AU2016253557B2 - A method for repairing a sprocket wheel by 3d printing - Google Patents

A method for repairing a sprocket wheel by 3d printing Download PDF

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AU2016253557B2
AU2016253557B2 AU2016253557A AU2016253557A AU2016253557B2 AU 2016253557 B2 AU2016253557 B2 AU 2016253557B2 AU 2016253557 A AU2016253557 A AU 2016253557A AU 2016253557 A AU2016253557 A AU 2016253557A AU 2016253557 B2 AU2016253557 B2 AU 2016253557B2
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sprocket wheel
repairing
laser
printing
laser cladding
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Inventor
Xueyun Du
Jianqun He
Yang Li
Qiwei Song
Fanliang TANTAI
Changsheng Tao
Fan Yang
Qingdong YANG
Feng Zhou
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Dazu Remanufacturing Co of Shandong Energy Machinery Group
Shandong Energy Heavy Equipment Manufacturing Group Co Ltd
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Dazu Remanufacturing Co of Shandong Energy Machinery Group
Shandong Energy Heavy Equipment Manufacturing Group Co Ltd
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    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
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    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
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    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
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    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/08—Ferrous alloys, e.g. steel alloys containing nickel
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/12—Ferrous alloys, e.g. steel alloys containing tungsten, tantalum, molybdenum, vanadium, or niobium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/32—Ferrous alloys, e.g. steel alloys containing chromium with boron
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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  • Organic Chemistry (AREA)
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Abstract

This present disclosure provides a method for repairing a sprocket wheel by 3D printing, which includes the following steps: (1) Scanning: scan a sprocket wheel to obtain space coordinates of the surface of the sprocket wheel; (2) Model processing and code generating: compare the space coordinates of the surface of the sprocket wheel with the space coordinates of the standard surface of the sprocket wheel to obtain a need-to-be-repaired 3D model, and generate numerical control codes by slicing the 3D model; (3) 3D printing: in an initial stage of the printing, the power of a laser is set at 1200~1500W; after printing for 0.5~1.5mm, the power of the laser is set at 600~80OW; (4) post-processing: conduct sand blasting and polish processing on the sprocket wheel after 3D-printing.By using the repairing method of this present disclosure, it can repair the worn part precisely, and adopting the double-coating laser cladding method can ensure the cladding layer and the base body bonded by a metallurgical method, and meanwhile, the hardness and the wear resistance of the repaired surface of the sprocket wheel is better than the new one's. Fig. 1 Fig. 2

Description

B33Y 30/00 (2015.01) B65G 65/06 (2006.01)
(21) Application No: 2016253557 (22) Date of Filing: 2016.11.01
(30) Priority Data
(31) Number (32) Date (33) Country
201610158778.4 2016.03.18 CN
(43) Publication Date: 2017.10.05 (43) Publication Journal Date: 2017.10.05 (44) Accepted Journal Date: 2018.01.18 (71) Applicant(s)
Shandong Energy Heavy Equipment Manufacturing Group Co., Ltd.;Shandong Energy Heavy Equipment Group Dazu Remanufacturing Co., Ltd.
(72) Inventor(s)
Zhou, Feng;Yang, Qingdong;Tantai, Fanliang;Yang, Fan;He, Jianqun;Tao, Changsheng;Du, Xueyun;Song, Qiwei;Li, Yang (74) Agent / Attorney
Madderns Patent & Trade Mark Attorneys, GPO Box 2752, ADELAIDE, SA, 5001, AU (56) Related Art
CN 102021568 B CN 203419984 U US 5160389 A US 5378427 A CN 105154870 A
OLIVEIRA et al., 'Analysis of coaxial laser cladding processing conditions'
Surface coatings and technology', 2005, Volume 197, No. 2-3, page 127-136, abstract and figure 5 on page 131.
2016253557 01 Nov 2016
ABSTRACT
This present disclosure provides a method for repairing a sprocket wheel by 3D printing, which includes the following steps: (1) Scanning: scan a sprocket wheel to obtain space coordinates of the surface of the sprocket wheel; (2) Model processing and code generating: compare the space coordinates of the surface of the sprocket wheel with the space coordinates of the standard surface of the sprocket wheel to obtain a need-to-be-repaired 3D model, and generate numerical control codes by slicing the 3D model; (3) 3D printing: in an initial stage of the printing, the power of a laser is set at 1200-1500W; after printing for 0.5-1.5mm, the power of the laser is set at 600-800W; (4) post-processing: conduct sand blasting and polish processing on the sprocket wheel after 3D-printing.By using the repairing method of this present disclosure, it can repair the worn part precisely, and adopting the double-coating laser cladding method can ensure the cladding layer and the base body bonded by a metallurgical method, and meanwhile, the hardness and the wear resistance of the repaired surface of the sprocket wheel is better than the new one’s.
1/1
2016253557 01 Nov 2016
Figure AU2016253557B2_D0001
Fig. 1
Figure AU2016253557B2_D0002
Fig. 2
2016253557 01 Nov 2016
A METHOD FOR REPAIRING A SPROCKET WHEEL BY 3D PRINTING
TECHNIC ALFIELD
The present disclosure mainly relates to the technical field of repairing mining 5 machinery, and more particularly to a method for repairing a sprocket wheel by 3D (Three Dimension) printing.
BACKGROUND
The scraper conveyor and the transfer conveyor are the most common and 10 important parts of the mining machinery, while the sprocket wheel is an important component of the scraper conveyor and the transfer conveyor. The drag chains of the scraper conveyor and the transfer conveyor are driven by the sprocket wheel, when the sprocket wheel runs, the gear teeth engage the chain link in turn to drive the scraper chain to do a continuous motion, so as to convey coals to the designated spot.
During the operation, the sprocket shaft set needs to bear the maximum torque of the whole equipment and support the fluctuating load and the additional load, and the operating condition is very terrible. During the using process in the pit, the sprocket wheel of the mining scraper conveyor suffers the alternating stress from the chain, thus the sprocket socket is easy to be worn, which causes that the sprocket wheel is not able to operate normally but to be abandoned. It is definitely a huge waste if not repair the worn part of the sprocket wheel. The tooth of the sprocket wheel and the sprocket socket have curved surface on which the existing repairing technologies are difficult to be used, which increases the difficulty of repairing the sprocket wheel.
SUMMARY
Aim at the current defects in the prior art, this present disclosure accordingly provides a method for repairing a sprocket wheel by 3D printing, the repairing method of the present disclosure is used to repair the worn part precisely and make the cladding layer and the base body to be completely metallurgical bonding by using a double-coating cladding method, meanwhile, the hardness and the abrasion resistance of the repaired surface of the sprocket wheel is better than a new one’s.
2016253557 01 Nov 2016
In order to achieve the aim as above-mentioned, this present disclosure provides a method for repairing a sprocket wheel by 3D printing, which includes the following steps:
(1) Scanning: scan a sprocket wheel to obtain space coordinates of the surface of 5 the sprocket wheel;
(2) Model processing and code generating: compare the space coordinates of the surface of the sprocket wheel with the space coordinates of the standard surface of the sprocket wheel to obtain a need-to-be-repaired 3D model, and generate numerical control codes by slicing the 3D model;
(3) 3D printing: in an initial stage of the printing, the power of a laser is set at
1200-1500W; after printing for 0.5-1,5mm, the power of the laser is set at 600-800W;
(4) post-processing: conduct sand blasting and polish processing on the sprocket wheel after 3D-printing.
Further, in step (3), the cutter lifting speed of the laser is set at 15 2000~3000mm/min, the linear speed is set at 600-1800mm/min,
Further, in step (3), the negative defocusing amount of the laser is set at 3~8mm, the feeding speed of the powder is set at 10~20g/min.
Further, in step (3), a base coating is printed by the laser firstly, and then a top coating is printed by the laser; the hardness of the top coating is higher than the hardness of the base coating; and the top coating and the base coating are respectively formed by alloy powder.
Further, the thickness of the mono-layer powder of the base coating is 0.3-0.6mm, and there are 3-5 layers in the base coating.
Further, the elements with respective quality percentages of the alloy powder 25 formed the base coating include that: Cr16-23%, MnO.4-1.2%, SiO.5-1%, Ni23-30%,
Mo2-4%, and the rest is Fe.
Further, the elements with respective quality percentages of the alloy powder formed the top coating include that: C 0.8-1.2%, Cr 3-5%, Mn 0.3-1.0%, Si 0.2-0.5%,
2016253557 01 Nov 2016
Ni 8-10%, Mo 3.0-5.0%, V 1.0-2.0%, W 5.0-6.0%, and the rest is Fe.
Further, the elements with respective quality percentages of the alloy powder formed the top coating include that: C 0.8-1.2%, Cr 3.0-5.0%, Mn 3.0-4.0%, Si 1.0-1.5%, Ni 0.5-2.0%, B 0.1-1.0%, V 1.0-2.0%, W 8.0-10.0%, and the rest is Fe.
Further, in step (3), a shielding gas is Argon with the flow of 300m3/h and the pressure of 0.3-0.5MPa.
Further, before step (1), the method for repairing a sprocket wheel by 3D printing further includes steps of: cleaning and polishing a to-be-repaired part of the sprocket wheel.
This present disclosure has these advantages as below:
1. In this present disclosure, the technology of 3D printing is used for repairing a sprocket wheel, so as to solve the difficulty of repairing the sprocket wheel with many curved surfaces ingeniously. The repairing is precise and controllable by using the technology of 3D printing, not only decrease the waste of the repairing materials, but also avoid extensive machining after the repairing and reduce the repairing cost.
2. In this present disclosure, the double-coating laser cladding is adopted, and the base coating is used to achieve the transition between the base body of the sprocket wheel and the top coating, and ensure the base body, the base coating and the top coating are bonded by a metallurgical method, so as to solve the bonding problem of the high-intensity alloy powder and the base body. The top coating which adopts high-intensity alloy can enhance the surface strength of the repaired sprocket wheel.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 illustrates a testing result of the hardness test of Embodiment 3 of the 25 present disclosure; and
Fig. 2 illustrates a testing result of the hardness test of Embodiment 7 of the present disclosure.
2016253557 01 Nov 2016
DETAILED DESCRIPTION
In order to make the skilled in this art understand the present disclosure better, the technical solution of the present disclosure will now be described more clearly and fully hereinafter together with embodiments of the present disclosure, which are not all of the embodiments of the present disclosure. According to the exemplary embodiments of this disclosure, all other similar embodiments obtained by those skilled in this art without any creative work belong to the protection scope of the present disclosure.
Embodiment One:
A method for repairing a sprocket wheel by 3D printing includes the following steps:
(1) Scanning: clean the to-be-repaired part of the sprocket wheel to remove the surface defect, the oxidizing material, the greasy dirty, etc., polish it to remove its fatigue surface and make it show the metallic luster by using grinding wheel, and scan the sprocket wheel in 3D to obtain the space coordinates of the surface of the sprocket wheel. It can achieve noncontact measurement by the technology of the 3D scanning, which is fast and highly precise.
(2) Model processing and code generating: compare the measured space coordinates of the surface of the sprocket wheel with the space coordinates of the standard surface of the sprocket wheel to obtain a need-to-be-repaired 3D model, and generate numerical control codes by slicing the 3D model.
(3) 3D printing: first, determine a base point of the part need to be repaired by using red laser spotting; and then, run the program, open the shielding gas, operate the powder feeder, and print to repair slice by slice. In an initial stage of the printing, the power of the laser is set at 1200-1500W; after printing for 0.5-1.5mm, the power of the laser is set at 600-800W, it can prevent the dilution rate of the cladding layer being too high by using this setting, and ensure the functions of the base coating and the top coating, meanwhile it is in favor of cooling during the printing by reducing the power of the laser after printing for a certain thickness. The cutter lifting speed of the
2016253557 01 Nov 2016 laser is set at 2000~3000mm/min, the linear speed is set at 600-1800mm/min, the negative defocusing amount of the laser is set at 3~8mm, the speed of feeding powder is set at 10~20g/min. The base coating is printed by the laser firstly, and then a top coating is printed, and the hardness of the top coating is higher than the hardness of the base coating. The thickness of the mono-layer powder of the base coating is 0.3-0.6mm, and there are 3-5 layers in the base coating. The shielding gas is Argon with the flow of 300m3/h and the pressure of 0.3~0.5MPa. The base body of the sprocket wheel is 42CrMo steel.
(4) post-processing: after 3D-printing, conduct sand blasting and polish processing on the sprocket wheel, process the repaired area of the sprocket wheel to reach the standard size. In this embodiment, the technology of 3D printing is used for repairing the sprocket wheel to solve the difficulty of repairing the sprocket wheel with many curved surfaces ingeniously. The repairing is precise and controllable by using the technology of 3D printing, not only decrease the waste of the repairing materials, but also avoid extensive machining after the repairing and reduce the repairing cost.
The elements with respective quality percentages of the alloy powder used to form the base coating include that: Cr 16-23%, Mn 0.4-1.2%, Si 0.5-1%, N i23-30%, Mo 2-4%, and the rest is Fe. There are high contents of Ni and Cr in this alloy powder, the friendly user interface of the cladding layer is promoted by fine wettability of Ni, and the corrosion resistance of the cladding layer is improved by using quite a high proportion of Cr with a low price. Additionally, the cladding layer has good ductility and toughness simultaneously because of using a certain amount of Mo. But when the composition percentage of Cr exceeds 15%, the strength and the hardness of the cladding layer may be decreased; when the composition of Ni is at a larger percentage, the toughness of the cladding layer may be reduced obviously, thus, the inventor of this present disclosure invents a new composition and content of the alloy powder for the base coating to make every component cooperate with each other, which makes the cladding layer not only have quite high hardness and a certain abrasive resistance, but also have good corrosion resistance and well toughness by using the alloy powder at a low cost, and also can make well bonding with the base
2016253557 01 Nov 2016 body of the sprocket wheel.
The elements with respective quality percentages of the alloy powder used to form the top coating include that: C 0.8-1.2%, Cr 3-5%, Mn 0.3-1%, Si 0.2-0.5%, Ni 8-10%, Mo 3.0-5.0%, V 1.0-2.0%, W 5.0-6.0%, and the rest is Fe. This alloy powder can achieve higher hardness, wherein the elements of Ni, Mn and Mo can form a stable austenite with self-hardening capacity, and the elements of W and V are strong carbide forming elements which can form fine and dispersive carbide, so as to make the cladding layer have a nice strength. Under the high temperature of laser cladding, the elements of Cr and Si can make the metal surface grow a compact oxidation film, which enhance the whole inoxidizability and the resistance to high temperature corrosive gases. In this present disclosure, the double-coating laser cladding is adopted, and the base coating is used to achieve the transition between the base body of the sprocket wheel and the top coating and ensure the base body, the base coating and the top coating are bonded by a metallurgical method, so as to solve the problem of bonding the high-intensity alloy powder and the base body. The top coating which adopts high-intensity alloy can enhance the surface strength of the repaired sprocket wheel.
Embodiment Two:
Herein, the parts which are same with Embodiment One are no longer repeated, which are different from Embodiment One include that:
The elements with respective quality percentages of the alloy powder formed the base coating include that: Cr 16%, Mn 0.4%, Si 0.5%, Ni 23%, Mo2%, and the rest is Fe.
The elements with respective quality percentages of the alloy powder formed the 25 top coating include that: C 0.8%, Cr 3%, Mn 0.3%, Si 0.2%, Ni 8%, Mo 3.0%, V
1.0%, W 5.0%, and the rest is Fe.
Embodiment Three:
Herein, the parts which are same with Embodiment One are no longer repeated, which are different from Embodiment One include that:
2016253557 01 Nov 2016
The elements with respective quality percentages of the alloy powder formed the base coating include that: Cr 20.4%, Mn 0.82%, Si 0.71%, Ni 26.5%, Mo 3.3%, and the rest is Fe.
The elements with respective quality percentages of the alloy powder formed the 5 top coating include that: C 1.0%, Cr 4%, Mn 0.7%, Si 0.4%, Ni 9%, Mo 4.0%, V
1.5%, W 5.5%, and the rest is Fe.
Do a hardness testing and a microstructure testing to the repaired sprocket wheel obtained through implementing this embodiment as follows:
The size of a sample is 10mmx10mmx10mm, after sand-papering and polishing, 10 conduct the hardness testing on the section of the sample using a micro-hardness tester of HVS-1 OOOAwith digital display, and the zone for taking a detecting point is cut across the base body, the bonding area, the base coating and the top coating. In order to observe conveniently, the detecting point is taken at an interval of 0.1 mm, and the area with a stable hardness value is taken at interval of 0.5mm. The result of the hardness testing is shown in Fig. 1, the horizontal ordinate denotes a distance to the surface of the base body (unit: mm), the vertical coordinates denotes the result of the hardness testing, the average hardness of the top coating is 660HV (58HRC), the average hardness of the base coating is 350HV (37HRC), the average hardness of the base body is 275HV (20-30HRC), therefore, the surface hardness of the sprocket wheel is evidently improved by the top coating. The result of the microscopic structure shows that the boning interface of the base coating and the base body and the boning interface of the base coating and the top coating are clear and smooth, presenting as metallurgical bonding. The top coating and the base coating are well-closed information with no defects.
Embodiment Four:
Herein, the parts which are same with Embodiment One are no longer repeated, which are different from Embodiment One include that:
The elements with respective quality percentages of the alloy powder formed the base coating include that: Cr 23%, Mn 1.2%, Si 1%, Ni 30%, Mo 4%, and the rest is
2016253557 01 Nov 2016
Fe.
The elements with respective quality percentages of the alloy powder formed the top coating include that: C 1.2%, Cr 5%, Mn 1%, Si 0.5%, Ni 10%, Mo 5.0%, V 2.0%, W 6.0%, and the rest is Fe.
Embodiment Five:
Herein, the parts which are same with Embodiment One are no longer repeated, which are different from Embodiment One include that:
The elements with respective quality percentages of the alloy powder formed the top coating include that: C 0.8-1.2%, Cr 3.0-5.0%, Mn 3.0-4.0%, Si 1.0-1.5%, Ni
0.5-2.0%, B 0.1-1.0%, V 1.0-2.0%, W 8.0-10.0%, and the rest is Fe. This alloy powder is a Cr-B-W-V series of multi-component intensified iron-based alloy with high-temperature and wear resistance, and it has a quite high hardness (HRC66-68). The elements such as Si and B are alloying elements with strong deoxidation and slaggability, and they can preferentially react with oxygen of the coating material and the oxide of the base body surface to generate the floating materials such as borosilicate with low melting point which floats on the surface of the furnace hearth, so as to reduce the oxygen contain and the slag inclusion and enhance the wettability and the processability of the base body and the coatings. The elements of Cr, W, V and B can form stereoplasm particle phrase to improve the whole abrasive resistance of the top coating, wherein the element of W also can increase the red hardness of the cladding layer.
Embodiment Six:
Herein, the parts which are same with Embodiment One are no longer repeated, which are different from Embodiment One include that:
The elements with respective quality percentages of the alloy powder formed the base coating include that: Cr 16%, Mn 0.4%, Si 0.5%, Ni 23%, Mo 2%, and the rest is Fe.
The elements with respective quality percentages of the alloy powder formed the
2016253557 01 Nov 2016 top coating include that: C 0.8%, Cr 3.0%, Mn 3.0%, Si 1.0%, Ni 0.5%, B 0.1%, V 1.0%, W 8.0%, and the rest is Fe.
Embodiment Seven:
Herein, the parts which are same with Embodiment One are no longer repeated, which are different from Embodiment One include that:
The elements with respective quality percentages of the alloy powder formed the base coating include that: Cr 19.2%, Mn 0.76%, Si 0.72%, Ni 27.4%, Mo 3.1%, and the rest is Fe.
The elements with respective quality percentages of the alloy powder formed the 10 top coating include that: C 1.02%, Cr 4.1%, Mn 3.55%, Si 1.23%, Ni 1.21%, B
0.56%, V 1.52%, W 9.2%, and the rest is Fe.
Do the hardness testing and the microstructure testing to the repaired sprocket wheel obtained by implementing this embodiment as follows:
The size of a sample is 10mmx10mmx10mm, after sand-papering and polishing, 15 conduct the hardness testing on the section of the sample by using a micro-hardness tester of HVS-1 OOOAwith digital display, and the zone for taking a detecting point is cut across the base body, the bonding area, the base coating and the top coating. In order to observe conveniently, the detecting point is taken at an interval of 0.1 mm, and the area with a stable hardness value is taken at interval of 0.5mm. The result of the hardness testing is shown in Fig. 2, the horizontal ordinate denotes the distances to the surface of the base body (unit: mm), the vertical coordinates denotes the results of the hardness testing, the average hardness of the top coating is 900HV (68HRC), the average hardness of the base coating is 345HV (36.8HRC), and the average hardness of the base body is 275HV (20-30HRC), therefore, the surface hardness of the sprocket wheel is evidently improved by the top coating. The result of the microscopic structure shows that the boning interface of the base coating and the base body and the boning interface of the base coating and the top coating are clear and smooth, presenting as metallurgical bonding. The top coating and the base coating are well-closed information with no defects.
2016253557 01 Nov 2016
Embodiment Eight:
Herein, the parts which are same with Embodiment One are no longer repeated, which are different from Embodiment One include that:
The elements with respective quality percentages of the alloy powder formed the base coating include that: Cr 23%, Mn 1.2%, Si 1%, Ni 30%, Mo 4%, and the rest is Fe.
The elements with respective quality percentages of the alloy powder formed the top coating include that: C 1.2%, Cr 5.0%, Mn 4.0%, Si 1.5%, Ni 2.0%, B 1.0%, V 2.0%, W 10.0%,
Contrast Testing One:
Detect the wear resistance by using MMU-10G microprocessor control machine with a high temperature friction wear testing machine, take the repaired sprocket wheel obtained from Embodiment Three of this present disclosure as a sample of the testing group one, take the repaired sprocket wheel obtained from Embodiment Seven of this present disclosure as a sample of the testing group two, and take 42CrMo base-body as the control group. After cleaning and drying, respectively take the weights before experiment as the weight-before-being-worn, and the conduct the counter grinding with 45-Steel for 1.5 hours, and then take the weights after cleaning and drying once again as after-experiment weights. Repeat the testing for each group three times and obtain the results as shown in Table one.
Table one
sample name Weight before being worn/g Weight after being worn/g Weight loss/g
testing group1-1 3.8525 3.8486 0.0039
testing group1-2 3.8520 3.8492 0.0028
testing group1-3 3.8514 3.8473 0.0041
testing group2-1 3.4780 3.4755 0.0025
testing group2-2 3.9395 3.9379 0.0016
2016253557 01 Nov 2016
testing group2-3 3.9388 3.9360 0.0028
control group-1 3.5640 3.4715 0.0325
control group-2 3.7396 3.7000 0.0396
control group-3 3.6385 3.5957 0.0428
As shown from Table one, the weight losses of the control group are greatly more than the weight losses of the testing group, so the wear resistance of the sprocket wheels repaired through the alloy powder from Embodiment Three and Embodiment Seven are improved clearly, so that the service life of the repaired sprocket wheel is prolonged.
Additionally, it should be understood that even though this specification is described as exemplary embodiments, each embodiment include not only one method solution, which is considered to make this specification clear. The specification should be deem as a whole by those ordinary skilled in this art, the method solution of every embodiment can be can be properly devised to form other embodiments understood by those skilled in this art.
2016253557 07 Nov 2017

Claims (4)

1. A method for repairing a sprocket wheel by laser cladding, comprising:
(1) Scanning: scanning a sprocket wheel to obtain space coordinates of the surface of the sprocket wheel;
(2) Model processing and code generating: comparing the space coordinates of the surface of the sprocket wheel with the space coordinates of the standard surface of the sprocket wheel to obtain a need-to-be-repaired 3D model, and generate numerical control codes by slicing the 3D model;
(3) Laser cladding: in an initial stage of the printing, the power of a laser being set at 1200-1500W; after printing for 0.5-1,5mm, the power of the laser being set at 600-800W;
(4) post-processing: conducting sand blasting and polish processing on the sprocket wheel after 3D-printing;
wherein: in step (3), a base coating is printed by the laser firstly, and then a top coating is printed by the laser; the hardness of the top coating is higher than the hardness of the base coating; and the top coating and the base coating are respectively formed by alloy powder, wherein the elements with respective quality percentages of the alloy powder formed the base coating include: Cr 16-23%, Mn 0.4-1.2%, Si 0.5-1%, Ni 23-30%, Mo 2-4%, and the rest is Fe.
2. The method for repairing a sprocket wheel by laser cladding according to Claim 1, wherein: in step (3), the cutter lifting speed of the laser is set at 2000~3000mm/min, the linear speed is set at 600~1800mm/min.
3. The method for repairing a sprocket wheel by laser cladding according to Claim 1, wherein: in step (3), the negative defocusing amount of the laser is set at 3~8mm, the feeding speed of the powder is set at 10~20g/min.
4. The method for repairing a sprocket wheel by laser cladding according to Claim 1, wherein: the thickness of the mono-layer powder of the base coating is 0.3-0.6mm, and there are 3-5 layers in the base coating.
2016253557 07 Nov 2017
5. The method for repairing a sprocket wheel by laser cladding according to Claim 1, wherein: the elements with respective quality percentages of the alloy powder formed the top coating include that: C 0.8-1.2%, Cr 3-5%, Mn 0.3-1.0%, Si 0.2-0.5%. Ni 8-10%, Mo 3.0-5.0%. V 1.0-2.0%. W 5.0-6.0%. and the rest is Fe.
6. The method for repairing a sprocket wheel by laser cladding according to Claim 1, wherein: the elements with respective quality percentages of the alloy powder formed the top coating include that: C 0.8-1.2%. Cr 3.0-5.0%. Mn 3.0-4.0%. Si 1.0-1.5%. Ni 0.5-2.0%. B 0.1-1.0%. V 1.0-2.0%. W 8.0-10.0%, and the rest is Fe.
7. The method for repairing a sprocket wheel by laser cladding according to any one of Claims 1-6, wherein: in step (3), a shielding gas is Argon with the flow of 300m3/h and the pressure of 0.3-0.5MPa.
8. The method for repairing a sprocket wheel by laser cladding according to Claim 7, before step (1), further comprising steps of: cleaning and polishing a to-berepaired part of the sprocket wheel.
1/1
2016253557 01 Nov 2016
Fig. 1
Fig. 2
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