小支管插套焊高周疲劳失效机理与延寿技术研究
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摘要
小支管插套焊主要用在核电站主管与支管的连接上，插套焊管道里面经常流动着腐蚀性液体，而流动的液体又容易产生空穴现象并使管道发生简谐振动，小支管插套焊在振动和腐蚀的作用下特别容易高周疲劳失效；且焊根处尤为严重。本文针对耐腐蚀的304L不锈钢制备的插套焊焊接接头，进行了振动疲劳试验研究，分析其高周疲劳失效机理与影响因素，并提出相应的延寿技术。具体如下：
本文用振动台进行疲劳试验，其振动模式与实际相符；但也存在两个实施问题，一是进行疲劳试验时振动台不能像液压伺服试验机一样直接施加应力，二是如何监控试样是否失效。本文基于材料力学和机械振动学理论，推导了悬臂梁振动条件下插套焊接头应力的计算公式，明确了各个参数对应力的影响，使试样能在预设的交变应力下进行疲劳试验。
针对原始设计插套焊焊接接头的高周疲劳试验结果表明，在高应力条件下焊接接头倾向于在焊趾处开裂，在低应力条件下倾向于在焊根处失效。对疲劳试样的失效机理分析表明，径向间距、焊脚尺寸和焊趾处夹角能影响插套焊接头的疲劳性能，并且增加焊根熔深能改善插套焊接头的疲劳性能。
基于预制坡口能提高焊根熔深的思路，研究了预制3mm和5mm坡口对插套焊疲劳性能的影响。研究结果表明，加开坡口后，一方面插套焊接头的阻尼增大，提高了插套焊的抗振动能力；另一方面，随着坡口深度增加，在振动疲劳载荷下，虽然焊根处的应力降低幅度很小，但由于峰值应力超过了材料的屈服强度，其塑性应变值显著降低，即焊根处的塑性损伤随着坡口深度的增加逐渐降低，从而提高了焊根处的抗疲劳裂纹萌生能力。因此，加开坡口能够显著提高插套焊焊根处的高周疲劳性能，大幅延长疲劳寿命。
另外，由于加开坡口增加了焊趾处的焊接残余应力，在提高低应力条件下焊根处疲劳性能的同时，降低了高应力条件下焊趾处的疲劳性能。由于插套焊正常服役的振动条件为低应力下的高周疲劳，因此加开坡口能够显著提高插套焊接头的高周疲劳寿命。
The small bore piping socket weld is mainly used to the connection of the leaderpipe and the branch pipe in the nuclear power plants. In the socket welding pipe thecorrosive liquid flow and induce easily cavitations which result in the harmonicvibration of pipe. In the conditions of vibration and corrosion, the socket welds jointsfrequently present high-cycle fatigue failure; especially in the root of socket weld.Due to their factors, the304L stainless steel which has a better performance incorrosion resistance was selected as examples of vibration fatigue testing. Themechanism and factors of high-cycle fatigue failure of socket weld are studied deeply,and propose the prolonging life technology. The research work and results are listed asfollow:
The specimens of socket weld were tested in the vibration table which canimitate the actual vibration environment. However, the vibration fatigue testing usingshaker table exist two problems. One is that the shaker table cannot impose stress likethe hydraulic servo testing machine; the other is how to monitor whether thespecimens run normally. The formula of stress calculation is induced by the theory ofmechanics and machine vibration, the fatigue testing was conducted by the changingof parameters which can influence stress.
The socket weld joint of initial design was conducted to investigate thehigh-cycle fatigue property, and the test results show that failures tend to originate toeat higher stress while for the case of lower stress failures tend to occur at the root. Theresearch results present that the radial gap, the size of fillet weld and the flank angleof weld toe can affect the fatigue property and the higher penetration depth canimprove the fatigue property.
The groove was used to increase the penetration depth, and the specimens with3mm and5mm grooves were conducted to investigate the effect on the fatigueproperty. The research results show that the groove can increase the damping, whichcan improve the property of vibration resistance; the stress amplitude of rootdecreases a little with increasing penetration depth under the vibration fatigue load;however, the groove can decrease obviously the plastic strain due to the stressamplitude of root exceeding the yield stress, it means that the plastic damage of rootdecrease gradually with increasing the penetration depth which can improve theresistance performance of fatigue crack initiation. Hence, the groove can improve markedly the property of high-cycle fatigue, and prolong obviously the fatigue life.
In addition, the groove can improve the fatigue life of root on the conditions oflower stress while can decrease the fatigue property of toe at higher stress owing toincreasing the residual stress of toe. The socket weld subjects usually to the conditionsof lower stress and high-cycle fatigue, so the specimen with groove can improveobviously the high-cycle fatigue life of weld joint.
本文用振动台进行疲劳试验，其振动模式与实际相符；但也存在两个实施问题，一是进行疲劳试验时振动台不能像液压伺服试验机一样直接施加应力，二是如何监控试样是否失效。本文基于材料力学和机械振动学理论，推导了悬臂梁振动条件下插套焊接头应力的计算公式，明确了各个参数对应力的影响，使试样能在预设的交变应力下进行疲劳试验。
针对原始设计插套焊焊接接头的高周疲劳试验结果表明，在高应力条件下焊接接头倾向于在焊趾处开裂，在低应力条件下倾向于在焊根处失效。对疲劳试样的失效机理分析表明，径向间距、焊脚尺寸和焊趾处夹角能影响插套焊接头的疲劳性能，并且增加焊根熔深能改善插套焊接头的疲劳性能。
基于预制坡口能提高焊根熔深的思路，研究了预制3mm和5mm坡口对插套焊疲劳性能的影响。研究结果表明，加开坡口后，一方面插套焊接头的阻尼增大，提高了插套焊的抗振动能力；另一方面，随着坡口深度增加，在振动疲劳载荷下，虽然焊根处的应力降低幅度很小，但由于峰值应力超过了材料的屈服强度，其塑性应变值显著降低，即焊根处的塑性损伤随着坡口深度的增加逐渐降低，从而提高了焊根处的抗疲劳裂纹萌生能力。因此，加开坡口能够显著提高插套焊焊根处的高周疲劳性能，大幅延长疲劳寿命。
另外，由于加开坡口增加了焊趾处的焊接残余应力，在提高低应力条件下焊根处疲劳性能的同时，降低了高应力条件下焊趾处的疲劳性能。由于插套焊正常服役的振动条件为低应力下的高周疲劳，因此加开坡口能够显著提高插套焊接头的高周疲劳寿命。
The small bore piping socket weld is mainly used to the connection of the leaderpipe and the branch pipe in the nuclear power plants. In the socket welding pipe thecorrosive liquid flow and induce easily cavitations which result in the harmonicvibration of pipe. In the conditions of vibration and corrosion, the socket welds jointsfrequently present high-cycle fatigue failure; especially in the root of socket weld.Due to their factors, the304L stainless steel which has a better performance incorrosion resistance was selected as examples of vibration fatigue testing. Themechanism and factors of high-cycle fatigue failure of socket weld are studied deeply,and propose the prolonging life technology. The research work and results are listed asfollow:
The specimens of socket weld were tested in the vibration table which canimitate the actual vibration environment. However, the vibration fatigue testing usingshaker table exist two problems. One is that the shaker table cannot impose stress likethe hydraulic servo testing machine; the other is how to monitor whether thespecimens run normally. The formula of stress calculation is induced by the theory ofmechanics and machine vibration, the fatigue testing was conducted by the changingof parameters which can influence stress.
The socket weld joint of initial design was conducted to investigate thehigh-cycle fatigue property, and the test results show that failures tend to originate toeat higher stress while for the case of lower stress failures tend to occur at the root. Theresearch results present that the radial gap, the size of fillet weld and the flank angleof weld toe can affect the fatigue property and the higher penetration depth canimprove the fatigue property.
The groove was used to increase the penetration depth, and the specimens with3mm and5mm grooves were conducted to investigate the effect on the fatigueproperty. The research results show that the groove can increase the damping, whichcan improve the property of vibration resistance; the stress amplitude of rootdecreases a little with increasing penetration depth under the vibration fatigue load;however, the groove can decrease obviously the plastic strain due to the stressamplitude of root exceeding the yield stress, it means that the plastic damage of rootdecrease gradually with increasing the penetration depth which can improve theresistance performance of fatigue crack initiation. Hence, the groove can improve markedly the property of high-cycle fatigue, and prolong obviously the fatigue life.
In addition, the groove can improve the fatigue life of root on the conditions oflower stress while can decrease the fatigue property of toe at higher stress owing toincreasing the residual stress of toe. The socket weld subjects usually to the conditionsof lower stress and high-cycle fatigue, so the specimen with groove can improveobviously the high-cycle fatigue life of weld joint.
引文
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