On-line Repair Method and Reliability Assessment of Pitch Gear Ring Manufactured by 42CrMo

YAO Peng; QIN Siyuan; LIU Hongbing; CHEN Chaofan; WANG Jinsheng; LI Zhenguo; GUO Zhijie

doi:10.7512/j.issn.1001-2303.2023.01.08

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On-line Repair Method and Reliability Assessment of Pitch Gear Ring Manufactured by 42CrMo
Vol. 53, Issue 1, Pages: 49-55(2023)
DOI： 10.7512/j.issn.1001-2303.2023.01.08

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姚鹏，秦思远，刘洪冰，等.42CrMo制变桨齿圈在线焊接修复工艺及可靠性评估［J］.电焊机，2023，53（1）：49-55.

YAO Peng, QIN Siyuan, LIU Hongbing, et al.On-line Repair Method and Reliability Assessment of Pitch Gear Ring Manufactured by 42CrMo[J].Electric Welding Machine, 2023, 53(1): 49-55.
姚鹏，秦思远，刘洪冰，等.42CrMo制变桨齿圈在线焊接修复工艺及可靠性评估［J］.电焊机，2023，53（1）：49-55. DOI： 10.7512/j.issn.1001-2303.2023.01.08.

YAO Peng, QIN Siyuan, LIU Hongbing, et al.On-line Repair Method and Reliability Assessment of Pitch Gear Ring Manufactured by 42CrMo[J].Electric Welding Machine, 2023, 53(1): 49-55. DOI： 10.7512/j.issn.1001-2303.2023.01.08.

摘要

变桨齿圈是风电机组核心零部件之一，多由42CrMo加工制造而成。经过长时间的运行，变桨齿圈的轮齿易出现淬硬层磨损问题，需要进行塔上在线修复。采用合金耐磨焊材H27对42CrMo变桨齿圈进行手工钨极氩弧焊修复工艺试验，使用超音频感应加热设备和回火焊道技术进行焊前预热和焊后缓冷，并测量其有效硬度层、耐磨性和金相组织，采用模拟运行方式对结合可靠性进行评估。结果表明，相较于传统42CrMo焊接工艺，该修复工艺大大降低了42CrMo焊后出现裂纹、气孔等缺陷的概率，熔覆层中的马氏体基体上弥散分布了大量微米级碳化物颗粒，熔覆层耐磨性能优异，满足42CrMo制造的变桨齿圈在线焊接修复要求，为风电机组变桨齿圈在线修复提供了一种解决方案。

Abstract

Pitch gear ring is one of the core component of wind turbine, mostly processed and manufactured by 42CrMo. The hardened layer of gear teeth are prone to be worn after running a long time, which need to be repaired on-line in the tower. In order to solve the problem, the repair process of 42CrMo pitch gear was tested by using gas tungsten arc weld (GTAW) with H27. Before the welding, ultra-audio frequency induction heating equipment was used for heating. And the treatment of temper bead welding (TBW) for slow cooling was used after the welding. Some experiments including effective hardness layer, wear resistance, metallographic structure and simulation run mode were carried out to assess the reliability of the repair. The results show that this repair process greatly reduces the probability of cracks, pores and other defects after 42CrMo welding, which can be applied to the on-line operation and maintenance of wind turbines. In this way, the cost is decreased and good economic benefits are achieved.

关键词

风电机组变桨齿圈在线修复可靠性评估GTAW

Keywords

wind turbinepitch gear ringon-line repairreliability assessmentGTAW

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