大型水电装备关键部件高性能制造新技术新工艺  

Advanced Technologies and Processes for High-performance Manufacturing of Key Components for Large Hydropower Equipment

作　　者：蒋元龙 王星星[1] 彭岩 张雷 温暖[4] 刘怀亮 石如星 耿在明[5] 潘昆明 陈小明[7] 马怀立 土比木乃 张雷[10] JIANG Yuanlong;WANG Xingxing;PENG Yan;ZHANG Lei;WEN Nuan;LIU Huailiang;SHI Ruxing;GENG Zaiming;PAN Kunming;CHEN Xiaoming;MA Huaili;TUBI Munai;ZHANG Lei(Henan International Joint Laboratory of High-efficiency Special Green Welding,North China University of Water Resources and Electric Power,Zhengzhou 450045,China;CITIC Heavy Industries Co.,Ltd.,Henan Luoyang 471033 China;China Academy of Machinery Zhengzhou Research Institute of Mechanical Engineering Co.,Ltd.,Zhengzhou 450001,China;He-nan Agricultural University,Zhengzhou 450046,China;China Yangtze Power Co.,Ltd.,Wuhan 430014,China;Longmen Laboratory,Henan Luoyang 471000,China;Hangzhou Mechanical Design Research Institute,Ministry of Water Resources,Hangzhou 310012,China;Ningxia Yellow River Hydropower Qingtongxia Power Generation Co.,Ltd.,Ningxia Wuzhong 751608,China;Dongfang Electric Machinery Co.,Ltd.,Sichuan Deyang 618000,China;Yellow River Institute of Hy-draulic Research,Yellow River Conservancy Commission,Zhengzhou 450003,China)

机构地区：[1]华北水利水电大学河南省高效特种绿色焊接国际联合实验室,郑州450045 [2]中信重工机械股份有限公司,河南洛阳471033 [3]中国机械总院集团郑州机械研究所有限公司,郑州450001 [4]河南农业大学,郑州450046 [5]中国长江电力股份有限公司,武汉430014 [6]龙门实验室,河南洛阳471000 [7]水利部杭州机械设计研究所,杭州310012 [8]宁夏黄河水电青铜峡发电有限公司,宁夏吴忠751608 [9]东方电气集团东方电机有限公司,四川德阳618000 [10]黄河水利委员会黄河水利科学研究院,郑州450003

出　　处：《精密成形工程》2025年第3期90-101,共12页Journal of Netshape Forming Engineering

基　　金：国家自然科学基金(52475347);国家外国专家项目(G2023026003L);中原科技创新领军人才项目;河南省重点研发专项;河南省高端外国专家引进项目(HNGD2025026);中国博士后基金面上项目(2023M740475)。

摘　　要：大型水电装备中转轮、水斗、叶片等关键部件在水电机组稳定高效运行过程中发挥着至关重要的作用。为满足这些部件在极端工况下的性能要求,高性能制造技术应用显得尤为重要。近年来,先进锻焊工艺、焊接与增材制造、激光熔覆技术、喷涂技术等制造技术在水电装备关键部件领域的应用成效显著。本文概述了大型水电装备关键部件高性能制造技术研究现状,重点讨论了锻造、焊接与增材制造、激光熔覆、喷涂等技术在转轮、水斗、叶片等关键部件中的应用现状。通过对水电装备关键部件锻造工艺参数、焊接残余应力、激光熔覆及喷涂表面强化效果等进行系统探讨,深入分析了这些技术工艺在部件性能提升方面的优势与挑战。锻造工艺能够有效改善材料力学性能和组织结构,提高部件抗疲劳性和冲击韧性;焊接与增材制造工艺有助于降低制造过程中产生的残余应力与变形,提升部件连接质量;激光熔覆及喷涂技术则能有效增强部件表面耐磨性、抗腐蚀性及抗氧化性,从而延长使用寿命。此外,还指出现阶段大型水电装备关键部件制造研究存在的不足之处,对相关领域的未来研究重点进行了展望。Key components such as runners,buckets,and blades in large hydropower equipment are crucial for the stable and efficient operation of hydropower units.To meet performance requirements of these components under extreme conditions,the application of high-performance manufacturing technologies is essential.In recent years,advancements in forging,welding and additive manufacturing,laser cladding,and spraying technologies have yielded significant results in key components of hy-dropower equipment.This paper summarized the current status of high-performance manufacturing technologies for key com-ponents of large hydropower equipment,focusing on the application of forging,welding and additive manufacturing,laser clad-ding,and spraying in critical components like runners,buckets,and blades.By systematically discussing forging process pa-rameters,welding residual stress,and the surface strengthening effects of laser cladding and spraying on key components of hy-dropower equipment,the advantages and challenges of these technology processes in enhancing component performance were analyzed.The forging process could significantly enhance the mechanical properties and microstructure of materials,improving fatigue resistance and impact toughness of components.Welding and additive manufacturing processes reduced residual stress and deformation,improving joining quality of components.Laser cladding and spraying technologies enhanced surface wear,corrosion,and oxidation resistance,thereby extending service life.Additionally,this paper identified current research deficien-cies in manufacturing key components of large hydropower equipment and suggested future research priorities of relevant fields.

关 键 词：水电装备关键部件 锻造 焊接与增材制造 激光熔覆 喷涂 

分 类 号：TK73[交通运输工程—轮机工程]