As the core component of hydropower system, hydropower forgings play an important role in improving the operation efficiency and stability of hydroelectric power station. This paper will introduce the surface treatment technology and application of hydroelectricity forgings, aiming at optimizing the performance of hydroelectricity forgings, increasing its life and reducing the production cost.
First, the common surface treatment technology of hydropower forgings
Shot peening
Shot peening is a kind of treatment method that uses high-speed projectile jet to impact the forging surface to produce plastic deformation and strengthen the surface. Shot peening can effectively increase the residual compressive stress of the forging surface, reduce the surface roughness, and form a certain corrosion resistance. However, shot peening also has some limitations, such as large equipment investment and low production efficiency.
Rolling treatment
Rolling treatment is a treatment method that uses hard rollers to roll the forging surface to produce plastic deformation. Rolling treatment can effectively improve the flatness and finish of the forging surface, form a higher residual compressive stress, and enhance the corrosion resistance of the surface. Compared with shot peening, rolling processing equipment has less investment, high production efficiency and simple operation.
Brush plating
Brush plating treatment is a treatment method that uses the electrochemical principle to coat a layer of metal or alloy coating on the surface of the forging to improve the surface corrosion resistance and wear resistance. Brush plating treatment can effectively improve the corrosion resistance and wear resistance of the forging surface, and the binding force between the coating and the base metal is strong. However, the limitation of brush plating treatment is that the coating thickness is difficult to control, which can easily lead to over-coating or under-coating.
Chemical treatment
Chemical treatment is a treatment method that uses chemical reagents to react with the oxidation layer and rust on the surface of the forging, so as to clean the surface and improve corrosion resistance. Common chemical treatment methods include pickling, passivation, phosphating and so on. Chemical treatment has the advantages of simple operation and low cost, but the impact of chemical reagents on the environment should be paid attention to.
Second, the application field of water and electricity forging surface treatment technology
Hydroelectric power generation
Hydropower forgings play a vital role in hydroelectric power generation system, such as turbine blades, guide blades and so on. Surface treatment technology can effectively improve the corrosion resistance and wear resistance of the surface of hydropower forgings, reduce the roughness of the blade surface, reduce the friction resistance of water flow, and thus improve the efficiency of hydropower generation.
Automatic control system
Hydraulic forgings are also widely used in automatic control systems, such as hydraulic cylinders in hydraulic control systems and cylinders in pneumatic control systems. Surface treatment technology can effectively improve the surface corrosion resistance and wear resistance, reduce friction resistance, improve control accuracy and response speed.
Ocean engineering
Marine engineering involves a large number of underwater equipment and devices, such as ocean platform, underwater robot and so on. Surface treatment technology can effectively improve the corrosion resistance and wear resistance of the surface of hydropower forgings, enhance the reliability and safety of the equipment, and extend its service life.
Third, case study – the application of water and electricity forging surface shot peening
Due to the impact and wear of high-speed water flow for a long time, the turbine blades of a hydropower station have serious wear and cracks on the surface of the blades, resulting in the decrease of power generation efficiency. In order to solve this problem, the surface shot peening technology is used to treat the blade surface.
In the process of shot peening, the blade surface is sprayed with high-speed projectile to produce a certain amount of plastic deformation and form a residual compressive stress layer, so as to improve the strength and corrosion resistance of the blade surface. At the same time, shot peening can also reduce the roughness of blade surface, reduce the friction resistance of water flow, and improve the efficiency of hydropower generation. After shot peening, the blade surface has high hardness and good wear resistance, which effectively extends the service life of the blade and improves the operation efficiency of the hydropower station.
Iv. Conclusion
The surface treatment technology of hydroelectric forgings is of great significance to improve its performance and life. This paper introduces the common surface treatment technology of hydroelectricity forgings, such as shot blasting, rolling, brush plating, chemical treatment, and its advantages and disadvantages, and analyzes its application cases in hydroelectric power generation, automatic control system, ocean engineering and other fields. The results show that suitable surface treatment technology can significantly improve the performance and life of hydropower forgings, and has positive effects on sustainable development and green environmental protection. Therefore, the application of surface treatment technology for hydropower forgings should be further studied and promoted to contribute to the sustainable development of hydropower industry.
