表面技术2025，Vol.54Issue(4)：38-54,17.DOI:10.16490/j.cnki.issn.1001-3660.2025.04.003
表面工程技术在大型水轮发电机组中的应用:进展与挑战
Application of Surface Engineering Techniques in Large Hydrogenerator:Progress and Challenges
摘要
Abstract
The large hydrogenerator is the powerful heart of a hydropower station,serving as the core equipment for hydropower energy conversion,ensuring the stability of the national power system and enhancing the quality of electrical power.The stable and safe operation of a hydrogenerator depends greatly on the performance of core components such as the runner,rotor and thrust bearings which usually work under harsh conditions,including water erosion,environmental corrosion,bio-corrosion,strong magnetic and electrical fields,high speed and high stress.Thus,serious damages can be easily caused on the surfaces of these components.Surface engineering techniques,which can obviously improve the surface properties of the material,have provided an effective approach for strengthening the surface and extending the life of key components of hydrogenerator units. Guided by the surface damage behavior of core components of hydrogenerator units,the present work has systematically discussed the application progress and beneficial prospects of typical surface engineering techniques in the hydropower industry based on actual requirements. The surface engineering difficulties of key components in hydrogenerator units,including the corrosion damage of the flow parts,insulation and anti-corona failure of the rotor and stator parts,surface cavitation erosion of the runner,surface abrasion of the wicket gates,defect repairing of the runner,surface grinding of the mirror plate,and repairing of the bearing surface,were systematically listed and discussed one-by-one in the first time.The real working environments of these components were analyzed to study the surface failure of the hydrogenerator units.Engineering attempts to solve the abovementioned problems were also discussed in the current work. The research status of typical surface engineering techniques in the hydrogenerator units in China and abroad was summarized.Although most of the surface engineering techniques have not been introduced into the hydropower industry,some of them have been successfully used in the field of surface protection of hydrogenerator equipment.For instance,thermal sprayed carbide coating has been synthesized to the surface of runner to improve its cavitation erosion resistance,epoxy anti-corrosion paints have been wildly used on the surface of metal spiral cases for corrosion protection,and a large number of insulating paints have been used on the surface of stator and rotor of generators to obtain excellent dielectric properties.These techniques have provided new ways for protecting the core components of hydrogenerator units,but their performance has met challenges for the long-term service of the hydrogenerator.Thus,the rapid development of state-of-the-art surface engineering techniques has been also overviewed,and their possible applications in the hydrogenerator units are prospected.As for the repairing and processing of the hydrogenerator components,there are still gaps between the maintenance requirements and the surface remanufacturing and modification techniques.Remanufacturing and modification techniques have to adapt to the scenario-based needs of the maintenance works,such as flexible assembly,small size,multiple functions,etc. In conclusion,the present work has systematically prospected the application and challenges of advanced surface engineering techniques in the hydrogenerator units from the perspectives of practical engineering needs and scientific research.关键词
水轮发电机组/表面工程/功能涂料/表面再制造/表面涂层Key words
hydrogenerator/surface engineering/functional coatings/surface remanufacturing/surface coatings分类
机械制造引用本文复制引用
陈雷雷,何强锋,成传诗,王少龙,吴涛,万刚,马明,娄明,常可可..表面工程技术在大型水轮发电机组中的应用:进展与挑战[J].表面技术,2025,54(4):38-54,17.基金项目
湖北省自然科学基金项目(2024AFB455) （2024AFB455）
中国长江电力股份有限公司科研项目(1524020002-4.1) Hubei Provincial Natural Science Foundation of China(2024AFB455) （1524020002-4.1）
Scientific Research Project of China Yangtze Power Co.,Ltd.(1524020002-4.1) （1524020002-4.1）
