面向超设计基准工况的核主泵推力轴承制造原理与方法

福岛核电事故后，我国华龙一号对核主泵提出了更严苛的安全性和可靠性要求：在全厂断电、设备冷却水缺失等超设计基准工况下，造成轴承高压顶起装置与润滑油换热失效，要求核主泵能安全可靠运行，推力轴承不发生损伤破坏，且核主泵能再次启动正常运转，给核主泵大直径重载推力轴承的设计与制造带来极大挑战。拟建立核主泵推力轴承润滑与冷却系统的流固热耦合模型，揭示不同使役工况下推力轴承的瞬态响应规律与失效机制；提出基于微纳协同和多种减摩填料复配效应的多尺度增强自润滑耐磨损复合材料轴瓦与推力盘摩擦副高性能界面设计制备技术；探索推力轴承基体-摩擦副材料与结构一体化形性协同制造工艺与表面改性处理方法，实现轴承表面完整性状态的调控；开展核主泵全尺寸推力轴承多使役工况综合性能测试评估。形成核主泵推力轴承材料-结构-工艺-性能集成化制造理论与方法，为我国核主泵轴承自主化设计与制造以及三代核电技术“走出去”战略实施提供理论支撑。

China's self-dependently designed third-generation nuclear power unit HPR1000 named as Hualong One has put forward stricter safety and reliability requirements for the reactor coolant pump (RCP) to avoid the disaster accident as occurred in Fukushima Daiichi nuclear power plant. The reactor coolant pump should keep to work without obvious damage on thrust bearings even subjected to the beyond design specification including the station black-out (SBO) accident, where the hydraulic pressure designed to separate the bearing counterparts lost due to the lack of electricity，and loss of Component Cooling Water System accident, where the viscosity friction heat accumulated due to the internal pumping and friction within the bearing system resulting in high working temperature to bearings. These special requirements bring with great challenges to trust bearing development. With the aim to reveal the transient responses of thrust bearings and its failure mechanism in different working conditions of RCP, the fluid-structure-thermal coupling model of thrust bearing system is to be established to predict the bearing working conditions. The design and process technology on multi-scale reinforced self-lubricating wear-resistant composite material, based on micro-nano collaboration and the compound effects of various fillers, is proposed for the design of friction pair of thrust bearings. The material-structure integration and shape-performance synergy manufacturing process on substrate and friction-pair of the thrust bearing are to be explored. And the surface/interface modification treatment methods on the thrust bearing of RCP are to be investigated to regulate its surface integrity. Finally, the comprehensive performance of full-size thrust bearing for RCP is to be tested in different service conditions to validate the integrated design and manufacturing strategy of the thrust bearings to supply fundamental basis for the development of 3rd generation nuclear power unit.