Verification and Reliability Assessment of Hydraulic Welding Models Using Welding Materials Compatible with 1 000 MPa-grade High-strength Steel for Hydrostatic Testing

HUI Zhenguo; TIAN Ye; TIAN Jingcheng; GAN Hongfeng; LU Tiantian; WU Hailong

doi:10.7512/j.issn.1001-2303.2026.08.11

Quality and Efficiency in High\-Strength Steel Welding | Views : 0 下载量: 7 CSCD: 0

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Verification and Reliability Assessment of Hydraulic Welding Models Using Welding Materials Compatible with 1 000 MPa-grade High-strength Steel for Hydrostatic Testing
Vol. 56, Issue 8, Pages: 105-115(2026)
Received：01 July 2026，

Revised：2026-07-21，

Published：20 August 2026
DOI： 10.7512/j.issn.1001-2303.2026.08.11
稿件说明：

移动端阅览

惠振国，田野，田井成，等.1 000 MPa级高强钢配套焊材水电焊接模型水压试验验证及可靠性评估［J］.电焊机，2026，56（8）：105-115. DOI： 10.7512/j.issn.1001-2303.2026.08.11.

HUI Zhenguo, TIAN Ye, TIAN Jingcheng, et al.Verification and Reliability Assessment of Hydraulic Welding Models Using Welding Materials Compatible with 1 000 MPa-grade High-strength Steel for Hydrostatic Testing[J].Electric Welding Machine, 2026, 56(8): 105-115. DOI： 10.7512/j.issn.1001-2303.2026.08.11.

摘要

为验证1 000 MPa级水电用高强钢配套焊材在压力钢管焊接结构中的适用性和可靠性，设计并制造了两套局部缩比压力钢管焊接模拟件并开展水压试验。1#模拟件纵缝及环缝分别采用国产和进口1 000 MPa级气体保护焊丝，在9.5 MPa峰值压力下监测关键焊缝区域的结构应力分布与承载响应；2#模拟件纵缝采用国产1 000 MPa级埋弧焊丝/焊剂，环缝采用国产1 000 MPa级手工电弧焊条和600 MPa级气体保护焊丝，峰值压力10.25 MPa，同步测试水压试验前后焊接残余应力并监测结构位移。结果表明：1#模拟件实测最大结构应力为175.8 MPa，低于运行和水压试验工况下的许用应力，卸压后UT与TOFD复检未发现超标缺陷；2#模拟件在10.25 MPa下内壁和外壁最大结构应力分别为348.9 MPa和260.5 MPa，主要测点应力和位移随压力变化呈较好的线性关系，卸压后复检未见线性缺陷；水压试验后焊接残余应力总体降低并发生重分布，内壁

和

方向平均消除率分别为26.6%和36.6%，外壁分别为27.9%和33.3%。研究表明，在本文模拟件结构、焊接工艺和水压试验条件下，所选国产配套焊材及工艺可满足1 000 MPa级水电用高强钢压力钢管焊接结构的水压验证要求。

Abstract

Hydraulic proof testing is a critical validation procedure for ensuring the structural integrity of welded penstock joints in hydropower stations. However

systematic experimental data remain limited regarding welded joints employing domestic welding consumables for 1000 MPa-grade high-strength steels. Two locally scaled cylindrical penstock mock-ups were designed and fabricated to evaluate the applicability of domestic welding consumables. The No. 1 mock-up utilized domestic and imported 1000 MPa-grade gas metal arc welding (GMAW) wires for the longitudinal and circumferential seams

respectively

and was pressurized to 9.5 MPa. Strain gauges installed at critical weld locations recorded structural stress distributions under loading. The second mock-up employed domestic 1000 MPa-grade submerged arc welding (SAW) wire/flux and 1000 MPa-grade shielded metal arc welding (SMAW) electrodes for different seams

and was pressurized to 10.25 MPa. Residual stresses were measured before and after testing

and structural displacements were monitored.

Results

indicate that for the No. 1 mock-up

the stress－pressure relationships at all gauge locations were linear (R

≥0.99)

with the maximum measured structural stress of 175.8 MPa well below the allowable stress limits for both operating and proof test conditions; no unacceptable defect indications were detected by UT and TOFD re-inspection after unloading. For the No. 2 mock-up

the maximum structural stresses at 10.25 MPa were 348.9 MPa (inner wall) and 260.5 MPa (outer wall)

both stress and displacement exhibited proportional responses to pressure

and no linear defects were found upon post-test re-inspection. Post-test welding residual stresses decreased notably

with average relief rates of 26.6%-36.6% on the inner wall and 27.9%-33.3% on the outer wall. The findings suggest that the selected domestic welding consumables and procedures can satisfy the hydraulic proof testing requirements for 1000 MPa-grade high-strength steel penstock welded structures wit

hin the scope of the mock-up configurations and test conditions presented.

关键词

Keywords

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