The dilution rate of surfacing layers and the quality of weld forming are important factors affecting the quality of surfacing layers in open-arc surfacing. They are determined by the interaction of various surfacing parameters. In this paper, the response surface method is used to optimize the process parameters of open-arc surfacing welding. Mathematical models of the surfacing current, surfacing voltage, surfacing speed, dilution rate and weld residual height were established, and the reliability of the models was verified by variance analysis. By performing an analysis of the perturbation diagram and response surface diagram, the influence law of each influencing factor on the response value was obtained. The parameters of surfacing welding were optimized by setting optimization targets, and the experimental results of optimized parameters were compared with the predicted results. The optimized surfacing parameters were tested by grinding roller surfacing repair. The experimental results show that the quality of the grinding roller can meet the repair requirements. This shows that the model can be used to guide the surface repair of rollers and is of great significance to ensure the surface-repair quality of rollers.

The hydroturbine runner is the core of the whole hydroelectric generating unit, which is employed to transform water energy into mechanical energy. In the process of service, the runner frequently suffers from abrasion due to erosion and cavitation. Defects are usually repaired by welding. To acquire suitable weld cladding repair process parameters, a combination of experimental and numerical simulation was applied to investigate the temperature and weld residual stress distribution in the repair zone under the different welding repair approaches. The results illustrate that the temperature and welding residual stress distribution of the blade and the shroud are out of symmetry, the temperature conduction rate is faster on the blade side, and the high-stress zone is predominantly concentrated in the weld and its adjacent area. When the preheating temperature is up to 150 °C, the peak value of welding residual stress reaches a minimum of 796.29 MPa. The welding sequence can adjust the distribution trend of welding residual stresses. The welding sequence of three-stage welding can effectively reduce the welding residual stresses near the shroud at the water outlet side of the blade. The results of the study will provide theoretical guidance for the welding repair of hydraulic turbine runners.