Numerical Simulation and Residual Stress Analysis of OVERLAY Welding Repair of Nozzle Fillet Welds in Nuclear Power Plant

Yong CUI

doi:10.7512/j.issn.1001-2303.2022.04.11

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Numerical Simulation and Residual Stress Analysis of OVERLAY Welding Repair of Nozzle Fillet Welds in Nuclear Power Plant
Vol. 52, Issue 4, Pages: 71-81(2022)
DOI： 10.7512/j.issn.1001-2303.2022.04.11

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崔勇.核电站接管角焊缝OVERLAY堆焊修复数值模拟及残余应力分析［J］.电焊机，2022，52（4）：71-81.

CUI Yong.Numerical Simulation and Residual Stress Analysis of OVERLAY Welding Repair of Nozzle Fillet Welds in Nuclear Power Plant[J].Electric Welding Machine, 2022, 52(4): 71-81.
崔勇.核电站接管角焊缝OVERLAY堆焊修复数值模拟及残余应力分析［J］.电焊机，2022，52（4）：71-81. DOI： 10.7512/j.issn.1001-2303.2022.04.11.

CUI Yong.Numerical Simulation and Residual Stress Analysis of OVERLAY Welding Repair of Nozzle Fillet Welds in Nuclear Power Plant[J].Electric Welding Machine, 2022, 52(4): 71-81. DOI： 10.7512/j.issn.1001-2303.2022.04.11.

摘要

针对某核电站主管道仪表接管角焊缝及其预堆层可能出现的缺陷等问题，开展了OVERLAY堆焊修复技术研发，并采用数值模拟方式开展焊接工艺研究。完成了堆焊修复结构设计；基于Abaqus建立有限元分析模型，采用生死单元法及热循环曲线法对多层多道堆焊过程进行数值模拟，研究堆焊过程中温度场和应力场的分布特性；开展不同堆焊厚度及线能量堆焊工艺下应力对比。计算结果表明，焊趾处存在应力集中区域，原角焊缝及预堆层表面在堆焊后以压应力为主，堆焊层自内向外拉应力逐渐增大；随着堆焊厚度的增加，应力水平呈下降趋势，但焊后变形呈增大趋势，且向内收缩增大幅度比轴向收缩更为明显；随着线能量的增加，应力水平和焊后变形均有增大趋势，但增大幅度并不明显。上述研究可为现场堆焊维修方案的制定提供数据支撑。

Abstract

Aiming at the possible defects of the nozzle fillet weld and buttering of the main pipeline of a nuclear power plant, the research and development of OVERLAY welding repair technology was carried out, and the study of welding technology was carried out by numerical simulation. First, the overlay welding repair structure design was completed; secondly, a finite element analysis model was established by Abaqus, combined with the method of birth-death element and welding thermal cycle curve, the process of multi-layer and multi-pass welding was researched by numerical simulation, and the temperature field and stress field distribution characteristics of the overlay welding process was studied; finally, the stress comparison under different overlay welding thickness and line energy was carried out. The calculation results show that there is a stress concentration area at the weld toe, the original fillet weld and the buttering surface are dominated by compressive stress after overlay welding, and the tensile stress of the overlay weld gradually increases from the inside to the outside. With the increase of the surfacing thickness, the stress level shows a downward trend, however, the deformation shows an increasing trend, and the increasing range of inward shrinkage is more obvious than that of axial shrinkage；and with the increase of the line energy, the stress level and post-weld deformation have an increasing trend, but the increase is not obvious. The above research results are able to provide data support for the formulation of on-site surfacing maintenance programs.

关键词

接管角焊缝OVERLAY 堆焊数值模拟残余应力热循环曲线

Keywords

nozzle fillet weldsoverlay weldingnumerical simulationresidual stressthermal cycle curve

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