华龙一号CRDM中部Ω焊缝高精度自动焊技术研究

Research on High-Precision Automated Welding Technology for the Mid-Section Omega Seal Weld of HPR1000 CRDM

  • 摘要: “华龙一号”核电机组控制棒驱动机构(CRDM)中部Ω焊缝是确保反应堆60年服役期内高温、高压、强辐照环境下零泄漏的关键密封结构,其现场焊接面临空间受限与质量要求严苛等挑战。针对上述问题,本文研制了高精度自动焊成套设备,其行走、送丝、电流控制精度优于±1%,弧压控制精度达±0.1V;同时采用模块化设计,可通过更换送丝组件与前保气罩实现自熔焊工艺与填丝焊工艺的切换。同步开发了适用于CRDM中部Ω焊缝的填充环自熔焊及填丝焊工艺。通过大量的模拟件焊接及切割再焊接试验验证了两种工艺的稳定性,试验结果表明,两种工艺的焊缝正面圆滑饱满,背面余高适当,焊缝与母材熔合良好,焊缝组织为典型枝状晶,接头成形及质量符合相关要求。本研究为CRDM焊接技术国产化及“华龙一号”机组批量化建设提供了关键技术支撑。

     

    Abstract: The mid-section Ω weld of the Control Rod Drive Mechanism (CRDM) in the "HPR1000" nuclear power unit serves as a critical sealing structure, requiring zero leakage under high-temperature, high-pressure, and intense irradiation conditions throughout the reactor’s 60-year service life. Its on-site welding faces significant challenges including confined space and stringent quality requirements. To address these issues, a high-precision integrated automatic welding system was developed. This system achieves positioning, wire-feeding, and current control accuracy better than ±1%, with arc voltage control precision of ±0.1V. Employing a modular design, it enables seamless switching between self-fusing and wire-filling welding processes by replacing the wire-feeding module and front gas shield. Dedicated self-fusing and wire-filling welding processes were synchronously developed for CRDM mid-section Ω welds. Extensive simulated welding and repeated cutting-repair welding tests validated the stability of both processes. Results demonstrate that welds produced by both techniques exhibit smooth, well-contoured bead surfaces, appropriate backside reinforcement, and excellent fusion with the base metal. Metallographic examination revealed typical dendritic microstructures, with all joints meeting relevant quality standards. This study provides key technological support for the localization of CRDM welding technology and batch construction of "HPR1000" units.

     

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