to conventional technical means in the field, and are not described herein.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Furthermore, it should be understood that although the present disclosure describes embodiments, not every embodiment is provided with a separate embodiment, and that this description is provided for clarity only, and that the disclosure is not limited to the embodiments described in detail below, and that the embodiments described in the examples may be combined as appropriate to form other embodiments that will be apparent to those skilled in the art.
The foregoing description of the preferred embodiments of the invention is not intended to limit the invention to the precise form disclosed, and any such modifications, equivalents, and alternatives falling within the spirit and scope of the invention are intended to be included within the scope of the invention.
Claims (10)
1. The honeycomb sealing vacuum brazing process of the aero-modified gas turbine is characterized by comprising the following specific steps of:
s1: removing old honeycomb on the honeycomb sealing structural member to obtain a matrix;
s2: performing vacuum brazing deformation control treatment on the matrix;
s3: and (3) carrying out tissue performance maintaining treatment on the matrix subjected to vacuum brazing deformation control.
2. The aero-retrofit gas turbine honeycomb seal vacuum brazing process of claim 1, wherein S2 specifically comprises:
s21: cutting and welding the honeycomb strips to obtain honeycomb rings, and cutting and shaping the honeycomb rings;
s22: the honeycomb ring is sleeved outside the matrix and vacuum brazing treatment is carried out.
3. The aero-retrofit gas turbine honeycomb seal vacuum brazing process of claim 2, wherein prior to S21 further comprises: and (3) carrying out fluorescence detection on the matrix to judge whether cracks exist on the matrix, and if the cracks are found, stopping the use.
4. The aero-retrofit gas turbine honeycomb seal vacuum brazing process of claim 2, further comprising between S21 and S22: and (3) carrying out sand blasting on the brazing surface of the matrix, cleaning the honeycomb ring and the matrix after sand blasting, removing oil stains and rust stains on the surfaces of the matrix and the honeycomb ring, and then carrying out drying treatment on the matrix and the honeycomb ring.
5. The aero-retrofit gas turbine honeycomb seal vacuum brazing process of claim 4, wherein: the substrate is sandblasted by wet sandblasting of 200-800 mesh.
6. The method for aero-retrofit gas turbine honeycomb seal vacuum brazing process according to any one of claims 2 to 5, wherein S21 specifically comprises:
s211: cutting two ends of the honeycomb ring to form an oblique angle of 58-62 degrees, and spot welding and splicing the two ends of the cut honeycomb ring to form the honeycomb ring;
s212: positioning the honeycomb ring on the tool ring by resistance welding;
s213: removing the tilted part on the inner side of the honeycomb ring by wire cutting, and separating the honeycomb ring after wire cutting from the tool ring.
7. The method of aero-retrofit gas turbine honeycomb seal vacuum brazing process according to any one of claims 2 to 5, wherein S22 comprises:
s221: pressing the brazing filler metal strip into the honeycomb core cells of the honeycomb ring, and positioning the honeycomb ring on the substrate by spot welding;
s222: uniformly coating the brazing paste on an included angle between the honeycomb ring and the matrix;
s223: and (3) placing the substrate with the fixed honeycomb ring in a vacuum heat treatment furnace for vacuum brazing treatment to obtain a semi-finished product.
8. The aero-retrofit gas turbine honeycomb seal vacuum brazing process of claim 7, wherein S3 specifically comprises:
s31: performing aging heat treatment on the semi-finished product by adopting a vacuum heat treatment furnace;
s32: and (3) adopting electric spark equipment to carry out spark erosion through an electrode head, and processing the surface of the honeycomb ring on the semi-finished product to a finished size to obtain a finished product.
9. The aero-retrofit gas turbine honeycomb seal vacuum brazing process of claim 8, further comprising between S223 and S31: and performing leakage detection on the semi-finished product to judge whether the inner side of the honeycomb ring is tightly sealed, and if the inner side of the honeycomb ring is not tightly sealed, performing repair welding until the sealing is tight.
10. The aero-retrofit gas turbine honeycomb seal vacuum brazing process according to any one of claims 1 to 5, wherein S1 specifically comprises:
and fixing the honeycomb sealing structural member by adopting a tool, and removing old honeycomb on the honeycomb sealing structural member by machining.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202311164910.9A CN117139988A (en) | 2023-09-11 | 2023-09-11 | Honeycomb sealing vacuum brazing process method for aero-modified gas turbine |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202311164910.9A CN117139988A (en) | 2023-09-11 | 2023-09-11 | Honeycomb sealing vacuum brazing process method for aero-modified gas turbine |
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