【摘要】：基于國家核電大發(fā)展的市場背景,相關(guān)的各個子行業(yè)都由此受益,核燃料提純設(shè)備中必不可少的核用真空閥門市場巨大。波紋管組件軟釬焊技術(shù)一直是困擾核用真空閥門生產(chǎn)的一項關(guān)鍵技術(shù)難題,多年來仍保持比較原始的手工憑經(jīng)驗操作的方式,當(dāng)遇到批量訂單生產(chǎn)時,技術(shù)及產(chǎn)能瓶頸影響按期交貨。本課題基于產(chǎn)品設(shè)計、制造、檢驗及驗收現(xiàn)有標(biāo)準(zhǔn),采用理論分析與試驗驗證相結(jié)合的方法,開展了核用真空閥門軟釬焊工藝研究。利用壓力表、氦質(zhì)譜檢漏儀等對波紋管組件釬焊焊縫強度及密封性能進(jìn)行了測試,研究出了一套真空閥門波紋管組件軟釬焊工藝,釬料成分、焊接質(zhì)量檢驗一次合格率和裝配試驗一次合格率均提高到了95%以上,達(dá)到了節(jié)能降耗的目的。主要內(nèi)容如下:1、根據(jù)核燃料系統(tǒng)真空閥門軟釬焊焊料S-Sn60PbB、S-Sn60PbSbB的主要成分構(gòu)成完成了釬料試制,分析原材料、工藝流程、工具及溫度等因素對釬料成分的影響,確定了釬料熔煉錫(Sn99.90AA)、鉛(Pb99.990)重量配比為6:4,同時將制備工具材質(zhì)改進(jìn)為超低碳奧氏體不銹鋼,解決了雜質(zhì)成分超標(biāo)的問題,完成了錫鉛釬料制備工藝研究。2、通過分析不同助焊劑的成分及功用,確定助焊劑以精制松香為主,松香酒精溶液和氯化鋅溶液配合使用。氯化鋅溶液采用鋅粉與37%的鹽酸配制,松香酒精溶液采用精制松香粉末與濃度≥99.7%的分析純乙醇CH3CH2OH配制。3、通過分析核用真空閥門波紋管組件焊縫結(jié)構(gòu),結(jié)合生產(chǎn)實踐,研究出了兩種軟釬焊焊料規(guī)格,尺寸分別為3×16×R1.5及6×6×R2,能滿足現(xiàn)有口徑DN3~DN100范圍內(nèi)閥門波紋管組件軟釬焊的生產(chǎn)需求,同時對焊料模具材質(zhì)及結(jié)構(gòu)進(jìn)行了改進(jìn),保證了釬焊質(zhì)量,提高了生產(chǎn)效率。4、通過分析及試驗,完成了波紋管組件加工工藝研究,釬焊焊縫最佳間隙為30~50μm;分析波紋管組件釬焊工藝對釬焊質(zhì)量的影響,完成釬焊工藝及工裝研究,產(chǎn)品裝配試驗一次合格率由70~80%提高到95%以上。5、收集并整理了核用真空閥波紋管組件軟釬焊典型質(zhì)量問題,完成了原因分析,明確了處理辦法,制定了預(yù)防措施。
[Abstract]:Based on the market background of the great development of national nuclear power, all the related sub-industries benefit from it. The nuclear vacuum valve market, which is indispensable in the nuclear fuel purification equipment, is huge. Corrugated tube assembly soldering technology has been a key technical problem that puzzles the production of nuclear vacuum valves. For many years, it still maintains a relatively primitive manual operation by experience, when it comes to mass order production, Technical and capacity bottlenecks affect timely delivery. Based on the existing standards of product design, manufacture, inspection and acceptance, the soft brazing technology of nuclear vacuum valve is studied by combining theoretical analysis with test verification. Using pressure gauge, helium mass spectrometry leak detector and so on, the weld strength and sealing performance of brazing of bellows assembly were tested, and a set of soft brazing technology and solder composition of bellows assembly of vacuum valve were studied. The qualification rate of welding quality inspection and assembly test is increased to more than 95%, and the purpose of saving energy and reducing consumption is achieved. The main contents are as follows: 1. According to the main composition of the solder S-Sn60PbBU S-Sn60PbSbB for vacuum valve of nuclear fuel system, the effects of raw materials, technological process, tools and temperature on the composition of solder are analyzed. The solder smelting tin (Sn99.90AA), lead (Pb99.990) weight ratio is 6: 4, and the material of the preparation tool is improved to ultra-low carbon austenitic stainless steel, which solves the problem that the impurity composition exceeds the standard. The preparation process of tin lead solder was studied. 2. By analyzing the composition and function of different flux, it was determined that the flux was mainly refined rosin, the rosin alcohol solution and zinc chloride solution were used together. Zinc chloride solution was prepared with zinc powder and 37% hydrochloric acid, and rosin alcohol solution with refined rosin powder and analytical pure ethanol CH3CH2OH with concentration 鈮，

本文編號：2367221