大容量汽轮发电机转子槽楔铜合金研制及高温性能研究
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摘要
随着国民经济的高速发展,我国对电力的需求迅猛增长,而超(超)临界汽轮发电机组因热效率高、煤耗低、产生的污染少,受到国内的高度重视与发展。铜合金槽楔是汽轮发电机组核心构件转子的重要结构件之一,长期在高温下连续工作,为了确保发电机组的安全可靠运行,研制综合性能优良的超(超)临界汽轮发电机用槽楔铜合金,替代进口产品,实现国产化,具有重要的工程应用价值。
本文利用我国资源丰富、不用或少用贵重元素、对环境产生污染少的元素,研制了一系列的槽楔铜合金,并运用万能材料试验机、硬度机和涡流导电仪等手段来研究热处理过程中铜合金力学性能和电学性能的变化,运用金相显微镜、SEM、XRD等仪器来研究合金元素的加入对材料微观结构的影响和变化规律,并从理论上分析和解释其相关机制。同时,考虑到实际工程中的应用,对部分合金的高温性能作了初步的研究。研究结果表明:
(1)新研制的9种合金,经(950±10℃)×1.5h固溶+30~40%冷变形+(480±20℃)×3~4h时效可获得较佳的综合性能,在室温性能研究中,CuNiCrSiBeZr系2#合金、CuNiCoCrBeZr系4#、5#、6#合金均达到了0#合金的性能指标,2#合金的硬度达到HB 225,导电率为47.24 %IACS,抗拉强度达到831 MPa,屈服强度达到765 Mpa,延伸率为16.09 %;在427℃高温拉伸试验中,CuNiCoCrBeZr系4#、5#和6#合金均达到了0#合金指标性能,其中,4#合金的抗拉强度σb为531MPa,屈服强度σ0.2为529MPa,延伸率δ5达到了11.5 %。
(2)室温拉伸断口分析表明,CuNiCrSiBeZr系3#合金和CuNiCoCrBeZr系6#合金为韧性断裂,CuNiCrBeSiZr系7#合金为韧性的准解理断裂;高温拉伸断口分析表明,CuNiCrSiBeZr系3#合金为沿晶脆性断裂,CuNiCoCrBeZr系6#合金为较多微孔聚集型韧窝和较少准解理断裂组成的混合断裂;而且5#和6#合金的软化温度分别达到了616℃、606℃,具有较高的抗软化性能。
(3)经过分析,CuNiCrSiBeZr系合金的时效析出相为Cr、Cr2Zr、Cu3Zr、Ni5Si2,可能含有CuBe、NiBe、ZrBe等细小粒子,CuNiCoCrBeZr系合金的时效析出相为Cr、Cr2Zr、Ni11Zr9、Co0.52Cu0.48,可能含有CuBe、NiBe、ZrBe、CoBe等细小粒子,CuNiCrBeSiZr系合金的析出相为Cr、Cr2Zr、Cu3Cr、Ni10Zr7、NiSi,可能含有CuBe、NiBe、ZrBe等细小粒子。这些多种第二相化合物的析出,正是合金中多元微量元素交互作用的结果,使合金获得比较好的强化效果。
(4)CuNiCoCrBeZr系的4#、5#和6#合金的高温硬度比0#合金CuCo2BeZr的高温硬度高,且4#、5#和6#合金的高温硬度依次增加;在427℃,250MPa的条件下,CuNiCoCrBeZr系6#合金与0# CuCo2BeZr合金相比具有较好的抗蠕变性能,断裂时间长达149.7 h,稳态蠕变速率为4.96×10~(-5) h~(-1),裂纹呈沿晶断裂为主,部分穿晶断裂的混合断裂模式。
(5)对新研制的CuNiCoCrBeZr系6#合金进行高温蠕变试验,但CuNiCoCrBeZr系4#、5#和6#合金,均能满足汽轮发电机组转子在高温恶劣条件下的使用要求,其中,6#合金的硬度达到HB 247,导电率为52.93 %IACS,抗拉强度达到861 MPa,屈服强度达到805 Mpa,延伸率为15.08 %;在427℃高温拉伸试验中,其抗拉强度σb为596MPa,屈服强度σ0.2为590MPa,延伸率δ5达到了10.2 %。
With the rapid development of the national economy, China's electricity demands have rapid growth, while the (ultra) supercritical turbine generator unit for high thermal efficiency, lower coal consumption, less pollution has been given great attention and been developed in China. Copper alloy slot wedge is one of the important structural components of turbine rotor, long-term continuous work at high temperature, in order to ensure safe and reliable operation of generating units, developing a good overall performance with (ultra) supercritical turbine-generator wedge of copper alloy, to replace imported products, to achieve localization has important engineering application value.
This paper manufactured a series of slot wedge copper alloys with rich in natural resources, not or less of precious elements and elements of less pollution to the environment, universal testing machines, hardness machines and means of eddy current conductivity meter are used to study the copper alloys the mechanical and electrical properties in different heat treatment process, investigated impact of the microstructure when alloy elements added through metallographic microscope, SEM, XRD, and other equipments, and then analzyed and explained in theory. At the same time, taking into account the practical engineering application, it made a preliminary study about high temperature properties of some alloys. The results are shown as follows:
(1) The new developed nine kinds of alloys got a better overall performance after solid solution at (950±10℃)×1.5 h and 30~40 % cold deformation and ageing at (480±20℃)×3~4 h. 2# alloy of CuNiCrSiBeZr series, 4#, 5# and 6# alloys of CuNiCoCrBeZr series all reached a performance index 0# alloy in the performance test of room temperature, and the values of hardness and electrical conductivity of 2# alloy are HB 225 and 47.24 %IACS, it’s tensile strength, yield strength and elongation can reach 831 MPa, 765 Mpa and 16.09 %; 4#, 5# and 6# alloys of CuNiCoCrBeZr series all reached a performance index 0# alloy in the high temperature tensile test at 427℃, thereinto, tensile strength, yield strength and elongation of 6# alloy can reach 596 MPa, 590 Mpa and 10.2 %.
(2) Tensile fracture of room temperature analysis show that 3# and 6# alloys are ductile rupture, and 7# alloy is tough quasi-cleavage rupture; Tensile fracture of high temperature analysis show that 6# alloy has a mixed fracture with plenty of microvoid accumulation dimples and less quasi-cleavage rupture; Moreover softening temperature of 5# and 6# alloys reached 616℃and 606℃, and has a high resistance to softening performance.
(3) The analysis show that, precipitates in alloys of CuNiCrSiBeZr series are Cr, Cr2Zr, Cu3Zr and Ni5Si2, may contain CuBe, NiBe, ZrBe and other small particles; Precipitates in alloys of CuNiCoCrBeZr series are Cr, Cr2Zr, Ni11Zr9 and Co0.52Cu0.48, may contain CuBe, NiBe, ZrBe, CoBe and other small particles; Precipitates in alloys of CuNiCrBeSiZr series are Cr, Cr2Zr, Cu3Cr, Ni10Zr7 and NiSi, may contain CuBe, NiBe, ZrBe and other small particles; Because interaction of multiple trace elements in the alloys result in various precipitation of second phase compounds, and gain good strengthening effect.
(4) High temperature hardness of 4#, 5# and 6# alloys are higher than 0# alloy, and high temperature hardness of 4#, 5# and 6# alloys increase in turn; 6# alloy of CuNiCoCrBeZr series compared with 0# CuCo2BeZr alloy has good creep resistance, fracture time of 6# alloy is up to 149.7 h, steady-state creep rate is 4.96×10~(-5) h~(-1), cracks are mixed fracture modes with mainly intergranular fracture and partial transgranular fracture.
(5) We only researched high temperature creep of 6# alloy of the new developed CuNiCoCrBeZr series, but 4#, 5# and 6# alloys of CuNiCoCrBeZr series can meet the turbine generator rotor at high temperature using requirement under bad conditions, in the performance test of room temperature, and the values of hardness and electrical conductivity of 6# alloy are HB 247 and 52.93 %IACS, it’s tensile strength, yield strength and elongation can reach 861 MPa, 805 Mpa and 15.08 %; in the high temperature tensile test at 427℃, tensile strength, yield strength and elongation of 6# alloy can reach 596 MPa, 590 Mpa and 10.2 %.
本文利用我国资源丰富、不用或少用贵重元素、对环境产生污染少的元素,研制了一系列的槽楔铜合金,并运用万能材料试验机、硬度机和涡流导电仪等手段来研究热处理过程中铜合金力学性能和电学性能的变化,运用金相显微镜、SEM、XRD等仪器来研究合金元素的加入对材料微观结构的影响和变化规律,并从理论上分析和解释其相关机制。同时,考虑到实际工程中的应用,对部分合金的高温性能作了初步的研究。研究结果表明:
(1)新研制的9种合金,经(950±10℃)×1.5h固溶+30~40%冷变形+(480±20℃)×3~4h时效可获得较佳的综合性能,在室温性能研究中,CuNiCrSiBeZr系2#合金、CuNiCoCrBeZr系4#、5#、6#合金均达到了0#合金的性能指标,2#合金的硬度达到HB 225,导电率为47.24 %IACS,抗拉强度达到831 MPa,屈服强度达到765 Mpa,延伸率为16.09 %;在427℃高温拉伸试验中,CuNiCoCrBeZr系4#、5#和6#合金均达到了0#合金指标性能,其中,4#合金的抗拉强度σb为531MPa,屈服强度σ0.2为529MPa,延伸率δ5达到了11.5 %。
(2)室温拉伸断口分析表明,CuNiCrSiBeZr系3#合金和CuNiCoCrBeZr系6#合金为韧性断裂,CuNiCrBeSiZr系7#合金为韧性的准解理断裂;高温拉伸断口分析表明,CuNiCrSiBeZr系3#合金为沿晶脆性断裂,CuNiCoCrBeZr系6#合金为较多微孔聚集型韧窝和较少准解理断裂组成的混合断裂;而且5#和6#合金的软化温度分别达到了616℃、606℃,具有较高的抗软化性能。
(3)经过分析,CuNiCrSiBeZr系合金的时效析出相为Cr、Cr2Zr、Cu3Zr、Ni5Si2,可能含有CuBe、NiBe、ZrBe等细小粒子,CuNiCoCrBeZr系合金的时效析出相为Cr、Cr2Zr、Ni11Zr9、Co0.52Cu0.48,可能含有CuBe、NiBe、ZrBe、CoBe等细小粒子,CuNiCrBeSiZr系合金的析出相为Cr、Cr2Zr、Cu3Cr、Ni10Zr7、NiSi,可能含有CuBe、NiBe、ZrBe等细小粒子。这些多种第二相化合物的析出,正是合金中多元微量元素交互作用的结果,使合金获得比较好的强化效果。
(4)CuNiCoCrBeZr系的4#、5#和6#合金的高温硬度比0#合金CuCo2BeZr的高温硬度高,且4#、5#和6#合金的高温硬度依次增加;在427℃,250MPa的条件下,CuNiCoCrBeZr系6#合金与0# CuCo2BeZr合金相比具有较好的抗蠕变性能,断裂时间长达149.7 h,稳态蠕变速率为4.96×10~(-5) h~(-1),裂纹呈沿晶断裂为主,部分穿晶断裂的混合断裂模式。
(5)对新研制的CuNiCoCrBeZr系6#合金进行高温蠕变试验,但CuNiCoCrBeZr系4#、5#和6#合金,均能满足汽轮发电机组转子在高温恶劣条件下的使用要求,其中,6#合金的硬度达到HB 247,导电率为52.93 %IACS,抗拉强度达到861 MPa,屈服强度达到805 Mpa,延伸率为15.08 %;在427℃高温拉伸试验中,其抗拉强度σb为596MPa,屈服强度σ0.2为590MPa,延伸率δ5达到了10.2 %。
With the rapid development of the national economy, China's electricity demands have rapid growth, while the (ultra) supercritical turbine generator unit for high thermal efficiency, lower coal consumption, less pollution has been given great attention and been developed in China. Copper alloy slot wedge is one of the important structural components of turbine rotor, long-term continuous work at high temperature, in order to ensure safe and reliable operation of generating units, developing a good overall performance with (ultra) supercritical turbine-generator wedge of copper alloy, to replace imported products, to achieve localization has important engineering application value.
This paper manufactured a series of slot wedge copper alloys with rich in natural resources, not or less of precious elements and elements of less pollution to the environment, universal testing machines, hardness machines and means of eddy current conductivity meter are used to study the copper alloys the mechanical and electrical properties in different heat treatment process, investigated impact of the microstructure when alloy elements added through metallographic microscope, SEM, XRD, and other equipments, and then analzyed and explained in theory. At the same time, taking into account the practical engineering application, it made a preliminary study about high temperature properties of some alloys. The results are shown as follows:
(1) The new developed nine kinds of alloys got a better overall performance after solid solution at (950±10℃)×1.5 h and 30~40 % cold deformation and ageing at (480±20℃)×3~4 h. 2# alloy of CuNiCrSiBeZr series, 4#, 5# and 6# alloys of CuNiCoCrBeZr series all reached a performance index 0# alloy in the performance test of room temperature, and the values of hardness and electrical conductivity of 2# alloy are HB 225 and 47.24 %IACS, it’s tensile strength, yield strength and elongation can reach 831 MPa, 765 Mpa and 16.09 %; 4#, 5# and 6# alloys of CuNiCoCrBeZr series all reached a performance index 0# alloy in the high temperature tensile test at 427℃, thereinto, tensile strength, yield strength and elongation of 6# alloy can reach 596 MPa, 590 Mpa and 10.2 %.
(2) Tensile fracture of room temperature analysis show that 3# and 6# alloys are ductile rupture, and 7# alloy is tough quasi-cleavage rupture; Tensile fracture of high temperature analysis show that 6# alloy has a mixed fracture with plenty of microvoid accumulation dimples and less quasi-cleavage rupture; Moreover softening temperature of 5# and 6# alloys reached 616℃and 606℃, and has a high resistance to softening performance.
(3) The analysis show that, precipitates in alloys of CuNiCrSiBeZr series are Cr, Cr2Zr, Cu3Zr and Ni5Si2, may contain CuBe, NiBe, ZrBe and other small particles; Precipitates in alloys of CuNiCoCrBeZr series are Cr, Cr2Zr, Ni11Zr9 and Co0.52Cu0.48, may contain CuBe, NiBe, ZrBe, CoBe and other small particles; Precipitates in alloys of CuNiCrBeSiZr series are Cr, Cr2Zr, Cu3Cr, Ni10Zr7 and NiSi, may contain CuBe, NiBe, ZrBe and other small particles; Because interaction of multiple trace elements in the alloys result in various precipitation of second phase compounds, and gain good strengthening effect.
(4) High temperature hardness of 4#, 5# and 6# alloys are higher than 0# alloy, and high temperature hardness of 4#, 5# and 6# alloys increase in turn; 6# alloy of CuNiCoCrBeZr series compared with 0# CuCo2BeZr alloy has good creep resistance, fracture time of 6# alloy is up to 149.7 h, steady-state creep rate is 4.96×10~(-5) h~(-1), cracks are mixed fracture modes with mainly intergranular fracture and partial transgranular fracture.
(5) We only researched high temperature creep of 6# alloy of the new developed CuNiCoCrBeZr series, but 4#, 5# and 6# alloys of CuNiCoCrBeZr series can meet the turbine generator rotor at high temperature using requirement under bad conditions, in the performance test of room temperature, and the values of hardness and electrical conductivity of 6# alloy are HB 247 and 52.93 %IACS, it’s tensile strength, yield strength and elongation can reach 861 MPa, 805 Mpa and 15.08 %; in the high temperature tensile test at 427℃, tensile strength, yield strength and elongation of 6# alloy can reach 596 MPa, 590 Mpa and 10.2 %.
引文
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