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[1]张思,周名将,梁玉恒,等.脉冲电流作用下弯管裂尖熔池相变及流动模拟[J].油气储运,2025,44(02):1-18.
　ZHANG Si,ZHOU Mingjiang,LIANG Yuheng,et al.Phase transformation and flow simulation of weld pools at the crack tips of elbows under pulsed current[J].Oil & Gas Storage and Transportation,2025,44(02):1-18.
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脉冲电流作用下弯管裂尖熔池相变及流动模拟

《油气储运》[ISSN:1000-8241/CN:13-1093/TE] 卷: 44 期数: 2025年02期 页码: 1-18 栏目: 出版日期: 2025-02-25
Title:
Phase transformation and flow simulation of weld pools at the crack tips of elbows under pulsed current
作者:
张思; 周名将; 梁玉恒; 付必伟
长江大学机械工程学院
Author(s):
ZHANG Si;  ZHOU Mingjiang;  LIANG Yuheng;  FU Biwei
School of Mechanical Engineering, Yangtze University
关键词:
脉冲电流; 弯管; 裂纹修复; 熔池; 相变; 数值模拟
Keywords:
pulsed current;  elbow;  crack repair;  weld pool;  phase transformation;  numerical simulation
分类号:
TH17
文献标志码:
A
摘要:
【目的】利用脉冲电流修复弯管基体时，裂纹尖端处会产生绕流现象，使局部温度升高并生成熔池，熔池尺寸及其流动、凝固行为对裂纹愈合具有决定性作用。探究脉冲电流作用下弯管裂纹附近熔池的演化规律，并进一步研究裂纹尖端及前缘的愈合机制对脉冲电流管道裂纹修复技术的发展具有重要意义。【方法】使用Comsol软件，以含裂纹的NiCr21Mo高压弯管为研究对象，建立脉冲电流修复含裂纹的90°高压弯管有限元模型，在“电-热-结构”三场耦合的基础上添加“两相流-相场”多物理场耦合模型，进行熔池相变及流动模拟，分析脉冲电流放电时弯管裂纹熔池的演化规律及停止放电后的液相金属相变规律与流动特性。【结果】脉冲放电时长与间隔均会影响裂纹熔池产生影响。设置脉冲电流密度为2.4×108 A/m2，当放电时长达0.65 s时，熔池开始在裂纹尖端及裂纹前缘形成，形态呈U形柱状；当放电时长超过0.75 s后，裂纹附近外的其他区域开始熔化，部分液态金属蒸发，不利于裂纹愈合。停止放电后，熔池金属流速逐渐减慢，在0.008 s内完全凝固，前0.001 s内裂纹愈合效率最高。脉冲放电间隔应大于0.008 s，否则将影响下一次形成的熔池面积，导致修复性能降低。【结论】在脉冲电流作用下，裂纹尖端将形成U形柱状熔池，裂纹附近的液相体积随放电时间增加而增加。为充分发挥修复能力，应选择适宜的放电时长，使裂纹尖端及前缘充分发生相变并形成熔池，避免其他区域发生固液相变。同时，脉冲放电间隔应大于熔池液态金属凝固所需时间，否则将缩小熔池尺寸，降低修复效率。在实际利用脉冲电流修复高压弯管微裂纹时，可先通过仿真确定脉冲放电功率、时长与间隔，从而更加精准高效地修复弯管裂纹。
Abstract:
[Objective] In the base metal repair for elbows using pulsed currents, detour flow typically occurs at the crack tips, resulting in the formation of weld pools due to local temperature increases. The size, flow, and solidification behaviors of these weld pools, has a decisive effect on crack healing. Exploring the evolution patterns of weld pools near elbow cracks under the influence of pulsed currents, along with a further investigation into the healing mechanisms of crack tips and fronts, holds significant importance for the technological advancement of pipe crack repair utilizing pulsed currents. [Methods] A finite element model for repairing 90° high-pressure elbows with cracks using pulsed currents was established, based on Comsol software, focusing on NiCr21Mo high-pressure elbows with cracks. This model incorporated a multi-physical field coupling approach that combines “two-phase flow and phase field” within an “electrical-thermal-structural” three-field coupling framework. This integration allows for the simulation of phase transformation and the flow of weld pools. Further analysis explored the evolution patterns of weld pools near cracks in elbows during pulsed current discharge, as well as the phase transformation patterns and flow characteristics of the liquid-phase metal after halting the discharge. [Results] Both the duration and interval of pulse discharge were identified to be influential to the formation of molten pools associated with cracks.With a pulsed current density set at 2.4×108 A/m2, weld pools formed at the crack tips and fronts in U-shaped columns following current discharge exceeding 0.65 seconds. Beginning at 0.75 seconds of discharge, the melting effect extended from the regions around the cracks into the surrounding areas, and partial evaporation of the liquid-phase metal occurred, both of which are detrimental to crack healing. After the discharge was halted, the metal flow of the weld pools gradually slowed down, with crack healing efficiency peaking within the first 0.001 seconds, followed by complete solidification within 0.008 seconds. Consequently, a pulse interval greater than 0.008 seconds was identified as optimal to prevent adverse effects on the weld pool area during subsequent pulses, thereby enhancing repair performance. [Conclusion] The application of pulsed currents results in the formation of U-shaped columnar weld pools at the crack tip, with an increasing volume of liquid-phase material near the cracks as discharge time progresses. To maximize repair effectiveness, it is essential to select an appropriate discharge duration that allows for sufficient phase transformation at the crack tips and fronts, resulting in the formation of weld pools while avoiding solid-liquid phase transitions in surrounding areas. Additionally, the pulse discharge interval should be longer than the solidification time of the liquid metal in the weld pools. Otherwise, repair efficiency may decrease due to smaller weld pool sizes. It is advisable to determine the pulse discharge power, duration, and interval through simulations prior to repairing microcracks in high-pressure elbows using pulsed currents, thereby improving both the accuracy and efficiency of actual elbow crack repairs.

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备注/Memo

基金项目：国家自然科学基金资助项目“计算压裂泵头体寿命的‘无形边界’新方法”，52174018。
作者简介：张思，女，1990年生，副教授，2018年博士毕业于长江大学石油矿产机械专业，现主要从事疲劳与断裂方向的研究工作。地址：湖北省荆州市荆州区南环路1号，434023。电话：13872282477。Email：medeka@163.com
通信作者：付必伟，男，1988年生，副教授，2018年博士毕业于西南石油大学机械工程专业，现主要从事连续管工艺及装备，深部地热高效开采与余热回收技术，带压作业智能控制方向的研究工作。地址：湖北省荆州市荆州区南环路1号，434023。电话：18328080082。Email：fbw0910@126.com

更新日期/Last Update: 2024-12-09