Some standard content:
JB/T3735--1999
This standard adopts the Francis runner part of 1EC193 Amendment No.1 "International Code for Acceptance Test of Hydraulic Turbine Models" in a non-equivalent manner, and revises JB3735-84 "Cast Steel Francis Runner". This standard has some changes from JB3735-84 in the following important technical contents: 1. The original standard grade ZG20SiMn is revised to ZG20Mn, and its chemical composition requirements are C0.16%~~0.22%, Mn1.00%~1.30%, P≤0.04%, S≤0.04%, which are now revised to C 0.12%~0.22%, Mn 1.00%~1.60%, P≤0.035%, S≤0.035%; the original standard mechanical property requirements are ≥509.6MPa, which are now revised to α≥510MPa, ≥295MPa, ≥14%, ≥30%, Akt≥39J, HB=156 in the heat treatment state and αu=500~600MPa, α≥300MPa, 8 in the quenched and tempered state. ≥24%, Akv≥45J, HB150~190. - Add the grade ZG06Cr13Ni6Mo in Table 1, and its chemical composition requirements are C≤C.06%, Si≤0.70%, Mn≤0.80%, P≤0.030%, S≤0.030%, Cr 12.0%~~14.0%, Ni 5.50%~6.50%, Mo 0.40%~1.00%, and the mechanical properties requirements are gb≥750MPa, d.≥550MPa, 8≥15%~≥35%, HB≥220. This standard replaces JB3735-84 from the date of implementation. This standard is proposed and managed by Deyang Large Castings and Forgings Research Institute. The drafting unit of this standard: Second Heavy Machinery Group Corporation. The main drafters of this standard: Tian Suzhen and Liu Haibing. 495
1 Range
Standard of the Machinery Industry of the People's Republic of China
Steel casting for francis runner
Steel casting for francis runnerJB/T3735--1999
Replaces JB/T3735-84
This standard specifies the technical requirements, inspection rules and test methods for the castings of the runner of a Francis turbine generator. This standard is applicable to the Francis runners of various models and specifications cast in whole or in half of ZG20Mn steel. The Francis runners cast in whole or in half of carbon steel, alloy steel and stainless steel can also be implemented by reference. 2 Referenced standards
The provisions contained in the following standards constitute the provisions of this standard by reference in this standard. When this standard is published, the versions shown are all valid. All standards are subject to revision. Parties using this standard should explore the possibility of using the latest versions of the following standards: GB/T 223—1994
Methods for chemical analysis of steel and alloy
GB/T 228—1987
GB/T 229--1994
GB/T 231-1984
Metal tensile test method
Metal Charpy notched impact test method
Metallic material Brinell hardness test method
GB/T 6397—1986
Metal tensile test specimen
GB/T 6414—-1986
GB/T7233—1987
GB/T 9444—1988
GB/T 11350—1989
GB/T 11352—1989
Dimensional tolerances of castings
Methods for ultrasonic flaw detection and quality rating of steel castingsMethods for magnetic particle flaw detection and quality rating of steel castingsMachining allowance of steel castings
Carbon steel castings for general engineering
GB/T 15056—1994
Methods for evaluating surface roughness of castings
ASTMA488/A488M：1981Standard for the assessment of welding procedures and welding personnel for steel castings3 Definitions
This standard adopts the following definitions (see Figure 1). 3.1 Line deviation
Refers to the deviation between the prototype surface line and the nominal line. Line deviation can be checked using a single or combined sample made according to the nominal line.
3.2 Waviness
refers to the deviation between the surface profile and the smooth curve formed by the profile with a flexible ruler. The waviness is expressed by the ratio of the maximum gap X and the spacing V between the surface profile and the smooth curve. 3.3 Surface roughness
refers to the microscopic geometric dimensional characteristics of the tiny peaks and valleys on the flow surface that deviate from the contour center line. Approved by the State Bureau of Machinery Industry on June 28, 1999 496
Implementation on January 1, 2000
4 Technical requirements
4.1 Materials
4.1.1 Chemical composition
ZG20Mn
ZG06Cr13Ni6Mo
JB/T3735--1999
Prying dimension
Waviness XV
Mold line deviation
Nominal mold line
Waviness
Figure 1 Definition of mold line deviation and waviness
The chemical composition shall conform to the requirements of Table 1.
Table 1 Chemical composition
Chemical composition.%
o. 12 ~0. 221. 00 ~~ 1. 60 0. 60 ~- 0. 800.06
Mechanical properties
ZG20Mn
ZG06Cr13Ni6Mo
The mechanical properties of castings shall conform to the requirements of Table 2. Table 2 Mechanical properties
Heat treatment state
Normalizing + tempering
≥510
500~650
≥750
≥295
≥300
≥550
Surface roughness
12. 0~14. 05. 50~6. 50 0. 40~1. 00
≥156
150～190
≥220
4.2 Surface qualitybzxz.net
4.2.1 Profile, inlet and outlet angles (see Figure 2) JB/T3735—1999
4.2.1.1 Blade inlet profile limit deviation: ±0.1%D, (D, is the nominal diameter of the runner. Same below). The inlet profile template should extend 0.1D from the top of the blade along the front and back of the blade. 4.2. 1.2
Blade outlet profile limit deviation: ±0.1%D. The front outlet profile template should extend 0.1D from the tail end of the blade along the front of the blade, and the back outlet profile template should extend 0.15D from the tail end of the blade along the back of the blade. 4.2.1.3 Blade inlet angle limit deviation
Single value: ±3°
Average value: 1.5°
The blade inlet angle is checked with a template. The inspection template extends 0.05D from the top of the blade along the front and back of the blade. When aligning the template, the gap between the blade and the template must be uniform.
4.2.1.4 Blade outlet angle limit deviation
Single value: ±2°
Average value: 1°
The blade outlet angle is checked with a template. The inspection template extends 0.05D from the tail end of the blade along the front and back of the blade. When aligning the template, the gap between the blade and the template must be uniform.
4.2.1.5 Blade inlet and outlet profiles, the inspection positions of the inlet and outlet angles are shown in Figures 2 and 3. Each blade is inspected at 2~~3 sections. Inlet section
Inlet angle
Outlet new surface
Outlet angle
Figure 2 Profile and inlet and outlet angles of runner blades
4.2.2 Waviness:
JB/T3735-1999
Figure 3 Inspection position of blade inlet and outlet profiles
The waviness of the front and back surfaces of the blades and the flow surfaces of the upper crown and lower ring should be less than 2/100.4.2.3 Roughness:
The surface roughness of the flow surfaces of the runner blades and the upper crown and lower ring shall be within 100um according to R in GB/T15056. 4.2.4 Surface defects of castings are allowed to be finished and welded within the following specified range to achieve smoothness and flatness. 4.2.4.1 The depth of defects such as cold shut, sand hole, air hole, fleshy, loose, etc. on the surface of the casting shall not exceed 20% of the thickness of the defect, and the area of the defect shall not exceed 1.5% of the area of the casting.
4.2.4.2 The surface wrinkles of the casting are within the following ranges: Wrinkles with a depth of 4 to 5 mm shall not exceed 10% of the total area of the blade. Wrinkles with a depth of 2 to 4 mm shall not exceed 40% of the total area of the blade, and their total shall not exceed 45%. 4.2.4.3 The total area of the peeling defects on the surface of the casting shall not exceed 2% of the total area of the blade. 4.2.4.4 The cracks of the casting are within the range of Table 3. Table 3 Range of casting cracks that are allowed to be finished and welded Position
Blade root
Upper crown, lower ring
Crack length
Less than 1/4 of the blade length in the crack direction
Less than 1/3 of the blade length in the crack direction
Note: B is the body thickness at the crack.
Crack depth
Number of blades
Number of cracks
No more than two cracks per blade
No more than four cracks
JB/T3735—1999
Defects exceeding the above range can only be processed after the purchaser agrees. 4.2.5 The casting riser should be cut off. The cutting allowance is shown in Table 4. The cutting allowance on the non-machined surface is required to be leveled. Table 4
Cutting length
Cutting allowance
Cutting allowance of casting riser
251～550
Note: The difference between the high and low residual heights of the cutting allowance shall not exceed 50% of the specified value. 4.3 Dimensions and tolerances
551～800
801～1000
4.3.1 The dimensional tolerance of the non-machined part of the runner, the average value of which shall be in accordance with GB/T6414, and the main inspection dimensions are shown in Figure 4: D4
Figure 4 Main dimensions of the runner
4.3.2 The dimensions of the machined part of the runner shall ensure that the machining allowance meets the requirements of GB/T11350. 4.3.3 The size deviation of the opening ao of the adjacent blade outlet is (see Figure 2): ±3% ao)-2A
The average opening limit deviation of each circle section: The limit deviation of a single opening:
A is the grinding amount.
%a)--2A
4.3.4 The limit deviation of the blade inlet pitch P (see Figure 2) is: ±0.4%DI. (+%)+2A
4.3.5 The limit value of the blade thickness deviation is: ()8 is the blade design thickness.
4.4 Internal quality
4.4.1 Ultrasonic flaw detection
The inner flange of the upper crown of the runner (M in Figure 5) is subjected to ultrasonic inspection after rough machining, and the flaw detection standard shall be implemented in accordance with GB/T7233. 4.4.2 Magnetic particle inspection
The junction between the upper crown and the blade of the wheel, and the junction between the lower ring and the blade (N shown in Figure 5. For small wheels, the junction reached by the probe) is ground and then subjected to magnetic particle inspection. The inspection standard is implemented in accordance with GB/T9444. All defects found by magnetic particle inspection must be repaired, and then inspected again until all defects are eliminated. 500
4.5 Welding repair
JB/T 3735—1999
Figure 5 Inspection area of the wheel
4.5.1 Welding repair is carried out in accordance with the requirements for welding personnel and welding methods in ASTMA488/A488M. 4.5.2 When repairing defects, the method of removing defects can be grinding, arc gouging, machining and gas cutting to form a groove. Magnetic particle inspection is carried out before welding repair.
4.5.3 Welding repairs shall be made with welding rods that have performance not lower than that of the parent metal and can be well fused with the parent metal. For more serious parts with defects exceeding the scope specified in 4.2.4, a special welding repair process shall be prepared for welding repairs. The welding repair process shall be formulated by the supplier. 4.5.4 The repair of runner defects shall be carried out before the last heat treatment. 4.5.5 The repair of more serious parts with defects exceeding the scope specified in 4.2.4 shall be recorded in the inspection record of the turbine runner. 4.6 Heat treatment
4.6.1 The heat treatment of runner castings shall be carried out in accordance with the "Technical Specifications for Heat Treatment of Turbine Runners" prepared by the supplier. 4.6.2 The final process of runner heat treatment shall be tempering. 5 Inspection rules and test methods
5.1 The following inspections must be carried out on the runner castings: a) Chemical composition;
b) Mechanical properties;
c) Surface quality inspection;
d) Dimension inspection,
e) Internal quality inspection;
f) Inspection of defect repair process.
5.2 Chemical composition analysis
5.2.1 The chemical composition is analyzed according to the ladle sample. One sample is taken from each furnace of molten steel. When the molten steel taken from more than two furnaces is concentrated in one ladle, it can be regarded as the same furnace of molten steel. 5.2.2 The analysis method shall be carried out in accordance with the provisions of GB/T223. 5.3 Mechanical properties test
JB/T3735--1999
5.3.1 Mechanical properties Take one casting as an inspection unit, and take one tensile test sample and a group of three impact test samples for each inspection unit. 5.3.2 The tensile test shall be carried out in accordance with GB/T228, the impact toughness test shall be carried out in accordance with GB/T229, and the Brinell hardness test shall be carried out in accordance with GB/T231. 5.3.3 The shape and size of the rough specimens for mechanical properties test shall be carried out in accordance with GB/T6397. The test blocks can be attached to the casting body or cast separately and heat treated together with the casting. The number of test blocks must be sufficient. The shape and size of single-cast test blocks shall be carried out in accordance with GB/T11352. The location and method of attaching the test blocks shall be agreed upon by both parties, but the thickness of the test blocks shall not be less than 28mm. 5.4 Acceptance and retest
5.4.1 During the mechanical properties test, as long as one indicator fails to meet the requirements, a double sample shall be used for retest. If there is still one unqualified sample, the casting and the sample can be reheat treated and re-inspected in accordance with the regulations. Repeated heat treatment shall not exceed two times, but the number of tempering is unlimited. If the test result is still unqualified, the casting is unqualified. 5.4.2 The test results of plum blossom specimens or kiel specimens can be used as the basis for acceptance. The hardness test of castings shall be carried out in accordance with GB/T231, but it shall not be used as a condition for delivery acceptance.
5.4.3 The acceptance of the runner shall be accompanied by the supplier's factory certificate, which shall record the order number, production drawing number, smelting furnace number, weight, heat treatment specifications, chemical composition and mechanical properties, surface quality inspection results, dimension inspection results, internal quality inspection results, repair process inspection records and the conclusion of the inspection department on product quality.
6 Marking and packaging
6.1 The non-machined surface of the inner wall of the lower ring of the runner shall be marked, including the order number, production drawing number, and casting name, and red lead paint shall be applied to the marked area. 6.2 The rough-machined surface and blades of the runner shall be properly protected to prevent damage or deformation during lifting. The supplier shall also carry out rust-proof packaging for the castings after acceptance to prevent shipping damage. 5024 Internal quality
4.4.1 Ultrasonic flaw detection
The inner flange of the upper crown of the runner (M in Figure 5) is subjected to ultrasonic inspection after rough machining, and the flaw detection standard is implemented in accordance with GB/T7233. 4.4.2 Magnetic particle flaw detection
The junction between the upper crown of the runner and the blade, and the junction between the lower ring and the blade (N in Figure 5. For small runners, the junction reached by the probe) is subjected to magnetic particle flaw detection after grinding, and the flaw detection standard is implemented in accordance with GB/T9444. Defects found by magnetic particle flaw detection must be repaired, and then flaw detection is carried out again after repair until all defects are eliminated. 500
4.5 Welding repair
JB/T 3735—1999
Figure 5 Rotor flaw detection area diagram
4.5.1 Welding repair shall be carried out in accordance with the requirements for welding personnel and welding methods in ASTMA488/A488M. 4.5.2 When repairing defects, the defects can be removed by grinding, arc gouging, machining and gas cutting to form a groove. Magnetic particle flaw detection shall be carried out before welding repair.
4.5.3 Welding repair shall be carried out with welding rods whose performance is not lower than that of the parent metal and can be well fused with the parent metal. For more serious areas where the degree of defects exceeds the range specified in 4.2.4, a special welding repair process shall be prepared for welding repair. The welding repair process shall be formulated by the supplier. 4.5.4 Repair of rotor defects shall be carried out before the last heat treatment. 4.5.5 Repairs to more serious parts where the degree of defects exceeds the scope specified in 4.2.4 shall be recorded in the turbine runner inspection record. 4.6 Heat treatment
4.6.1 The heat treatment of runner castings shall be carried out in accordance with the "Turbine Runner Heat Treatment Process Specifications" compiled by the supplier. 4.6.2 The final step of runner heat treatment shall be tempering. 5 Inspection rules and test methods
5.1 The runner castings must be inspected for the following: a) Chemical composition;
b) Mechanical properties;
c) Surface quality inspection;
d) Dimension inspection,
e) Internal quality inspection;
f) Inspection of defect repair process.
5.2 Chemical composition analysis
5.2.1 The chemical composition shall be analyzed according to the ladle sample. One sample shall be taken from each furnace of molten steel for analysis. When molten steel taken from more than two furnaces is concentrated in one ladle, it can be regarded as the same furnace of molten steel. 5.2.2 The analysis method shall be carried out in accordance with the provisions of GB/T223. 5.3 Mechanical properties test
JB/T3735--1999
5.3.1 Mechanical properties Take one casting as an inspection unit. Take one tensile specimen and a group of three impact specimens for each inspection unit. 5.3.2 The tensile test shall be carried out in accordance with GB/T228, the impact toughness test shall be carried out in accordance with GB/T229, and the Brinell hardness test shall be carried out in accordance with GB/T231. 5.3.3 The shape and size of the rough specimen for mechanical properties test shall be carried out in accordance with the provisions of GB/T6397. The test block can be attached to the casting body or poured separately and heat treated together with the casting. The number of test blocks must be sufficient. The shape and size of the single cast test block shall be in accordance with the provisions of GB/T11352. The location and method of the attached cast test block shall be agreed upon by both parties, but the thickness of the test block shall not be less than 28mm. 5.4 Acceptance and retest
5.4.1 During the mechanical properties test, as long as one indicator fails to meet the requirements, a double sample should be used for retest. If there is still one sample that fails to meet the requirements, the casting and the sample can be reheat treated and re-inspected according to the regulations. Repeated heat treatment shall not exceed two times, but the number of tempering is unlimited. If the test result is still unqualified, the casting is unqualified. 5.4.2 The test results of the plum blossom sample or the kiel sample can be used as the basis for acceptance. The casting hardness test is carried out in accordance with GB/T231, but it is not a condition for delivery acceptance.
5.4.3 The acceptance of the runner should be accompanied by the supplier's factory certificate, which contains the order number, production drawing number, smelting furnace number, weight, heat treatment specifications, chemical composition and mechanical properties, surface quality inspection results, size inspection results, internal quality inspection results, repair process inspection records and the conclusion of the inspection department on product quality.
6 Marking and packaging
6.1 The non-machined surface of the inner wall of the lower ring of the runner should be marked, including the order number, production drawing number, and casting name, and the marked area should be painted with red lead paint. 6.2 The rough-machined surface and blades of the runner should be properly protected to prevent damage or deformation during lifting. The supplier should also carry out rust-proof packaging for the castings after acceptance to prevent shipping damage. 5024 Internal quality
4.4.1 Ultrasonic flaw detection
The inner flange of the upper crown of the runner (M in Figure 5) is subjected to ultrasonic inspection after rough machining, and the flaw detection standard is implemented in accordance with GB/T7233. 4.4.2 Magnetic particle flaw detection
The junction between the upper crown of the runner and the blade, and the junction between the lower ring and the blade (N in Figure 5. For small runners, the junction reached by the probe) is subjected to magnetic particle flaw detection after grinding, and the flaw detection standard is implemented in accordance with GB/T9444. Defects found by magnetic particle flaw detection must be repaired, and then flaw detection is carried out again after repair until all defects are eliminated. 500
4.5 Welding repair
JB/T 3735—1999
Figure 5 Rotor flaw detection area diagram
4.5.1 Welding repair shall be carried out in accordance with the requirements for welding personnel and welding methods in ASTMA488/A488M. 4.5.2 When repairing defects, the defects can be removed by grinding, arc gouging, machining and gas cutting to form a groove. Magnetic particle flaw detection shall be carried out before welding repair.
4.5.3 Welding repair shall be carried out with welding rods whose performance is not lower than that of the parent metal and can be well fused with the parent metal. For more serious areas where the degree of defects exceeds the range specified in 4.2.4, a special welding repair process shall be prepared for welding repair. The welding repair process shall be formulated by the supplier. 4.5.4 Repair of rotor defects shall be carried out before the last heat treatment. 4.5.5 Repairs to more serious parts where the degree of defects exceeds the scope specified in 4.2.4 shall be recorded in the turbine runner inspection record. 4.6 Heat treatment
4.6.1 The heat treatment of runner castings shall be carried out in accordance with the "Turbine Runner Heat Treatment Process Specifications" compiled by the supplier. 4.6.2 The final step of runner heat treatment shall be tempering. 5 Inspection rules and test methods
5.1 The runner castings must be inspected for the following: a) Chemical composition;
b) Mechanical properties;
c) Surface quality inspection;
d) Dimension inspection,
e) Internal quality inspection;
f) Inspection of defect repair process.
5.2 Chemical composition analysis
5.2.1 The chemical composition shall be analyzed according to the ladle sample. One sample shall be taken from each furnace of molten steel for analysis. When molten steel taken from more than two furnaces is concentrated in one ladle, it can be regarded as the same furnace of molten steel. 5.2.2 The analysis method shall be carried out in accordance with the provisions of GB/T223. 5.3 Mechanical properties test
JB/T3735--1999
5.3.1 Mechanical properties Take one casting as an inspection unit. Take one tensile specimen and a group of three impact specimens for each inspection unit. 5.3.2 The tensile test shall be carried out in accordance with GB/T228, the impact toughness test shall be carried out in accordance with GB/T229, and the Brinell hardness test shall be carried out in accordance with GB/T231. 5.3.3 The shape and size of the rough specimen for mechanical properties test shall be carried out in accordance with the provisions of GB/T6397. The test block can be attached to the casting body or poured separately and heat treated together with the casting. The number of test blocks must be sufficient. The shape and size of the single cast test block shall be in accordance with the provisions of GB/T11352. The location and method of the attached cast test block shall be agreed upon by both parties, but the thickness of the test block shall not be less than 28mm. 5.4 Acceptance and retest
5.4.1 During the mechanical properties test, as long as one indicator fails to meet the requirements, a double sample should be used for retest. If there is still one sample that fails to meet the requirements, the casting and the sample can be reheat treated and re-inspected according to the regulations. Repeated heat treatment shall not exceed two times, but the number of tempering is unlimited. If the test result is still unqualified, the casting is unqualified. 5.4.2 The test results of the plum blossom sample or the kiel sample can be used as the basis for acceptance. The casting hardness test is carried out in accordance with GB/T231, but it is not a condition for delivery acceptance.
5.4.3 The acceptance of the runner should be accompanied by the supplier's factory certificate, which contains the order number, production drawing number, smelting furnace number, weight, heat treatment specifications, chemical composition and mechanical properties, surface quality inspection results, size inspection results, internal quality inspection results, repair process inspection records and the conclusion of the inspection department on product quality.
6 Marking and packaging
6.1 The non-machined surface of the inner wall of the lower ring of the runner should be marked, including the order number, production drawing number, and casting name, and the marked area should be painted with red lead paint. 6.2 The rough-machined surface and blades of the runner should be properly protected to prevent damage or deformation during lifting. The supplier should also carry out rust-proof packaging for the castings after acceptance to prevent shipping damage. 502
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