大型冲击式转轮机器人电弧增材制造技术应用研究  

Application Research on Robot Weld Arc Additive Manufacturing Technology for Large Pelton Runner

作　　者：杨年浩 金宝 李海军 冯涛 蔡喜 李红辉 郭中才 高炼玲 YANG Nianhao;JIN Bao;LI Haijun;FENG Tao;CAI Xi;LI Honghui;GUO Zhongcai;GAO Lianling(China Three Gorges Construction Engineering Corporation,Wuhan 430000,China;Dongfang Eelectric Machinery Co.,Ltd.,Deyang 618000,China)

机构地区：[1]中国三峡建工(集团)有限公司,湖北武汉430000 [2]东方电气集团东方电机有限公司,四川德阳618000

出　　处：《电焊机》2024年第4期23-28,共6页Electric Welding Machine

摘　　要：随着冲击式机组容量参数越来越大,机组核心部件转轮的尺寸不断增大,受制于锻件厂家设备制造能力和性能保障工艺,厚大马氏体不锈钢锻件质量风险巨大,成为大型冲击式机组能否研制成功的关键因素。而外部水斗结构复杂,锻件加工时材料利用率低,制造成本高,人工焊接时气孔、夹渣等缺陷不易控制,焊接质量风险大。本文通过基于电弧增材制造工艺结构设计、机器人电弧增材制造系统集成及工艺研究,开发出了一套适用于大型冲击式转轮制造的增材工艺,并成功应用于冲击式转轮的制造,大幅压缩了中心体锻件的规格,释放了厚大马氏体不锈钢锻件的制造风险,提高了外部水斗的材料利用率和焊接质量。With the increasing capacity parameters of the pelton unit,the size of the core component runner of the unit continues to increase.Due to the manufacturing capacity and performance guarantee process of forging manufacturers,the quality risk of thick and large martensitic stainless steel forgings is enormous,which has become a key factor in the success of the development of large pelton units.The external water bucket has a complex structure,low material utilization during forging processing,high manufacturing costs,and difficult to control defects such as pores and slag inclusions during manual welding,resulting in high welding quality risks.This article develops a set of additive technology suitable for the manufacturing of large impact runners based on the structural design of arc additive manufacturing process,integration of robot arc additive manufacturing system,and process research.It has been successfully applied to the manufacturing of impact runners,greatly compressing the specifications of center body forgings,releasing the manufacturing risks of thick and large martensitic stainless steel forgings,and improving the material utilization rate and welding quality of external buckets.

关 键 词：冲击式转轮 尾翼 外部水斗 机器人 电弧增材 

分 类 号：TG409[金属学及工艺—焊接]