Article(id=1147999692174123807, tenantId=1146029695717560320, journalId=1146123346816638986, issueId=1147999688122430098, articleNumber=1000-8063(2025)02-0119-07, orderNo=null, doi=10.13426/j.cnki.yky.2024.09.07, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1726243200000, receivedDateStr=2024-09-14, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1751634055416, onlineDateStr=2025-07-04, pubDate=1747670400000, pubDateStr=2025-05-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1751634055416, onlineIssueDateStr=2025-07-04, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1751634055416, creator=13701087609, updateTime=1751634055416, updator=13701087609, issue=Issue{id=1147999688122430098, tenantId=1146029695717560320, journalId=1146123346816638986, year='2025', volume='44', issue='2', pageStart='1', pageEnd='160', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1751634054451, creator=13701087609, updateTime=1759123795578, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1179413939365491632, tenantId=1146029695717560320, journalId=1146123346816638986, issueId=1147999688122430098, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1179413939365491633, tenantId=1146029695717560320, journalId=1146123346816638986, issueId=1147999688122430098, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=119, endPage=125, ext={EN=ArticleExt(id=1147999692480308027, articleId=1147999692174123807, tenantId=1146029695717560320, journalId=1146123346816638986, language=EN, title=Research and Practice of Improving the Yield of Electron Beam Welding of Fuel Rods, columnId=1175805041752556213, journalTitle=Uranium Mining and Metallurgy, columnName=MINING AND HYDROMETALLURGY, runingTitle=null, highlight=null, articleAbstract=

This paper focuses on the abnormal fluctuation of yield during the electron beam welding process of fuel rods. Considering that the main defects leading to the rejection of fuel rods are surface scratches and out-of-tolerance straightness, through analysis and research, it is clarified that the direct causes of the abnormal yield of fuel rods are the excessively large aperture of the welding tooling baffle, the excessive use of the welding top, and the design of the top bearing. By taking measures such as reducing the aperture of the baffle, determining the reasonable number of uses for the welding top, and designing the top bearing, defects can be controlled in a timely manner, the yield can be improved, the manufacturing cost can be further reduced, and a foundation can be laid for the subsequent exploration of fuel rod manufacturing processes.

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在燃料棒电子束焊接过程中,易出现成品率异常情况,其中表面划伤和直线度超差是燃料棒成品率异常的主要缺陷。通过分析,明确了焊接挡板孔径过大、顶头焊接使用次数过多和顶头无轴承设计等因素是造成燃料棒成品率异常的直接原因;通过缩小挡板孔径、确定顶头焊接合理使用次数、设计轴承等措施,及时控制缺陷,提高成品率,进一步降低了制造成本,研究结果为燃料棒制造工艺改进奠定了基础。

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付豪(1987—),男,四川仪陇人,硕士,高级工程师,主要从核燃料元件制造工作。

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付豪(1987—),男,四川仪陇人,硕士,高级工程师,主要从核燃料元件制造工作。

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付豪(1987—),男,四川仪陇人,硕士,高级工程师,主要从核燃料元件制造工作。

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北京: 高等教育出版社, 2019., articleTitle=null, refAbstract=null)], funds=null, companyList=[AuthorCompany(id=1179483428207607825, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, xref=null, ext=[AuthorCompanyExt(id=1179483428215996434, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, companyId=1179483428207607825, language=EN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, remark=CNNC Jianzhong Nuclear Fuel Co., Ltd., Yibin 644000, China), AuthorCompanyExt(id=1179483428220190739, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, companyId=1179483428207607825, language=CN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, remark=中核建中核燃料元件有限公司, 四川 宜宾 644000)])], figs=[ArticleFig(id=1179483429495259184, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=EN, label=Fig. 1, caption=Diagram of fuel rods, figureFileSmall=JaMCPXBfeMba4w/w7qb1RA==, figureFileBig=xTURhZtBnLyXNJimNFA2BQ==, tableContent=null), ArticleFig(id=1179483429566562353, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=CN, label=图1, caption=燃料棒示意图, figureFileSmall=JaMCPXBfeMba4w/w7qb1RA==, figureFileBig=xTURhZtBnLyXNJimNFA2BQ==, tableContent=null), ArticleFig(id=1179483429621088306, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=EN, label=Fig. 2, caption=Statistics of fuel rod defect types, figureFileSmall=MNEZFlEBV3WqTGpgavqBpQ==, figureFileBig=ONLm9KsOlsbw0zBVRgZK8g==, tableContent=null), ArticleFig(id=1179483429679808563, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=CN, label=图2, caption=燃料棒缺陷类型统计, figureFileSmall=MNEZFlEBV3WqTGpgavqBpQ==, figureFileBig=ONLm9KsOlsbw0zBVRgZK8g==, tableContent=null), ArticleFig(id=1179483429738528820, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=EN, label=Fig. 3, caption=Statistics of surface defect types, figureFileSmall=isodO2Z86GP2t7bP0OjWew==, figureFileBig=OxiN/wSOqGSz50RMI3MmMg==, tableContent=null), ArticleFig(id=1179483429801443381, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=CN, label=图3, caption=表面缺陷类型统计, figureFileSmall=isodO2Z86GP2t7bP0OjWew==, figureFileBig=OxiN/wSOqGSz50RMI3MmMg==, tableContent=null), ArticleFig(id=1179483429864357942, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=EN, label=Fig. 4, caption=Comparison pictures of metal splashes attached before and after clamp welding, figureFileSmall=9W7oRS44tqgDGX8WKBqebA==, figureFileBig=hFz0aUOBhqqjxcoGt1+p5A==, tableContent=null), 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articleId=1147999692174123807, language=CN, label=图9, caption=顶头改进后缺陷类型统计, figureFileSmall=WeLzBxMvNnQLB3yKbidiGg==, figureFileBig=E6v1XaU4sBj7Tn4o+6m3oA==, tableContent=null), ArticleFig(id=1179483430606749763, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=EN, label=Table 1, caption=

Influence of baffle aperture on surface scratches

, figureFileSmall=null, figureFileBig=null, tableContent=
试验组 焊接燃料
棒/支
挡板
孔径/mm
表面划伤
缺陷/支
表面划伤
占比/%
一组 100 10.00 3 3
二组 100 10.50 3 3
三组 100 11.00 4 4
四组 100 13.00 9 9
五组 100 14.00 16 16
), ArticleFig(id=1179483430682247236, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=CN, label=表1, caption=

挡板孔径对表面划伤的影响

, figureFileSmall=null, figureFileBig=null, tableContent=
试验组 焊接燃料
棒/支
挡板
孔径/mm
表面划伤
缺陷/支
表面划伤
占比/%
一组 100 10.00 3 3
二组 100 10.50 3 3
三组 100 11.00 4 4
四组 100 13.00 9 9
五组 100 14.00 16 16
), ArticleFig(id=1179483430761939013, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=EN, label=Table 2, caption=

Influence of the use number of top welding on surface scratches

, figureFileSmall=null, figureFileBig=null, tableContent=
焊接燃料
棒/支
顶头焊接
使用次数/次
表面划
伤数/支
表面划伤
占比/%
100 0 4 4
100 2 000 5 5
100 4 000 10 10
100 6 000 16 16
), ArticleFig(id=1179483430816464966, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=CN, label=表2, caption=

顶头焊接使用次数对表面划伤的影响

, figureFileSmall=null, figureFileBig=null, tableContent=
焊接燃料
棒/支
顶头焊接
使用次数/次
表面划
伤数/支
表面划伤
占比/%
100 0 4 4
100 2 000 5 5
100 4 000 10 10
100 6 000 16 16
), ArticleFig(id=1179483430879379527, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=EN, label=Table 3, caption=

Influence of the structure of the top bearing on straightness

, figureFileSmall=null, figureFileBig=null, tableContent=
顶头 焊接累
计数/支
飞溅物累
计数/颗
直线度
缺陷/支
直线度缺陷
占比/%
原顶头 100 3 3 3
200 8 4 4
300 12 5 5
改进后顶头 100 0 0 0
200 0 0 0
300 1 1 1
), ArticleFig(id=1179483430950682696, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=CN, label=表3, caption=

顶头轴承对直线度的影响

, figureFileSmall=null, figureFileBig=null, tableContent=
顶头 焊接累
计数/支
飞溅物累
计数/颗
直线度
缺陷/支
直线度缺陷
占比/%
原顶头 100 3 3 3
200 8 4 4
300 12 5 5
改进后顶头 100 0 0 0
200 0 0 0
300 1 1 1
), ArticleFig(id=1179483431013597257, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=EN, label=Table 4, caption=

Statistics of maximum static friction force of fuel rods when the top welding uses 1 000 times

, figureFileSmall=null, figureFileBig=null, tableContent=
顶头序号 最大静摩擦力/N
1 13.80 13.90 13.80 13.90
2 13.60 13.90 14.00 13.80
3 13.90 13.80 14.00 13.90
4 13.70 13.90 13.80 13.80
5 13.90 14.00 13.90 13.90
6 13.90 13.90 13.70 13.90
7 14.00 13.80 14.20 13.80
8 13.80 13.90 13.90 13.80
9 13.90 14.10 13.80 13.90
10 14.00 13.90 14.10 13.80
11 13.80 13.90 13.80 14.00
12 13.80 13.70 13.90 13.90
13 13.90 13.90 13.80 14.00
), ArticleFig(id=1179483431097483338, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=CN, label=表4, caption=

顶头焊接使用1 000次时燃料棒最大静摩擦力统计

, figureFileSmall=null, figureFileBig=null, tableContent=
顶头序号 最大静摩擦力/N
1 13.80 13.90 13.80 13.90
2 13.60 13.90 14.00 13.80
3 13.90 13.80 14.00 13.90
4 13.70 13.90 13.80 13.80
5 13.90 14.00 13.90 13.90
6 13.90 13.90 13.70 13.90
7 14.00 13.80 14.20 13.80
8 13.80 13.90 13.90 13.80
9 13.90 14.10 13.80 13.90
10 14.00 13.90 14.10 13.80
11 13.80 13.90 13.80 14.00
12 13.80 13.70 13.90 13.90
13 13.90 13.90 13.80 14.00
), ArticleFig(id=1179483431198146635, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=EN, label=Table 5, caption=

Reliability of maximum static friction force of different welding top usage times

, figureFileSmall=null, figureFileBig=null, tableContent=
焊接使用次数 R(F)
1 000 1-7.582 79×10-28
2 500 1-1.573 91×10-5
3 000 0.951 79
3 500 0.201 20
), ArticleFig(id=1179483431265255500, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=CN, label=表5, caption=

不同焊接使用次数顶头最大静摩擦力可靠性

, figureFileSmall=null, figureFileBig=null, tableContent=
焊接使用次数 R(F)
1 000 1-7.582 79×10-28
2 500 1-1.573 91×10-5
3 000 0.951 79
3 500 0.201 20
), ArticleFig(id=1179483431386890317, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=EN, label=Table 6, caption=

Maximum static friction force when the top welding uses 3 000 times

, figureFileSmall=null, figureFileBig=null, tableContent=
序号 最大静摩擦力/N
1 2 3 4 5 6 7 8 9 10
1组 13.5 13.0 13.3 13.1 13.1 13.2 13.0 13.1 13.2 13.3
2组 13.3 13.1 13.4 13.2 13.0 13.1 13.2 13.1 13.0 13.3
3组 13.0 13.2 13.5 13.3 13.2 13.1 13.0 13.2 13.1 13.2
), ArticleFig(id=1179483431474970702, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=CN, label=表6, caption=

顶头使用次数为3 000次时最大静摩擦力测量结果

, figureFileSmall=null, figureFileBig=null, tableContent=
序号 最大静摩擦力/N
1 2 3 4 5 6 7 8 9 10
1组 13.5 13.0 13.3 13.1 13.1 13.2 13.0 13.1 13.2 13.3
2组 13.3 13.1 13.4 13.2 13.0 13.1 13.2 13.1 13.0 13.3
3组 13.0 13.2 13.5 13.3 13.2 13.1 13.0 13.2 13.1 13.2
), ArticleFig(id=1179483431542079567, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=EN, label=Table 7, caption=

Material selection of the top

, figureFileSmall=null, figureFileBig=null, tableContent=
材料 选择依据 材料硬度 导热系数/
[W/(m·K)]
经济性/
(元/kg)
综合评价 结论
紫铜 导热性能好,硬度低,不易划伤燃料棒 布氏硬度(HB)约为35~45 386.4 约50 价格略高,但硬度低,导热性能较好 采用
黄铜 导热性能好,硬度低,不易划伤燃料棒 布氏硬度(HB)约为80~110 108.9 约28 经济性略好,硬度高,导热性能较差 不采用
), ArticleFig(id=1179483431613382736, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=CN, label=表7, caption=

顶头材质选择

, figureFileSmall=null, figureFileBig=null, tableContent=
材料 选择依据 材料硬度 导热系数/
[W/(m·K)]
经济性/
(元/kg)
综合评价 结论
紫铜 导热性能好,硬度低,不易划伤燃料棒 布氏硬度(HB)约为35~45 386.4 约50 价格略高,但硬度低,导热性能较好 采用
黄铜 导热性能好,硬度低,不易划伤燃料棒 布氏硬度(HB)约为80~110 108.9 约28 经济性略好,硬度高,导热性能较差 不采用
), ArticleFig(id=1179483431676297297, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=EN, label=Table 8, caption=

Dust-proof top processing inspection

, figureFileSmall=null, figureFileBig=null, tableContent=
检查项目 小顶头全长/mm 顶头座长/mm 顶头直径/mm 中心孔径/mm 检查结果
图纸要求 37.0±0.1 55.0±0.1 φ30.0±φ0.1 φ10.50±φ0.1 符合设计要求
实测值 36.94 55.06 φ30.04 φ10.54
), ArticleFig(id=1179483431730823250, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=CN, label=表8, caption=

防尘顶头加工检查

, figureFileSmall=null, figureFileBig=null, tableContent=
检查项目 小顶头全长/mm 顶头座长/mm 顶头直径/mm 中心孔径/mm 检查结果
图纸要求 37.0±0.1 55.0±0.1 φ30.0±φ0.1 φ10.50±φ0.1 符合设计要求
实测值 36.94 55.06 φ30.04 φ10.54
), ArticleFig(id=1179483431814709331, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=EN, label=Table 9, caption=

Experimental statistics of attached metal spatter before and after the top improvement

, figureFileSmall=null, figureFileBig=null, tableContent=
顶头轴类型 焊接累积数/支 顶头金属附着物累积数/颗
原顶头 100 3
200 8
300 12
改进后顶头 100 0
200 0
300 0
), ArticleFig(id=1179483431898595412, tenantId=1146029695717560320, journalId=1146123346816638986, articleId=1147999692174123807, language=CN, label=表9, caption=

顶头改进前后附着金属飞溅物试验统计

, figureFileSmall=null, figureFileBig=null, tableContent=
顶头轴类型 焊接累积数/支 顶头金属附着物累积数/颗
原顶头 100 3
200 8
300 12
改进后顶头 100 0
200 0
300 0
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提高燃料棒电子束焊接成品率的研究与实践
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付豪 , 王清平
铀矿冶 | 开采·选冶 2025,44(2): 119-125
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铀矿冶 | 开采·选冶 2025, 44(2): 119-125
提高燃料棒电子束焊接成品率的研究与实践
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付豪, 王清平
作者信息
  • 中核建中核燃料元件有限公司, 四川 宜宾 644000
  • 付豪(1987—),男,四川仪陇人,硕士,高级工程师,主要从核燃料元件制造工作。

Research and Practice of Improving the Yield of Electron Beam Welding of Fuel Rods
Hao FU, Qingping WANG
Affiliations
  • CNNC Jianzhong Nuclear Fuel Co., Ltd., Yibin 644000, China
出版时间: 2025-05-20 doi: 10.13426/j.cnki.yky.2024.09.07
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在燃料棒电子束焊接过程中,易出现成品率异常情况,其中表面划伤和直线度超差是燃料棒成品率异常的主要缺陷。通过分析,明确了焊接挡板孔径过大、顶头焊接使用次数过多和顶头无轴承设计等因素是造成燃料棒成品率异常的直接原因;通过缩小挡板孔径、确定顶头焊接合理使用次数、设计轴承等措施,及时控制缺陷,提高成品率,进一步降低了制造成本,研究结果为燃料棒制造工艺改进奠定了基础。

燃料棒  /  电子束焊接  /  表面缺陷  /  顶头  /  成品率

This paper focuses on the abnormal fluctuation of yield during the electron beam welding process of fuel rods. Considering that the main defects leading to the rejection of fuel rods are surface scratches and out-of-tolerance straightness, through analysis and research, it is clarified that the direct causes of the abnormal yield of fuel rods are the excessively large aperture of the welding tooling baffle, the excessive use of the welding top, and the design of the top bearing. By taking measures such as reducing the aperture of the baffle, determining the reasonable number of uses for the welding top, and designing the top bearing, defects can be controlled in a timely manner, the yield can be improved, the manufacturing cost can be further reduced, and a foundation can be laid for the subsequent exploration of fuel rod manufacturing processes.

fuel rod  /  the electron beam welding  /  surface defects  /  top  /  yield rate
付豪, 王清平. 提高燃料棒电子束焊接成品率的研究与实践. 铀矿冶, 2025 , 44 (2) : 119 -125 . DOI: 10.13426/j.cnki.yky.2024.09.07
Hao FU, Qingping WANG. Research and Practice of Improving the Yield of Electron Beam Welding of Fuel Rods[J]. Uranium Mining and Metallurgy, 2025 , 44 (2) : 119 -125 . DOI: 10.13426/j.cnki.yky.2024.09.07
燃料棒是核燃料元件的关键组成部分,其焊接质量直接影响燃料组件在堆内的运行安全[1]。目前,一般采用电子束焊接技术进行燃料棒制造,电子束焊接具有变形小、热影响区窄、接头性能优良等优点[2-9]。近年来,随着新建生产线投入运行,生产线稳定性对质量造成较大冲击;在生产中发现燃料棒的焊接缺陷较多,焊接成品率较低,影响燃料棒质量,增加制造成本。
燃料棒常见缺陷有表面缺陷、体积型缺陷和面型缺陷等[10-13]。李强等人对焊接表面缺陷中的气孔形成原理及裂纹产生机理进行了深度分析[14],也有对真空电子束焊接组织结构及焊接性等进行研究,但并未对焊接飞溅物对燃料棒表面缺陷的影响进行深入研究[15-18]。本研究基于表面划伤、气孔形成机理、轴承应用等基础,主要分析电子束焊接过程中飞溅物对燃料棒表面造成划伤和直线度缺陷等的原因,并通过对挡板孔径、顶头焊接次数和顶头轴承设计进行研究,采取切实有效的改进措施,及时控制缺陷,提升燃料棒的成品率。
燃料棒结构由上端塞、空腔、包壳管、UO2芯块、下端塞等零部件构成,见图1。燃料棒制造工艺为:包壳管制备→压下端塞→下端塞与包壳管焊接→UO2芯块装入焊接好的包壳管→压上端塞→上端塞与包壳管焊接,形成燃料棒。燃料棒焊接主要采用电子束焊接工艺。
2022年1—3月制造的燃料棒平均成品率下降约10%,燃料棒焊接缺陷较多(图2),其中表面缺陷占比为91.40%,表面缺陷是导致燃料棒焊接成品率偏低的主要原因。进一步对表面缺陷类型的统计(图3)表明,表面划伤和直线度缺陷占所有表面缺陷的89%,是造成燃料棒焊接成品率表面缺陷的主要因素。
金属飞溅物是指焊接后在夹头出现的最大直径超过0.10 mm的金属颗粒。夹头焊接前后附着金属飞溅物对比见图4。可以看出,当挡板孔过大时,焊接时穿过挡板孔的金属飞溅物多,在夹头内壁附着率高,会造成包壳管表面划伤。
挡板孔径实际为14.00 mm。为确认挡板孔径对表面划伤的影响,采用不同孔径(13.00、11.00、10.50、10.00 mm)的简易挡板进行焊接试验,在焊接束流8 mA、焊接时间10 s、工件转速35转/min的焊接条件下,对比研究使用不同孔径的挡板时燃料棒表面划伤情况(表1)。
表1可看出,挡板孔径减小后,表面划伤占比明显降低,当孔径为10.00 mm时有1只燃料棒在挡板处存在环向划痕缺陷。因此,挡板孔径较大时对表面划伤的影响程度较大。
在焊接过程中,顶头与端塞接触,确保燃料棒转动过程中直线度稳定,顶头一般采用铜质材料。顶头使用次数与端塞的接触面磨损程度有关,顶头使用次数越多,端塞的接触面磨损越大且接触面越光滑,最大静摩擦力越小。当最大静摩擦力小于伺服电机的输出拉力时,接触面会产生相对位移,导致燃料棒表面划伤。
通过测力计测得伺服电机传动皮带输出拉力为13 N,合理控制顶头焊接使用次数,使最大静摩擦力≥13 N,是较为理想的状态。若要进行最大静摩擦力测量,一般需停止焊接操作,这会影响生产进度;因此生产现场不会对顶头焊接使用数次后的最大静摩擦力进行测量,也未对顶头焊接使用次数进行规定。实际中,操作者在表面划伤出现频繁或划伤较多时才更换顶头。从相关操作岗位记录和生产量调查得知,操作者通常在顶头使用次数为5 000~6 000次时,更换顶头。
为确认顶头焊接使用次数对表面划伤的影响程度,在其他条件不变的情况下,选择同一个顶头在焊接使用次数分别为2 000次、4 000次、6 000次时继续焊接100支燃料棒,统计表面划伤情况,结果见表2。可以看出,焊接使用次数不同,对表面划伤的影响程度不同;使用次数越多,表面划伤占比越大。因此,顶头焊接使用次数过多对表面划伤的影响程度较大。
顶头轴承的主要作用是为顶头旋转固定位置并减少摩擦,同时防止因焊接时产生的金属飞溅物附着在小顶头和顶头座接触面而使顶头同轴度降低,产生直线度缺陷。为确认顶头轴承对燃料棒直线度的影响,加工顶头轴承,并对加工后的顶头结构与原顶头分别进行300支试验棒焊接试验,每焊接100支统计金属飞溅物累计数量和直线度缺陷情况,结果见表3。可以看出,顶头增加轴承设计后,直线度缺陷占比降低。因此,顶头轴承设计对燃料棒直线度缺陷的影响较大。
为了能最大程度阻止进入夹头内壁的金属飞溅物,又不让挡板与燃料棒产生刮擦;需确定挡板孔径,重新设计挡板。燃料棒直径为9.50 mm,挡板孔径应略大于燃料棒直径,结合表1数据分析,最终采用挡孔径φ10.50 mm、厚度1 mm、加工精度±0.10 mm的挡板,挡板材质为304不锈钢(图5)。
用测力计在旋转伺服电机的传动皮带上测量燃料棒和顶头接触界面的最大静摩擦力(简称燃料棒最大静摩擦力),并对13个不同顶头在焊接使用次数达1 000次时,分别进行4次最大静摩擦力统计(表4)。
顶头的静摩擦力(f)分布近似符合正态分布[19-20],使用可靠性分析方法建立顶头静摩擦力的可靠性相关函数。

$\left\{\begin{array}{l}\mathrm{R}\left(F\right)={\int }_{F}^{\infty }P\left(f\right)df\\ \mathrm{P}\left(f\right)=\frac{1}{2\sqrt{\mathrm{\pi }}\sigma }·{e}^{\frac{{(f-\mu )}^{2}}{2{\sigma }^{2}}}\\ E\left(x\right)=\mu,V\left(x\right)={\sigma }^{2}\end{array}\right.$

式中:R(F)—燃料棒最大静摩擦力可靠性函数;P(f)—静摩擦力正态分布函数;E(x)—静摩擦力分布的数学期望;V(x)—静摩擦力分布的标准差;μ—摩擦系数;σ2—方差。其中当焊接使用次数(i)为1 000时,μ=13.87,σ2=0.08。通过该模型,计算得到当顶头焊接使用次数为1 000、f≥13 N时,R(F)=1-7.582 79×10-28,约等于1。
因此,当顶头焊接使用次数为1 000时,更换顶头可靠性很高,但生产中还需考虑经济性。为找到合理的顶头焊接使用次数,根据该模型对不同的焊接使用次数进行可靠性分析。
分别对i=2 500、i=3 000、i=3 500的不同顶头进行最大静摩擦力统计,并将测得的最大静摩擦力进行可靠性分析(表5)。可以看出,为保证顶头最大静摩擦力有较高的可靠性,其顶头使用次数不应大于3 000次。在实际生产中,统计3组使用次数均为3 000次的顶头,并随机抽样10支燃料棒进行最大静摩擦力测量,结果见表6。可以看出,在顶头使用次数为3 000次时,静摩擦力均≥13 N。
在焊接时,顶头与燃料棒同步旋转。为降低焊接时金属飞溅物对顶头同轴度偏移量的干扰,专门设计轴承,将原顶头整体拆分为小顶头和顶头座2部分(图6),顶头座固定在工装内不旋转,小顶头在顶头座内旋转,小顶头和顶头座间通过轴承连接以减少摩擦并减小或避免径向受力。轴承设计主要作用:一是连接小顶头和顶头座;二是防止金属飞溅物及粉尘附着在小顶头和顶头座接触面而影响顶头同轴度,进而影响燃料棒直线度。
在采用真空电子束焊接时,燃料棒焊缝热量主要通过热传导方式从顶头和夹头散热;为提高焊缝性能,顶头需优选散热性能好、硬度低、不易划伤燃料棒的材质(表7)。对比紫铜和黄铜的各项物理性能,认为以紫铜作为顶头材质较合理。
在焊接时,通过对顶头的受力分析可知,该轴承不受径向剪切力,仅受小顶头轴向载荷,因此选用减少顶头旋转摩擦效果较好的推力球轴承。由于顶头在焊接时环境温度在300~400℃,通过调查、综合对比后最终选择固体润滑推力球轴承。
按照图纸进行加工。考虑到工装与设备的适配性,顶头轴承材质为不锈钢,外观尺寸应与原顶头一致。用游标卡尺对加工后的顶头进行测量,顶头设计尺寸和加工情况见表8,加工的顶头(图6)符合设计要求。
各部分配件设计加工完毕后,对顶头进行组装和实验,效果见图7,不同顶头附着金属飞溅物累计数测量结果见表9。可以看出,安装顶头轴承并焊接300支燃料棒后,顶头金属飞溅物累积数为0。
使用改进后顶头进行焊接生产,2022年7—9月期间燃料棒焊接成品率和燃料棒焊接缺陷数见图8~图9。可以看出,燃料棒焊接成品率提升10.41%,表面划伤占比由69.10%降至26.10%,直线度缺陷占比由19.90%降至11.70%,2种缺陷占比由现状调查期的89%降至37.80%。
导致燃料棒成品率异常的直接原因是挡板孔径过大、顶头焊接使用次数过多和顶头无轴承设计等因素,通过改进、优化研究,确定适宜的挡板孔径为10.50 mm,顶头焊接使用次数为3 000次,并且设计了固体润滑推力球顶头轴承。改进措施控制了燃料棒表面划伤和直线度超差等缺陷,表面缺陷占比由89%降至37.80%,燃料棒成品率提升10.41%。
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doi: 10.13426/j.cnki.yky.2024.09.07
  • 接收时间:2024-09-14
  • 首发时间:2025-07-04
  • 出版时间:2025-05-20
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  • 收稿日期:2024-09-14
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    中核建中核燃料元件有限公司, 四川 宜宾 644000
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2种不同金属材料的力学参数

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Percentage of
total species (%)

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种数
Number of
species
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Percentage of total
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鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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