Water-cooled panel and welding test method, manufacturing method thereof

Abstract

The application discloses a water-cooled wall plate and a welding test method and a manufacturing method thereof, wherein the water-cooled wall plate comprises a panel and a cover plate made of 304 stainless steel; a groove is formed on the top surface of the panel; the inner side of the groove opening has a step part surrounding the groove opening; the step part comprises a vertical wall and a horizontal wall extending internally from the bottom side of the vertical wall towards the groove; the cover plate is assembled on the step part, the method comprises milling a groove on the panel; assembling the cover plate and the panel; detecting the assembly gap and performing laser positioning welding; flushing argon in the flow channel and performing laser self-fusion welding between the panel and the cover plate; detecting the flatness of the welded water-cooled wall plate and milling a flat surface on the cover plate. The argon is directly flushed in the flow channel through the through hole, laser self-fusion welding is performed between the panel and the cover plate, full penetration welding can be realized through the groove structure and size design, the welding quality is ensured, the deformation of the cover plate is small, and the flatness requirement can be met.

Description

Technical Field

[0001] This invention relates to the field of welding technology for ship water-cooled wall panels, and in particular to a water-cooled wall panel and its welding test method and manufacturing method. Background Technology

[0002] Water-cooled wall panels are core components of marine water-cooling equipment. They consist of a cover plate and a panel, with the cover plate welded to the panel, forming a water-cooling channel. The working environment of water-cooled wall panels involves high temperatures and pressure. If the welding reliability of the cover plate and panel is insufficient, long-term use may lead to weld damage and failure at the weld joint due to stress concentration, corrosion, fatigue, and other factors, resulting in water leakage in the water-cooling channel or deformation of the cover plate. Currently, there are few reference cases for the manufacture of water-cooled wall panels, and there are many technical difficulties and risks in improving welding reliability. Therefore, how to provide a highly reliable welding technology for water-cooled wall panels is a technical problem that needs to be solved by personnel in related technical fields. Summary of the Invention

[0003] This invention provides a water-cooled wall panel and its welding test method and manufacturing method to solve the technical problem of insufficient welding reliability of water-cooled wall panels. To solve the aforementioned technical problem, this invention adopts the following technical solution.

[0004] In some embodiments, a water-cooled wall panel is provided, including a panel and a plurality of cover plates; the panel is made of 304 stainless steel, and its top surface has a plurality of grooves; the inner side of the groove opening has a stepped portion surrounding the groove opening; the stepped portion includes a vertical wall and a transverse wall extending from the bottom side edge of the vertical wall toward the interior of the groove; the cover plate is made of 304 stainless steel, the bottom wall of the cover plate abuts against the transverse wall of the stepped portion, the outer wall of the cover plate is opposite to the vertical wall of the stepped portion, and is connected to the transverse wall of the stepped portion by a weld structure; the weld structure is formed by laser autofusion welding, the weld structure surrounds the cover plate, and extends downward from the top edge of the cover plate to at least the bottom edge of the cover plate; the bottom surface of the cover plate and the inner wall of the groove define a flow channel.

[0005] In some embodiments, the weld structure extends downward from the top edge of the cover plate to below the bottom edge of the cover plate, the width of the transverse wall is ≥2mm, and the thickness of the cover plate is not less than 9mm.

[0006] In some embodiments, the water-cooled wall panel includes multiple stiffening plates, which are Q355B alloy plates and are welded to the bottom surface of the panel.

[0007] In some embodiments, the flow channel has at least two through holes that connect to the outside, the through holes being used to introduce protective gas during the welding process and to allow cooling water to flow during operation.

[0008] In some embodiments, a laser welding test method for water-cooled wall panels is also provided, which is applied to welding water-cooled wall panels as described in any of the preceding claims, comprising the following steps: obtaining a corresponding first welding process by performing a trial welding on a first sample; performing a trial welding on a second sample using the first welding process to simulate the welding process of the panel and cover plate of the water-cooled wall panel; when the simulation results meet expectations, formulating a second welding process based on the first welding process; performing a trial welding on a third sample using the second welding process to simulate the entire welding process of the water-cooled wall panel; when the simulation results meet expectations, formulating a standard welding process based on the second welding process; and welding the panel, the cover plate, and the stiffeners using the standard welding process to obtain the water-cooled wall panel.

[0009] In some embodiments, the process of obtaining a first welding process through trial welding of a first sample includes: providing at least one set of first test plates and formulating welding parameters for the first test plates; welding the first test plates based on the welding parameters; when the welding result of the first test plates meets expectations, using the corresponding welding parameters of the first test plates as basic welding parameters; the basic welding parameters include basic welding power and basic welding speed; providing at least one set of second test plates; welding the second test plates based on the basic welding parameters; when the welding result of the second test plates meets expectations, using the weld head structure parameters of the second test plates as basic weld head structure parameters; the basic weld head structure parameters include: when the welding result of the second test plates meets expectations, the weld head structure shape and size parameters of the corresponding third test plate, the weld head structure shape and size parameters of the corresponding fourth test plate, and the assembly gap parameters of the weld heads of the corresponding third and fourth test plates; formulating a preliminary welding process based on the basic welding parameters and the basic weld head structure parameters; verifying the preliminary welding process; and when the preliminary welding process meets expectations, formulating the first welding process based on the preliminary welding process.

[0010] In some embodiments, the first test plate group includes a first test plate and a second test plate made of 304 stainless steel. The weld joints of the first and second test plates have the same thickness, 10 mm. The welding process of the first test plate group includes: splicing the weld joints of the first and second test plates; after splicing, the top surfaces of the two are flush, and the bottom surfaces of the two are flush, with a gap of ≤0.1 mm; welding the front surfaces of the weld joints of the first and second test plates using laser autofusion welding; after welding, visually inspecting the back surfaces of the weld joints of the first and second test plates; when the back surfaces of the weld joints of the first and second test plates are fully penetrated, the welding result of the first test plate group meets the expected welding test method; and / or, the second test plate group includes a third and a fourth test plate made of 304 stainless steel; the weld joint of the third test plate has a thickness of 10 mm, the weld joint of the fourth test plate has a thickness of 10 mm, and the weld joint of the second test plate has a thickness of 10 mm. The weld joint of the test plate has a butt joint step, the butt joint step having a vertical step wall and a transverse step wall extending laterally from the bottom side of the vertical step wall; the welding process of the second test plate group includes: splicing the butt joint steps of the weld joints of the third test plate and the fourth test plate, the bottom wall of the weld joint of the third test plate facing the transverse step wall, the gap between the side wall of the third test plate facing the vertical step wall and the vertical step wall is 0-0.04mm; welding the vertical step wall of the weld joint of the fourth test plate and the side wall of the weld joint of the third test plate facing the vertical step wall using laser self-fusion; detecting the metallographic penetration depth of the weld after welding the weld joints of the third and fourth test plates; when the metallographic penetration depth of the weld is greater than or equal to the thickness of the weld joint of the third test plate, the welding result of the second test plate group meets expectations; the structural parameters of the weld joints of the three test plates and the structural parameters of the weld joint of the fourth test plate are used as the basic weld joint structural parameters.

[0011] In some embodiments, the preliminary welding process includes: providing at least one third test plate group, the third test plate group including a seventh test plate and an eighth test plate, the weld joint of the seventh test plate and the eighth test plate being manufactured based on the basic weld joint structural parameters; welding the third test plate group using laser autofusion welding based on the basic welding power and the basic welding parameters; detecting the mechanical properties and weld formation results of the third test plate group; the process of verifying the preliminary welding process includes: implementing the preliminary welding process, determining whether the mechanical properties and weld formation results of the third test plate group meet expectations, and when both the mechanical properties and weld formation results meet expectations, the preliminary welding process meets expectations; the process of formulating a first welding process based on the preliminary welding process includes: formulating the first welding process based on the welding parameters and weld joint structural parameters of the preliminary welding process.

[0012] In some embodiments, the process of formulating a second welding process based on the first welding process includes: formulating a second welding process based on the welding parameters and weld joint structure parameters of the first welding process; the second welding process includes: providing a fifth test plate group, the fifth test plate group including an eleventh test plate, at least one twelfth test plate, and at least one thirteenth test plate; the structure of the eleventh test plate is the same as the panel structure of the water-cooled wall panel; the structure of the twelfth plate is the same as the cover plate structure of the water-cooled wall panel; the structure of the thirteenth test plate is the same as the stiffener structure of the water-cooled wall panel; the eleventh test plate has at least one second simulated groove, the second simulated groove has a second simulated step portion, the second simulated step portion surrounds the inner side of the groove opening of the second simulated groove, and has a second simulated vertical wall and a second simulated horizontal wall; the second simulated vertical wall and the second simulated horizontal wall... The wall and the side of the twelfth test plate are manufactured based on the structural parameters of the basic welded joint; the second test plate is assembled in the second simulated groove, so that the bottom side of the twelfth test plate abuts against the second simulated transverse wall, and the circumferential side of the twelfth test plate is opposite to the second simulated vertical wall; based on the basic welding parameters and the basic welding speed, the outer wall of the twelfth test plate and the second simulated vertical wall are welded by laser autofusion welding, and the welding is continuous along the circumference of the twelfth test plate; the thirteenth test plate is welded to the side of the eleventh test plate facing away from the twelfth test plate; the process of formulating a standard welding process based on the second welding process when the simulated structure meets expectations includes: implementing the second welding process, verifying the welding results of the second welding process, and formulating a standard welding process based on the second welding process when the welding results meet expectations.

[0013] In some embodiments, a method for manufacturing a water-cooled wall panel is also provided, which is applied to manufacturing a water-cooled wall panel as described in any of the preceding claims, comprising the following processes: milling grooves on a panel; assembling a cover plate with the panel; detecting the assembly gap and performing laser positioning welding; purging argon gas into the flow channel and performing laser autofusion welding between the panel and the cover plate; performing flatness detection on the welded water-cooled wall panel and milling the cover plate.

[0014] Compared with the prior art, the beneficial effects of the present invention are at least as follows: In some embodiments of the present invention, the panel is provided with a groove, the groove is provided with a stepped portion, the cover plate is assembled on the stepped portion, and the cover plate is welded to the stepped portion by laser self-fusion welding. The weld structure formed after welding extends from the top edge of the cover plate downward to at least the bottom edge of the cover plate, increasing the connection area between the cover plate and the panel, improving the connection strength and sealing performance of the connection between the two, and the welding reliability is high. In addition, the weld structure surrounds the cover plate and is formed in one go, with fewer welds, minimizing welding deformation and further improving welding reliability. Attached Figure Description

[0015] Figure 1 This is a top view of the structure of the water-cooled wall panel according to an embodiment of this application.

[0016] Figure 2 This is a cross-sectional view of the water-cooled wall panel according to an embodiment of this application.

[0017] Figure 3 This is a schematic diagram showing the connection between the panel and the cover plate in an embodiment of this application.

[0018] Figure 4 This is a schematic diagram of the groove structure according to an embodiment of this application.

[0019] Figure 5 This is a schematic flowchart of the water-cooled wall panel welding test method according to an embodiment of this application.

[0020] Figure 6 This is a schematic diagram of the structure of the first test plate group in an embodiment of this application.

[0021] Figure 7 This is a schematic diagram of the front structure of the first test plate group after welding according to an embodiment of this application.

[0022] Figure 8 This is a schematic diagram of the back structure of the first test plate group after welding according to an embodiment of this application.

[0023] Figure 9 This is a schematic diagram of the structure of the second test plate group according to an embodiment of this application.

[0024] Figure 10 This is a schematic diagram of the cross-sectional structure of the second test plate group according to an embodiment of this application.

[0025] Figure 11 This is a schematic diagram of the metallographic structure of the weld seam of the second test plate group in an embodiment of this application.

[0026] Figure 12 This is a schematic diagram of the structure of the ninth test plate in an embodiment of this application.

[0027] Figure 13 This is a schematic diagram of the structure of the fourth test plate group in an embodiment of this application.

[0028] Figure 14 This is a partial structural schematic diagram of the fifth test plate group in an embodiment of this application.

[0029] Figure 15 This is a schematic flowchart of a water-cooled wall panel manufacturing method according to an embodiment of this application.

[0030] The diagram is labeled as follows: 10, panel; 12, step section; 13, groove; 20, cover plate; 30, weld structure; 40, stiffening plate; 101, first test plate; 102, second test plate; 201, third test plate; 202, fourth test plate; 203, transverse step wall; 204, vertical step wall; 401, ninth test plate; 4011, first simulated groove; 4012, first simulated step section; 402, tenth test plate; 501, eleventh test plate; 502, twelfth test plate; 503, second simulated groove; 504, thirteenth test plate. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0032] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0033] Please see Figures 1 to 4 This embodiment provides a water-cooled wall panel. In some embodiments, the water-cooled wall panel includes a panel 10 and multiple cover plates 20. The panel 10 is made of 304 stainless steel, and its top surface has multiple grooves 13. The inner side of the groove opening of the groove 13 has a stepped portion 12 surrounding the groove opening of the groove 13. The stepped portion 12 includes a vertical wall and a transverse wall extending from the bottom side edge of the vertical wall toward the interior of the groove 13. In some embodiments, the width of the transverse wall is ≥2mm.

[0034] The number of cover plates 20 corresponds to the number of grooves 13, with each groove 13 fitted with one cover plate 20. The bottom surface of the cover plate 20 and the inner wall of the groove 13 define a flow channel, which has at least two through holes connecting to the outside. These through holes are used to introduce shielding gas during the welding process and to allow cooling water to flow during operation. When welding the panel 10 and the cover plate 20, a shielding gas, such as argon, is introduced into the groove 13 through the two through holes to provide atmospheric protection for the welding process. During operation, fluid is introduced into and discharged from the flow channel through the two through holes, enabling fluid flow within the channel.

[0035] The cover plate 20 is made of 304 stainless steel. Its bottom wall abuts against the transverse wall of the step portion 12, and its outer wall is opposite to the vertical wall of the step portion 12. It is connected to the transverse wall of the step portion 12 through a weld structure 30. The weld structure 30 is formed by laser autofusion welding. That is, the outer wall and the vertical wall of the cover plate 20 are welded by laser autofusion welding, so that the outer wall of the cover plate 20 and the vertical wall of the panel 10 are melted into a molten liquid. After the molten liquid cools, the weld structure 30 is formed.

[0036] During welding, the laser autofusion welding process is continuous, starting from one side of the cover plate 20 and continuously welding around the circumference of the cover plate 20, so that the weld structure 30 obtained after welding is formed in one go and presents a structure that continuously extends around the cover plate 20. Because the number of weld beads is small, welding deformation can be minimized.

[0037] The weld bead structure 30 extends downwards from the top edge of the cover plate 20 to at least the bottom edge of the cover plate 20. The depth of the weld bead structure 30 is greater than the thickness of the cover plate 20, achieving full penetration welding, improving the connection strength and sealing performance of the connection, and ensuring welding quality. In some embodiments, the weld bead structure 30 extends downwards from the top edge of the cover plate 20 to below the bottom edge of the cover plate 20, and the depth of the weld bead structure 30 is slightly greater than the thickness of the cover plate 20.

[0038] In some embodiments, the initial thickness of the cover plate 20 is 10 mm. During welding, the weld metallographic penetration depth is greater than 10 mm, that is, the initial weld bead structure 30 depth is greater than 10 mm. After machining, the thickness of the cover plate 20 may be less than 10 mm, and the thickness of a portion of the cover plate after the final water-cooled wall panel is manufactured is less than the initial thickness.

[0039] In some embodiments, the width of the transverse wall is ≥2mm, which can effectively prevent the molten pool from overflowing from the transverse wall into the flow channel during welding, and prevent weld penetration from affecting the flow channel structure. In some embodiments, the width of the transverse wall is 5mm.

[0040] In some embodiments, the water-cooled wall panel further includes multiple stiffening plates 40. The stiffening plates 40 are made of Q355B alloy plates, and are welded to the bottom surface of the panel 10. The stiffening plates 40 are welded into a frame.

[0041] Please see Figure 5 In some embodiments, a laser welding test method for water-cooled wall panels is provided, which is applied to welding water-cooled wall panels and includes the following process.

[0042] S1. By performing a trial weld on the first sample, the first welding process is obtained, providing a reasonable process basis for the subsequent simulated welding process of panel 10 and cover plate 20.

[0043] S2. Perform a second sample trial weld using the first welding process to simulate the welding process of the panel 10 and cover plate 20 of the water-cooled wall panel, providing a reasonable process basis for subsequent simulation of the full welding process of the water-cooled wall panel; if the simulation results meet expectations, formulate a second welding process based on the first welding process, and then proceed to step S3; if the simulation results do not meet expectations, proceed to step S1 and re-obtain the first welding process.

[0044] S3. Perform a trial weld on the third sample using the second welding process to simulate the entire welding process of the water-cooled wall panel. If the simulation results meet expectations, formulate a standard welding process based on the second welding process. If the simulation results do not meet expectations, proceed to step S2 and re-formulate the second welding process.

[0045] S4. Weld panel 10, cover plate 20, and stiffening plate 40 using standard welding process to obtain water-cooled wall panel. The standard welding process is obtained after two simulated welding tests in steps S2 and S3. During the simulated welding test, its rationality is greatly improved, which is conducive to improving the reliability of actual welding of water-cooled wall panel and improving the welding quality of water-cooled wall panel.

[0046] In some embodiments, step S1, the process of obtaining the first welding process by testing the first sample, includes the following steps.

[0047] S11. Provide two sets of first test plates, and determine the welding parameters for the two sets of first test plates. The structures and welding parameters of the two sets of first test plates are identical. Please refer to [link / reference]. Figure 6 The first test plate group includes a first test plate 101 made of 304 stainless steel and a second test plate 102 made of 304 stainless steel. Both the first test plate 101 and the second test plate 102 are flat plates without steps, and the thickness of the weld joints of the two is the same, which is 10mm. The welding parameters include welding power and welding speed.

[0048] S12. Weld the first test plate group based on welding parameters; the welding of the first test plate group includes the following process.

[0049] Clean the weld joints of the first test plate 101 and the second test plate 102. Then, splice the weld joints of the first test plate 101 and the second test plate 102 together. After splicing, the top surfaces of both are flush and the bottom surfaces are flush. Check and record the gap between the two to ensure that the gap is ≤0.1mm. The weld joint of the first test plate 101 is formed by the side structure of the first test plate 101 facing the second test plate 102, and the weld joint of the second test plate 102 is formed by the side structure of the second test plate 102 facing the first test plate 101.

[0050] Laser autofusion welding was used to weld the front sides of the weld joints of the first test plate 101 and the second test plate 102. The welding positions were the two opposite sidewalls of the weld joints of the first test plate 101 and the second test plate 102. The structure after welding is as follows. Figure 7 As shown, the welding power and welding speed are the welding power and welding speed determined in step S11, respectively. After welding, proceed to step S13.

[0051] S13. Determine whether the welding results of the first test plate group meet expectations, thereby verifying whether the planned welding power and welding parameters meet expectations. This includes the following process.

[0052] Visually inspect the weld joints of the first test plate 101 and the back of the weld joints of the second test plate 102; when the weld joints of the first test plate 101 and the back of the weld joints of the second test plate 102 are fully penetrated (e.g. Figure 8 As shown), the welding results of the first test group met expectations, meaning that the planned welding power and welding speed were able to penetrate the 10mm thick 304 stainless steel first test plate 101 and second test plate 102. Using the corresponding welding parameters of the first test plate group as the basic welding parameters, that is, using the planned welding power and welding speed of the first test plate group as the basic welding power and basic welding speed, step S14 was performed.

[0053] If the weld joint of the first test plate 101 and the back of the weld joint of the second test plate 102 are not fully penetrated, it indicates that the welding result of the first test plate group does not meet expectations, and the planned welding power and welding speed do not meet expectations. It is necessary to increase the welding power and / or decrease the welding speed, and then repeat steps S11-S13. Of course, in other embodiments, multiple first test plate groups can be set up, and different welding power and welding speed can be planned for each first test plate group, so as to verify the welding results corresponding to different welding power and welding speed at one time, select the welding power and welding speed that meet the expected welding structure as the basic welding power and basic welding speed, and then perform step S14.

[0054] Specifically, the two sets of first test plates were numbered 003 and 004 respectively. The welding results of the two sets of first test plates are shown in the table below. The welding results of the two sets of first test plates are in line with expectations.

[0055] Test plate number Test plate specifications Step width (mm) Assembly clearance (mm) Back overflow Weld inspection results 003 10×48×300mm+10×48×300mm none 0~0.05 none Visually, the back side appears to be fully melted. 004 10×48×300mm+10×48×300mm none 0~0.10 none Visually, the back side appears to be fully melted. S14. Provide 5 sets of second test plates, such as Figure 9As shown, each group of second test plates includes a third test plate 201 and a fourth test plate 202 made of 304 stainless steel. The weld joint of the third test plate 201 is formed by the side structure of the third test plate 201, which is flat and 10mm thick. The weld joint of the fourth test plate 202 is formed by the side structure of the fourth test plate 202, and it has a butt joint step. The structure of the butt joint step is the same as that of the step portion 12 of the cover plate 20. The butt joint step has a vertical step wall 204 and a transverse step wall 203 extending laterally from the bottom side of the vertical step wall 204.

[0056] S15. Weld the second test plate group based on the basic welding parameters. Simulate the welding process of the joint of the panel 10 and the cover plate 20 using the welding process of the joint of the third test plate 201 and the fourth test plate 202 to verify whether the basic welding parameters are applicable to the welding process of the joint of the panel 10 and the cover plate 20. Specifically, welding the second test plate group includes the following process.

[0057] The welding joints of the third test plate 201 and the fourth test plate 202 are joined together at the butt joint. The bottom wall of the welding joint of the third test plate 201 is opposite to the transverse step wall 203. The gap between the side wall of the third test plate 201 facing the vertical step wall 204 and the vertical step wall 204 is 0-0.04mm.

[0058] Laser self-fusion is used to weld the vertical step wall 204 of the weld head of the fourth test plate 202 and the side wall of the weld head of the third test plate 201 facing the vertical step wall 204; the welding power is the basic welding power obtained in step S13, and the welding speed is the basic welding speed obtained in step S13.

[0059] S16. Determine whether the welding results of the second test plate group meet expectations, including the following process.

[0060] Cut the welding positions of the third test plate 201 and the fourth test plate 202 along the direction perpendicular to the weld seam to obtain a cross-section of the welding position. The structure of this cross-section is as follows: Figure 10 As shown; the metallographic penetration depth of the weld joint after welding the joints of the third test plate 201 and the fourth test plate 202 can be inspected visually; when the metallographic penetration depth of the weld joint is greater than or equal to the thickness of the joint of the third test plate 201 (e.g. Figure 11 As shown in the figure, the welding results of the second test plate group met expectations, and the weld joint structure parameters of the second test plate group that met expectations were used as the basic weld joint structure parameters. The basic weld joint structure parameters include: the weld joint shape and size parameters of the corresponding third test plate 201, the weld joint shape and size parameters of the corresponding fourth test plate 202, and the assembly gap parameters of the weld joints of the corresponding third test plate 201 and the corresponding fourth test plate 202, when the welding results of the second test plate group met expectations.

[0061] The five sets of second test plates are numbered DJ-006, DJ-008, DJ-010, DJ-013, and DJ-014, respectively. Their specifications and test results are shown in the table below, and the test results all meet expectations. Therefore, the weld joint structure parameters of the five sets of second test plates can be used as the basic weld joint structure parameters.

[0062] Test plate number Test plate specifications (203mm width of the horizontal step wall) Assembly clearance (mm) back overflow Weld inspection results DJ-006 10×48×300mm+16×48×300mm 2mm 0~0.03 have Metallographic penetration depth: 10.71 mm DJ-008 10×48×300mm+16×48×300mm 2mm 0~0.04 have Metallographic penetration depth: 10.82 mm DJ-010 10×48×300mm+16×48×300mm 2mm 0~0.04 have Metallographic penetration depth: 10.65 mm DJ-013 10×48×300mm+16×48×300mm 2mm 0~0.03 have Metallographic penetration depth: 10.12 mm DJ-014 10×48×300mm+16×48×300mm 2mm 0~0.03 have Metallographic penetration depth: 10.19 mm S17. Based on the basic welding parameters and the basic weld joint structure parameters, formulate a preliminary welding process; the preliminary welding process includes the following steps.

[0063] At least one third test plate group is provided, which includes a seventh test plate and an eighth test plate. The weld joints of the seventh and eighth test plates are manufactured based on the structural parameters of the basic weld joint. That is, the structural parameters of the weld joints of the seventh and eighth test plates can be selected from one set of parameters among DJ-006, DJ-008, DJ-010, DJ-013, and DJ-014.

[0064] Based on the basic welding power and basic welding parameters, the third test plate group was welded using laser autofusion welding.

[0065] The mechanical properties and weld formation results of the third test plate group were tested. Specifically, the testing process included: testing the weld formation results using penetrant testing and ultrasonic testing, and testing the mechanical properties using transverse bending and transverse tensile tests.

[0066] S18. Verify the preliminary welding process. If the preliminary welding process meets expectations, formulate the first welding process based on the preliminary welding process.

[0067] The process of verifying the preliminary welding process includes the following steps.

[0068] Implement the preliminary welding process to determine whether the mechanical properties and weld formation results of the third test plate group meet the expectations. If both the mechanical properties and weld formation results meet the expectations, the preliminary welding process meets the expectations.

[0069] In some embodiments, the process of formulating a first welding process based on a preliminary welding process includes: formulating a first welding process based on the welding power, welding speed, and weld joint structural parameters of the preliminary welding process. Wherein, the welding power, welding speed, and weld joint structural parameters of the preliminary welding process are equivalent to the basic welding power, basic welding speed, and basic weld joint structural parameters.

[0070] In some embodiments, the proposed first welding process includes the following steps.

[0071] Provide a fourth set of test plates. For example... Figure 12 and Figure 13As shown, the fourth test plate group includes a ninth test plate 401 and three tenth test plates 402. The ninth test plate 401 has three first simulation grooves 4011. The structure of the first simulation grooves 4011 is the same as the structure of the groove 13 of the panel 10. The structure of the tenth test plate 402 is the same as the structure of the cover plate 20.

[0072] The first simulated groove 4011 has a first simulated stepped portion 4012, which surrounds the inner side of the groove opening of the first simulated groove 4011 and has a first simulated vertical wall and a first simulated horizontal wall. The first simulated vertical wall, the first simulated horizontal wall, and the side of the tenth test plate 402 are manufactured based on the structural parameters of the basic welded joint. The structural shape of the tenth test plate 402 is adapted to the groove opening shape of the first simulated groove 4011.

[0073] The tenth test plate 402 is assembled in the simulation tank, with the bottom side of the tenth test plate 402 abutting against the simulated transverse wall and the circumferential side of the tenth test plate 402 opposite to the simulated vertical wall.

[0074] Based on the basic welding parameters and basic welding speed, the outer wall and simulated vertical wall of the tenth test plate 402 were welded by laser autofusion welding, and the welding was carried out continuously along the circumference of the tenth test plate 402.

[0075] In some embodiments, step S2, which involves performing a second sample trial weld using a first welding process to simulate the welding process of the panel 10 and cover plate 20 of the water-cooled wall panel, includes the following steps.

[0076] The first welding process is implemented, and the welding results are inspected to determine whether the simulation results meet expectations. Specifically, the inspection process includes: inspecting the weld formation results using penetrant testing and ultrasonic testing; and visually inspecting the weld metallographic penetration depth by cutting the weld position and examining the cut surface. If the weld metallographic penetration depth and weld formation results meet expectations, a second welding process is formulated based on the welding power, welding speed, and weld joint structure parameters of the first welding process. The welding power, welding speed, and weld joint structure parameters of the first welding process are equivalent to the basic welding power, basic welding speed, and basic weld joint structure parameters.

[0077] In some embodiments, the second welding process includes the following steps.

[0078] Provide the fifth test panel group. (For example...) Figure 14 As shown, the fifth test board group includes an eleventh test board 501, at least one twelfth test board 502, and at least one thirteenth test board 504.

[0079] Multiple thirteenth test plates 504 are welded into a frame, and the back of the eleventh test plate 501 is welded to each thirteenth test plate 504; after welding, the flatness of the front of the eleventh test plate 501 is checked.

[0080] If the test is passed, the first annealing heat treatment will be carried out; if it fails, a second welding process will be devised.

[0081] After the first annealing heat treatment, the flatness of the front side of the eleventh test plate 501 was checked.

[0082] If the inspection is successful, the second simulated groove 503 is machined on the front side of the eleventh test plate 501. The second simulated groove 503 has a second simulated step portion 12, which surrounds the inner side of the groove opening of the second simulated groove 503 and has a second simulated vertical wall and a second simulated horizontal wall. The second simulated vertical wall, the second simulated horizontal wall, and the side of the twelfth test plate 502 are manufactured based on the basic weld joint structure parameters. If the inspection fails, the second welding process is re-planned.

[0083] After machining the second simulation tank 503, a second annealing heat treatment is performed.

[0084] After the second annealing heat treatment, the flatness of the front side of the eleventh test plate 501 was tested.

[0085] If the test is successful, deburr the eleventh test plate 501 and the twelfth test plate 502 and clean them with acetone; if the test is unsuccessful, a second welding process should be devised.

[0086] After cleaning, the twelfth test plate 502 is assembled in the second simulation tank 503, so that the bottom side of the twelfth test plate 502 abuts against the second simulation transverse wall, and the circumferential side of the twelfth test plate 502 is opposite to the second simulation vertical wall.

[0087] After assembly, spot welding is performed between the side of the 12th test plate 502 and the 11th test plate 501 to pre-position the 11th test plate 501 and the 12th test plate 502.

[0088] After tack welding, the gap between the eleventh test plate 501 and the twelfth test plate 502 is checked and recorded. Based on the basic welding parameters and the basic welding speed, the outer wall of the twelfth test plate 502 and the second simulated vertical wall are welded by laser autofusion welding. The welding is carried out continuously along the circumference of the twelfth test plate 502. During the welding, the welding parts are protected with argon gas.

[0089] After welding, the weld is inspected using ultrasonic waves. If weld defects are found, the defective area is locally cut to form a bevel, and then argon arc welding is performed on the bevel. After welding, weld defects are inspected using ultrasonic waves.

[0090] If no weld defects are found, the sample is vibrated using a vibration device to relieve stress; if weld defects still exist, a second welding process is devised.

[0091] After stress relief, the flatness of the outer wall surface of the sample is tested, and fluid is passed into the second simulation tank 503 of the eleventh test plate 501 to conduct a pressure test. The outer wall surface is composed of the front side of the eleventh test plate 501 and the side of the twelfth test plate 502 facing away from the eleventh test plate 501.

[0092] After the pressure test, ultrasonic testing was used to detect weld defects and to perform penetrant testing.

[0093] After all test results are satisfactory, the outer wall surface of the sample is milled flat; if the test results are unsatisfactory, a second welding process is devised.

[0094] After milling, fluid is continuously passed into the second simulation groove 503 of the eleventh plate for pressure testing.

[0095] After the pressure test, the flatness of the outer wall surface of the sample is checked. If the check is passed, it means that the performance of the sample meets expectations, that is, the simulation results meet expectations. If the check fails, a second welding process is re-planned.

[0096] In some embodiments, when the simulation results meet expectations, the process of formulating a standard welding process based on the second welding process includes: implementing the second welding process, verifying the welding results of the second welding process, and confirming that the simulation results meet expectations when the performance of the welded sample meets expectations. When the simulation results meet expectations, after replacing the eleventh test plate 501, the twelfth test plate 502, and the thirteenth test plate 504 of the second welding process with the panel 10, the cover plate 20, and the stiffening plate 40 of the water-cooled wall panel, respectively, the second welding process is then evaluated as a standard welding process.

[0097] In some embodiments, the preliminary welding process can be as follows: cleaning the weld joint → assembly → checking the assembly gap → tack welding → bottom argon gas injection → laser welding → PT testing → UT testing → sample cutting and sampling → mechanical testing → metallographic penetration testing.

[0098] In some embodiments, the steps of the first welding process may be: cleaning the welding head → assembly → checking the assembly gap → tack welding → bottom argon gas purging → laser welding → post-weld gap inspection → sample cutting and sampling → checking internal overflow → metallographic penetration detection.

[0099] In some embodiments, the steps of the second welding process can be: welding stiffeners into a frame structure → assembling and welding stiffeners, frames, panels, and reinforcing fixtures → post-weld flatness measurement → first annealing and flatness measurement → rough machining of the cooling water tank → second annealing and flatness measurement → completion of the cooling water tank finishing → residual stress testing → deburring and cleaning of the cover plate and water cooling tank → assembling the cover plate and panel → laser positioning welding → detecting assembly gaps → bottom argon gas protection → robot teaching programming → laser welding of the panel and cover plate → UT inspection → local rework welding of welds → UT inspection of the reworked weld area → post-laser welding flatness inspection → vibration stress relief → residual stress inspection → hydrostatic test → milling the cover plate → post-milling flatness measurement → hydrostatic test.

[0100] In some embodiments, the laser welding equipment for welding includes: a high-power laser system, a welding device, a robot system (including a robot body, a robot controller, and a robot teach programmer), a three-axis gantry machine tool and a worktable, a vertical rotary positioner, a horizontal rotary positioner, a main control system, and auxiliary equipment (a water chiller, a welding auxiliary device, laser radiation protective glasses, a voltage stabilizing facility, a wire feeding mechanism, etc.).

[0101] Among them, the high-power laser system can use a laser of not less than 12000W, with a rated output power of ≥12kW; laser output beam quality: ≤8.mard; transmission fiber length of not less than 30m, fiber core diameter of 200um or 400um; continuous output fluctuation at 100% rated power: ≤2%.

[0102] In some embodiments, a water-cooled wall panel is provided, the panel having a groove with a stepped portion, a cover plate being assembled on the stepped portion, and the cover plate being welded to the stepped portion using laser self-fusion welding. The weld structure formed after welding extends downward from the top edge of the cover plate to at least the bottom edge of the cover plate, increasing the connection area between the cover plate and the panel, improving the connection strength and sealing performance of the connection, and resulting in high welding reliability. In addition, the weld structure surrounds the cover plate and is formed in one pass, with fewer welds, minimizing welding deformation and further improving welding reliability.

[0103] In some embodiments, a welding test method for water-cooled wall panels is provided, the process of which includes: obtaining a corresponding first welding process by performing trial welding on a first sample; performing trial welding on a second sample using the first welding process to simulate the welding process of the panel and cover plate of the water-cooled wall panel; when the simulation results meet expectations, formulating a second welding process based on the first welding process; performing trial welding on a third sample using the second welding process to simulate the entire welding process of the water-cooled wall panel; when the simulation results meet expectations, formulating a standard welding process based on the second welding process; and welding the panel, cover plate, and stiffeners using the standard welding process to obtain the water-cooled wall panel. Through the aforementioned process, the manufacturing process of the water-cooled wall panel has been fully verified, thereby obtaining detailed data and forming a reasonable and feasible manufacturing process scheme for the water-cooled wall panel. This essentially eliminates the technical risks in the manufacturing of the water-cooled wall panel, improves welding reliability, provides a technical foundation for the subsequent first-piece manufacturing of products, and overcomes the key technologies of laser self-fusion welding and inspection of water-cooled wall panel cover plates, especially 10mm thick S30408 ​​material cover plates, without beveling.

[0104] In some embodiments of this application, a method for manufacturing a water-cooled wall panel is also provided, which is applied to the manufacture of water-cooled wall panels as described in any of the above embodiments. The method includes at least the following processes: milling grooves on the panel; assembling the cover plate and the panel; detecting the assembly gap and performing laser positioning welding; purging argon gas into the flow channel and performing laser self-fusion welding between the panel and the cover plate; performing flatness detection on the welded water-cooled wall panel and milling the cover plate. In the embodiments of this application, argon gas is directly purged into the flow channel through through holes to perform laser self-fusion welding between the panel and the cover plate. Through the groove structure and size design of this application, full penetration welding can be achieved, ensuring welding quality and minimizing cover plate deformation, thus meeting flatness requirements.

[0105] In some embodiments, the initial thickness of the cover plate is 10 mm, and the width of the transverse wall of the groove is greater than 2 mm. In some embodiments, the width of the transverse wall of the groove is equal to 5 mm. The assembly gap is adjusted and ensured to be 0.1~0.2 mm. By setting the width of the transverse wall to 5 mm and controlling the assembly gap to 0.1~0.2 mm, full penetration can be achieved while meeting the welding power and speed requirements. The penetration depth is greater than the initial thickness of the cover plate by 10 mm, and there is no overflow of the molten pool on the back side.

[0106] In some embodiments, the outer surface of the cover plate of the water-cooled wall panel requires high precision, with a flatness requirement of ≤1mm and a surface roughness of ≤3.2μm for a single water-cooled wall panel. In the embodiments of this application, the flatness of the welded water-cooled wall panel is tested, and the cover plate is milled to ensure flatness. In some embodiments, after milling the cover plate, the thickness of a portion of the cover plate after final water-cooled wall panel manufacturing is less than the initial thickness. In some embodiments, the initial thickness of the cover plate is 10mm. After milling, the thickness of a portion of the cover plate is less than 10mm, and the overall flatness of the water-cooled wall panel is less than 1mm.

[0107] In the specific implementation of the above embodiments, the technical features can be combined in any non-contradictory way. For the sake of brevity, not all possible combinations of the above technical features are described. However, as long as the combination of these technical features is not contradictory, it should be considered to be within the scope of this specification.

[0108] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A water-cooled wall panel, characterized in that, The device includes a panel (10) and multiple cover plates. The panel (10) is made of 304 stainless steel and has multiple grooves (13) on its top surface. The grooves (13) have a stepped portion (12) surrounding the groove opening. The stepped portion (12) includes a vertical wall and a transverse wall extending from the bottom side of the vertical wall toward the inside of the groove (13). The cover plates are made of 304 stainless steel. The bottom wall of the cover plate abuts against the transverse wall of the stepped portion (12), and the outer wall of the cover plate is opposite to the vertical wall of the stepped portion (12) and connected to the transverse wall of the stepped portion (12) through a weld structure (30). The weld structure (30) is formed by laser self-fusion welding. The weld structure (30) surrounds the cover plate and extends downward from the top edge of the cover plate to at least the bottom edge of the cover plate. The bottom surface of the cover plate and the inner wall of the groove (13) define a flow channel.

2. The water-cooled wall panel as described in claim 1, characterized in that, The weld structure (30) extends downward from the top edge of the cover plate to below the bottom edge of the cover plate, the width of the transverse wall is ≥2mm, and the thickness of the cover plate is not less than 9mm.

3. The water-cooled wall panel as described in claim 1, characterized in that, The water-cooled wall panel includes multiple stiffening plates (40), which are alloy plates made of Q355B material, and the stiffening plates (40) are welded to the bottom surface of the panel (10).

4. The water-cooled wall panel as described in claim 1, characterized in that, The flow channel has at least two through holes that connect to the outside. These through holes are used to introduce protective gas during the welding process and to allow cooling water to flow during operation.

5. A test method for laser welding of water-cooled wall panels, characterized in that, Its application in welding water-cooled wall panels as described in any one of claims 1-4 includes the following process: The first welding process was obtained by performing a trial weld on the first sample. The first welding process was used to perform a second sample test welding to simulate the welding process of the panel (10) and cover plate of the water-cooled wall panel; If the simulation results meet expectations, a second welding process is proposed based on the first welding process. The second welding process is used to perform a third sample trial welding to simulate the entire welding process of the water-cooled wall panel; when the simulation results meet expectations, a standard welding process is formulated based on the second welding process; the panel (10), the cover plate and the stiffener (40) are welded using the standard welding process to obtain the water-cooled wall panel.

6. The laser welding test method for water-cooled wall panels as described in claim 5, characterized in that, The process of obtaining the first welding process through trial welding of the first sample includes: Provide at least one set of first test plates, and formulate welding parameters for the first test plates; weld the first test plates based on the welding parameters; when the welding result of the first test plates meets expectations, use the corresponding welding parameters of the first test plates as basic welding parameters; the basic welding parameters include basic welding power and basic welding speed; Provide at least one set of second test plates; weld the second test plates based on the basic welding parameters; when the welding result of the second test plates meets expectations, use the weld head structure parameters of the second test plates as the basic weld head structure parameters; the basic weld head structure parameters include: when the welding result of the second test plates meets expectations, the weld head structure shape and size parameters of the corresponding third test plate (201), the weld head structure shape and size parameters of the corresponding fourth test plate (202), and the assembly gap parameters of the weld head of the corresponding third test plate (201) and the weld head of the corresponding fourth test plate (202); Based on the basic welding parameters and the basic weld joint structure parameters, a preliminary welding process is proposed; the preliminary welding process is verified, and if the preliminary welding process meets expectations, a first welding process is proposed based on the preliminary welding process.

7. The laser welding test method for water-cooled wall panels as described in claim 5, characterized in that, The first test plate group includes a first test plate (101) made of 304 stainless steel and a second test plate (102) made of 304 stainless steel. The weld joints of the first test plate (101) and the second test plate (102) have the same thickness, which is 10mm. The process of welding the first test plate group includes: The welding joints of the first test plate (101) and the second test plate (102) are spliced ​​together; after splicing, the top surfaces of the two are flush, and the bottom surfaces of the two are flush, with a gap of ≤0.1mm; the front surfaces of the welding joints of the first test plate (101) and the second test plate (102) are welded by laser self-fusion welding; after welding, the back surfaces of the welding joints of the first test plate (101) and the second test plate (102) are visually inspected; when the back surfaces of the welding joints of the first test plate (101) and the second test plate (102) are fully melted, the welding result of the first test plate group meets the expected welding test method; And / or, the second test plate group includes a third test plate (201) and a fourth test plate (202) made of 304 stainless steel; the thickness of the weld joint of the third test plate (201) is 10 mm, and the weld joint of the fourth test plate (202) has a butt joint step, the butt joint step having a vertical step wall (204) and a transverse step wall (203) extending laterally from the bottom side of the vertical step wall (204). The welding process for the second test plate group includes: The welding joints of the third test plate (201) and the fourth test plate (202) are joined together at the butt joint steps. The bottom wall of the welding joint of the third test plate (201) is opposite to the transverse step wall (203). The gap between the side wall of the third test plate (201) facing the vertical step wall (204) and the vertical step wall (204) is 0-0.04mm. The vertical step wall (204) of the weld joint of the fourth test plate (202) and the side wall of the weld joint of the third test plate (201) facing the vertical step wall (204) are welded by laser self-fusion. The metallographic penetration depth of the weld joint after welding the weld joint of the third test plate (201) and the weld joint of the fourth test plate (202) is detected; when the metallographic penetration depth of the weld joint is greater than or equal to the thickness of the weld joint of the third test plate (201), the welding result of the second test plate group meets the expectations; the structural parameters of the weld joint of the three test plates and the structural parameters of the weld joint of the fourth test plate (202) are used as the basic weld joint structural parameters.

8. The laser welding test method for water-cooled wall panels as described in claim 7, characterized in that, The preliminary welding process includes: At least one third test plate group is provided, the third test plate group including a seventh test plate and an eighth test plate, the weld joint of the seventh test plate and the eighth test plate is manufactured based on the structural parameters of the basic weld joint; the third test plate group is welded by laser autofusion welding based on the basic welding power and the basic welding parameters; the mechanical properties and weld formation results of the third test plate group are tested; The process of verifying the preliminary welding process includes: The preliminary welding process is implemented to determine whether the mechanical properties and weld formation results of the third test plate group meet expectations. If both the mechanical properties and weld formation results meet expectations, the preliminary welding process meets expectations. The process of formulating the first welding process based on the preliminary welding process includes: Based on the welding parameters of the preliminary welding process and the structural parameters of the welded joint, the first welding process is formulated.

9. The laser welding test method for water-cooled wall panels as described in claim 8, characterized in that, The process of formulating a second welding process based on the first welding process includes: formulating a second welding process based on the welding parameters and weld joint structure parameters of the first welding process; The second welding process includes: A fifth test plate group is provided, comprising an eleventh test plate (501), at least one twelfth test plate (502), and at least one thirteenth test plate (504); the structure of the eleventh test plate (501) is the same as the structure of the panel (10) of the water-cooled wall panel; the structure of the twelfth plate is the same as the structure of the cover plate of the water-cooled wall panel; the structure of the thirteenth test plate (504) is the same as the structure of the stiffener (40) of the water-cooled wall panel; the eleventh test plate (501) has at least one second simulated groove (503), the second simulated groove (503) has a second simulated step portion, the second simulated step portion surrounds the inner side of the groove opening of the second simulated groove (503), and has a second simulated vertical wall and a second simulated horizontal wall; the second simulated vertical wall The second simulated transverse wall and the side of the twelfth test plate (502) are manufactured based on the basic weld joint structure parameters; the second test plate (102) is assembled in the second simulated groove (503) so that the bottom side of the twelfth test plate (502) abuts against the second simulated transverse wall, and the circumferential side of the twelfth test plate (502) is opposite to the second simulated vertical wall; based on the basic welding parameters and the basic welding speed, the outer side wall of the twelfth test plate (502) and the second simulated vertical wall are welded by laser self-fusion welding, and continuous welding is performed along the circumferential direction of the twelfth test plate (502); the thirteenth test plate (504) is welded to the side of the eleventh test plate (501) facing away from the twelfth test plate (502); The process of formulating a standard welding process based on the second welding process when the simulated structure meets expectations includes: Implement the second welding process, verify the welding results of the second welding process, and when the welding results meet expectations, formulate a standard welding process based on the second welding process.

10. A method for manufacturing a water-cooled wall panel, characterized in that, Its application in the manufacture of water-cooled wall panels as described in any one of claims 1-4 includes the following process: Mill grooves on the panel; The cover plate is assembled with the panel; Inspect assembly gaps and perform laser positioning welding; Argon gas is purged into the flow channel to perform laser autofusion welding between the panel and the cover plate; The flatness of the welded water-cooled wall panel is checked, and the cover plate is milled.

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