This paper mainly discusses the repair and remanufacturing technology application of hydropower forgings. In view of the defects such as wear and crack in the process of production and use, the traditional repair technology, modern repair technology and intelligent repair technology are introduced. At the same time, remanufacturing technologies such as surface engineering remanufacturing and life cycle remanufacturing are introduced, and the application advantages and prospects of repair and remanufacturing technologies in the field of hydropower forgings are analyzed.
Hydropower forgings are important parts in hydraulic engineering, and their quality and performance directly affect the safety and operation of hydraulic engineering. In the process of long-term use, water and electricity forging will appear wear, cracks and other defects, need to be repaired or remanufactured. The traditional repair methods are usually welding, heat treatment and other methods, but these methods often cause certain damage to the forging, affecting the performance and life of the forging. Therefore, the research and application of advanced repair and remanufacturing technology is of great significance to improve the quality and life of hydropower forgings.
- Introduction of water and electricity forging repair technology
Traditional restoration technique
Traditional repair methods mainly include welding, heat treatment and so on. Welding repair is to fill the cracked or worn parts with welding materials, and then heat treatment to eliminate welding stress. This method is simple and feasible, but it is easy to produce thermal stress in the welding process, resulting in new cracks. Heat treatment repair is to change the structure and properties of metal materials by heating and cooling to achieve the purpose of eliminating cracks and restoring properties. However, it is easy to produce deformation and oxidation in the heat treatment process, which affects the repair effect.
Modern restoration technique
Modern repair techniques mainly include laser cladding, plasma spraying, brush plating and so on. Laser cladding is the use of high energy laser beam to melt alloy powder on the forging surface to form a layer of wear resistance, corrosion resistance and other new properties of alloy layer. Plasma spraying is the use of high temperature and high speed plasma flow to spray alloy powder on the surface of the forging to form a dense alloy layer. Brush plating is to use the principle of electrolysis to deposit a layer of metal or alloy on the surface of the forging to improve the hardness and wear resistance of the surface. These modern repair techniques have the advantages of fast speed, high efficiency and small damage to forgings, but the equipment investment is large and the cost is high.
Intelligent repair technology
Intelligent repair technology is a repair method based on artificial intelligence and big data technology. Through the analysis of a large number of historical and real-time data, the life and failure mode of forging can be predicted, and repair or replacement can be carried out in advance. Intelligent repair technology can reduce maintenance costs and time, improve the reliability and safety of equipment. However, the current intelligent repair technology is still in the research and exploration stage, and needs to be further developed and improved.
Introduction to remanufacturing technology of hydropower forgings
Surface engineering remanufacturing
Surface engineering remanufacturing is the use of various surface engineering technologies to repair and strengthen hydropower forgings in order to extend their service life and improve performance. Surface engineering remanufacturing technology includes modern repair technology such as laser cladding, plasma spraying, brush plating, as well as traditional technology such as chemical heat treatment and surface coating. These technologies can be selected and applied according to specific needs in the remanufacturing process to achieve the best remanufacturing results.
Full life cycle remanufacturing
Life cycle remanufacturing is a remanufacturing method based on product life cycle management. Through the management and optimization of the whole process from design, manufacture, use to scrap, the maximum utilization of resources and the minimum discharge of waste can be achieved. The whole life cycle remanufacturing technology includes many aspects, such as product design optimization, material selection, manufacturing process improvement, operation and maintenance, etc. It needs multi-disciplinary cooperation and support. The whole life cycle remanufacturing technology can improve the reliability and safety of hydropower forgings, reduce maintenance costs and environmental pollution, and has important social and economic benefits.
The turbine blades of a hydropower station have some defects such as wear and crack during long-term use, and laser cladding technology is used to repair them. After repair, the surface hardness of the blade is increased by 50%, the wear resistance is increased by 3 times, and the service life of the blade is effectively extended.
Fatigue cracks appeared in the rotor shaft of a generator in a hydropower station during operation, and the whole life cycle remanufacturing technology was used to optimize the rotor shaft. By optimizing the material selection, manufacturing process improvement and service maintenance of the rotor shaft, the cracks were successfully eliminated and the performance and life of the rotor shaft were improved. At the same time, it also reduces the maintenance cost and environmental pollution, and obtains good social and economic benefits.
The application of repair and remanufacturing technology of hydropower forgings is of great significance to improve the quality and life of hydropower forgings. Traditional repair methods have certain limitations and damage, modern repair technology and intelligent repair technology have the advantages of fast speed, high efficiency, small damage to forging, but the equipment investment is large and the cost is high. Remanufacturing technologies such as surface engineering remanufacturing and life cycle remanufacturing can maximize the utilization of resources and minimize the discharge of waste, and have important social and economic benefits. In the future, with the continuous development and progress of science and technology, the application of repair and remanufacturing technology in the field of hydropower forgings will be more extensive and in-depth.
