Steel Hydrogen-Induced Degradation Diagnostics for Turbo Aggregated Rotor Shaft Repair Technologies

Rotor equipment material samples with varying degrees of degradation during long-term operation are characterized by lower (up to 17%) corrosion and hydrogen resistance compared to the initial state. The scheme of redistribution of carbides in structural components in the initial state and after long-term operation is presented. The schemes of the turning rotor shaft are visualized, while taking the microstructure features into account. During long-term service, the properties of steels are affected by changes in the parameters of structural components caused by the action of a hydrogen-containing environment. Based on the experimental data, the regression equation and approximation probability R2 value describing the change in the electrochemical parameters of 38KhN3MFA rotor steel samples after 200, 225, 250, and 350 thousand hours of operation were obtained. During machining, an increase in hydrogen content was recorded in the chips, especially from degraded areas of the rotor shaft (up to 7.94 ppm), while in undegraded zones, it ranged from 2.1 to 4.4 ppm. A higher hydrogen concentration was correlated with increased surface roughness. The use of LCLs improved surface quality by 1.5 times compared to LCLp. Dispersion caused by degradation contributed to hydrogen accumulation and changed the nature of material destruction. After repair, the rotors demonstrated stable operation for over 25 thousand hours, with no reappearance of critical defects observed during scheduled inspections.