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电厂燃煤锅炉水冷壁管断裂分析

Fracture analysis of water wall tubes in a coal-fired boiler of a power plant

  • 摘要: 为了探究某电厂燃煤锅炉水冷壁管断裂的原因和机理,通过宏观观察、力学性能测试、材质成分分析、金相检验、扫描电子显微镜(SEM)和能谱(EDS)等方法对失效的水冷壁管进行了分析。结果表明:试样化学成分及向火面和背火面的屈服强度均满足相关标准对20G钢的要求,但硬度、抗拉强度和断后伸长率未达到标准要求;水冷壁管内壁有一层厚的氧化膜,爆口内壁周围有大量沿晶微裂纹(发纹),并向基体内部扩展,在裂纹周围存在严重脱碳现象,这些均为氢腐蚀显著特征。同时在断口表面有硫和磷等腐蚀性元素,表明也存在酸腐蚀。另外,焊缝是较易形成酸腐蚀的区域,熔合线区域是整个焊接接头最薄弱部位,当腐蚀产生的微裂纹逐渐长大,则最先在熔合线区域发生断裂。综合上述,可以判断该水冷壁管断裂是由氢腐蚀和酸腐蚀的共同作用造成的。

     

    Abstract: In order to investigate the fracture causes and mechanisms of water-cooled wall tube in coal-fired boiler of a certain power plant, the failed water wall tubes were analyzed through macroscopic observation, mechanical property testing, material composition analysis, metallographic examination, scanning electron microscope (SEM) and energy dispersive spectroscopy (EDS). The results showed that the chemical composition of the sample and the yield strength on both the fire-facing and back sides complied with the requirements stipulated in the relevant standards for 20G steel. However, the hardness, the tensile strength and the elongation after fracture had not reached the standard requirements. There was a thick oxide film on the inner wall of water wall tubes. Around the burst fracture, there were numerous of intergranular microcracks (fissures) propagating into the matrix interior, and severe decarburization occurred around the cracks. All these were obvious characteristics of hydrogen corrosion. At the fracture surface, there were corrosive elements such as sulfur and phosphorus, indicating that acid corrosion also existed. In addition, the weld seam was an area prone to acid corrosion, and the fusion line area was the weakest zone of the entire welding joint. As the corrosion-induced microcracks gradually propagated, fracture preferentially initiated at the fusion line region. Based on the above, it could be concluded that the fracture of the water wall tubes was caused by the combined effects of hydrogen corrosion and acid corrosion.

     

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