CN102259187A - Method and device for manufacturing and repairing composite roll with high performance through laser spray forming - Google Patents
Method and device for manufacturing and repairing composite roll with high performance through laser spray forming Download PDFInfo
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- CN102259187A CN102259187A CN2011100818011A CN201110081801A CN102259187A CN 102259187 A CN102259187 A CN 102259187A CN 2011100818011 A CN2011100818011 A CN 2011100818011A CN 201110081801 A CN201110081801 A CN 201110081801A CN 102259187 A CN102259187 A CN 102259187A
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Abstract
The invention provides a method and device for manufacturing and repairing a composite roll with high performance through laser spray forming. A transition layer and a working layer of a roll are manufactured by utilizing the laser spray forming, the method for manufacturing and repairing the composite roll with the high performance through the laser spray forming is characterized by comprising the following specific steps: (A) removing greasy dirt on the surface of a roll core body, and sand-papering the surface of the roll core body to further remove the greasy dirt; (B) respectively putting material powder of the working layer and powder of a roll core into a powder feeding system, and starting laser spraying and synchronously feeding the powder to directly metallically manufacture an intermediate transition layer of the roll through the surface of the roll, the stroke of which is controlled by a robot arm; (C) realizing interlaced deposition by changing the direction of square facula and the movement direction of the robot arm after depositing a layer; and (D) manufacturing the working layer by the added functional materials on the surface of the transition layer through spray forming completely after the transition layer is formed. According to the device for manufacturing and repairing the composite roll with the high performance through the laser spray forming, a high-power short-wavelength laser is taken as a machining light source, and the facula of laser is reshaped to be rectangular, thus the quality of products through the spray forming is effectively improved and the speed of machining is increased.
Description
Technical field
The present invention relates to the laser technology application, reaction-injection moulding manufacturing of particularly a kind of high-performance composite roll laser and restorative procedure and equipment and device thereof.
Background technology
Laser technology has a wide range of applications in the roll industry at present, and technology such as laser quenching, laser roughening, laser remolten, laser alloying, laser melting coating have been widely used in the reinforcement and the reparation of roller surface.Though these technology have improved the wearability of roll to a certain extent, prolonged its service life.But because factor affecting such as Stimulated Light power, spot size, sweep speed and powder feeding rate, the speed of processing is relatively slow, only suitable breaker roll carries out the part to be repaired, and is difficult to whole large-area reparation of realization of breaker roll and regeneration, more can't be used for directly making roll.In addition because the energy density height of laser, laser action area little (spot size is generally a millimeter rank), in the process of laser melting coating or laser alloying, form add and exist bigger thermal stress and residual stress between material and the base material, very easily cause the crackle of repair layer, therefore the working lining of being processed in the present laser technology is thin (0.1-2mm) relatively, and in the present large-scale roller, its working lining generally is about several centimetres, so still there is not a kind of laser technology roll of can fundamentally repairing or regenerate at present.And present other restorative procedure such as Induction Quenching, equally also there are such or such problem in technique for overlaying and plasma spray technology, can't be used on a large scale in the process of the manufacturing of roll or reparation.
Roll is a kind of special operation material, and its volume is very big, but the just surperficial very thin one deck (several centimetres of thickness) of working lining.The working lining of roll is determining the quality of whole roll.In case working lining is worn, whole roll just will be worn.Therefore matrix material can be relatively inexpensive material (as a cast iron etc.) in the manufacturing of roll, only uses the long-life material of high-hardness, wearable (various ceramic materials etc.) in working lining.But because the high pressure that roll work the time is born, harsh conditions such as high-temperature, problem such as tend to cause the cracking of working lining and peel off has limited the large-scale application of composite roll.And in the present laser spray forming technology, processing from level to level realizes to material by light source just, the material of each layer can design as required, and very strong of the adhesion between layer and the layer, is fit to very much the composite roll that manufacturing has intermediate layer.Therefore how to utilize the laser spray forming technology to make the long-life NEW TYPE OF COMPOSITE roll of high abrasion and become the great and urgent problem that whole roll manufacturing industry is faced.
Summary of the invention
In order to solve the problem in the above-mentioned background technology, the invention provides a kind of method and device thereof that utilizes laser direct injection forming technique to make the long-life NEW TYPE OF COMPOSITE roll of low-cost high abrasion.It has made full use of the advantage of Laser Processing, combine the characteristic of roll own, mode by the multichannel powder feeding goes up by adding the method for intermediate layer (progressively increasing the mass ratio of working layer) at relatively inexpensive core of the roll matrix material (magnesium iron or carbon steel), realized the appearance high abrasion, the long-life working lining (high ferrochrome and WC etc.) and the superhigh intensity of core material combine, effectively suppressed working lining crackle and peel off, realized the maximum utilizationization of material, reduced spillage of material, reduced production cost, on technical equipment, utilize existing laser processing technology combining with digital control Robotics to invent the laser reaction-injection moulding voluntarily and make the equipment of high abrasion long-life composite roll and explored manufacturing process.
To achieve these goals, technical scheme provided by the invention is:
The reaction-injection moulding manufacturing of a kind of high-performance composite roll laser and restorative procedure and equipment utilize the laser reaction-injection moulding to make the transition zone and the working lining of roll, it is characterized in that its concrete grammar step is as follows:
A) remove the greasy dirt on the surface of roll core body, and with sand papering with its greasy dirt of further removal;
B) powder of working layer and the powder of roller core are respectively charged in the powder feed system, begin laser by roller surface and spray the intermediate layer that the synchronous powder feeding system direct metal is made roll by mechanical arm control stroke;
C) deposited after one deck, realized intertonguing by the direction of change square focus spot and the direction of motion of mechanical arm;
D) after transition zone was shaped, being shaped at the transition zone jet surface constituted working lining by the functional material that is added fully again.
As preferred version of the present invention, in the transition zone, the layer of injection and the mass percent of working layer between the layer and roller core material are between 10%～100%.
As preferred version of the present invention, before depositing, can change the proportioning of powder feeding by the control feeding head, the excessive layer material of shaping different materials proportioning next time.
As preferred version of the present invention, described dusty material is a Ni base alloy composite powder, wherein powder Ni base alloy powder granularity is 100 ± 20 μ m, the WC powder granularity is 90～180 μ m, Ni base alloy composite powder is formed: WC 20%, and Cr 15%, and B 3.0%, Si 3.5%, and C 0.7%.Fe 14%, and surplus is Ni.
As preferred version of the present invention, the power of described laser is 4KW; Spot size is: circular light spot diameter 0.2m～2mm, square focus spot size 1 * 5mm to 2 * 30mm; Connect width 20%～50% with front and back passage tower in the layer, every layer thickness is 0.2～0.8mm; Sweep speed is 0.5～2m/min.
A kind of manufacturing installation of composite roll; described device comprises laser instrument; focusing system; mechanical arm, workbench, motor; powder feed system and computer programming system; described mechanical arm is connected with laser instrument, and described motor is connected with roll and is positioned on the workbench, and described powder feed system comprises that protective gas interface, powder interface, left side powder shower nozzle, right side powder shower nozzle and cooling system form.
Further, described roll is by the anchor clamps control of being fixed on the workbench.
The beneficial effect that the present invention brought is:
(1) to the shaping of light beam: the light beam of laser output is a Gaussian beam, and Energy distribution is inhomogeneous, the low characteristics of high rim in the middle of presenting.By modes such as integration mirror with beam shaping become equally distributed square focus spot (1 * 10mm), realize the even distribution of energy density, increase the active area of hot spot simultaneously.
(2) automatic powder feeding system: in the powder shower nozzle, use two or more powder accumulators, therefore proportioning that can the powder that canbe used on line is different in process can progressively increase the mass percent (5%～100%) of working layer.The crackle that suppresses the new material added and matrix material performance to have big difference and cause.Save the time of changing powder, improved operating efficiency.Last working lining then can be fully the functional material by selected super wear-resisting high rigidity constitute (as Ni base alloy, Co base alloy, WC TiC) to improve the wearability of roll, increases the service life.
(3) utilize mechanical arm to the laser work head is controlled, can realize the three-dimensional motion of laser Machining head, realize processing complex part; And improved process velocity.Effectively overcome large-scale workpiece and moved inconvenient shortcoming
(4) tower connects mode, because it is rectangular (as 1 * 10mm) spraying the shape of the hot spot that uses in the processing, in the reaction-injection moulding process, along the roll axial deposition, with axial consistent, follow-up passage An and front passage An-1 carry out tower and connect hot spot than long one side earlier, after depositing complete side, change the direction of hot spot in end point, one side and the axial consistent reaction-injection moulding that carries out that hot spot is short, follow-up passage Bn and front passage Bn-1 carry out the tower that identical tower connects rate equally and connect.
(5) adopt high power (more than the 1000W), (the processing laser of 530nm～1060nm) effectively raises the absorptivity and the process velocity of light to the short wavelength, and per hour the processed powders amount reaches as high as 5kg/h.
Description of drawings
The structural representation of Fig. 1 apparatus of the present invention
Number in the figure is:
1-focusing system 2-laser beam 3-protective gas interface
4-powder interface 5-cooling system 6-roll
7-workbench 8-anchor clamps 9-motor
Powder shower nozzle 11-right side, 10-left side powder shower nozzle 12-numerical control robot
The specific embodiment
Below in conjunction with accompanying drawing preferred embodiment of the present invention is described in detail, thereby protection scope of the present invention is made more explicit defining so that advantages and features of the invention can be easier to be it will be appreciated by those skilled in the art that.
The reaction-injection moulding manufacturing of a kind of high-performance composite roll laser and restorative procedure and equipment utilize the laser reaction-injection moulding to make the transition zone and the working lining of roll, it is characterized in that its concrete grammar step is as follows:
A) remove the greasy dirt on the surface of roll core body, and with sand papering with its greasy dirt of further removal;
B) powder of working layer and the powder of roller core are respectively charged in the powder feed system, begin laser by roller surface and spray the intermediate layer that the synchronous powder feeding system direct metal is made roll by mechanical arm control stroke;
C) deposited after one deck, realized intertonguing by the direction of change square focus spot and the direction of motion of mechanical arm;
D) after transition zone was shaped, being shaped at the transition zone jet surface constituted working lining by the functional material that is added fully again.
In the transition zone, the layer of injection and the mass percent of working layer between the layer and roller core material are between 10%～100%.Before depositing, can change the proportioning of powder feeding by the control feeding head, the excessive layer material of shaping different materials proportioning next time.Described dusty material is a Ni base alloy composite powder, and wherein powder Ni base alloy powder granularity is 100 ± 20 μ m, and the WC powder granularity is 90～180 μ m, Ni base alloy composite powder is formed: WC 20%, and Cr 15%, and B 3.0%, Si 3.5%, and C 0.7%.Fe 14%, and surplus is Ni.The power of described laser is 4KW; Spot size is: circular light spot diameter 0.2m～2mm, square focus spot size 1 * 5mm to 2 * 30mm; Connect width 20%～50% with front and back passage tower in the layer, every layer thickness is 0.2～0.8mm; Sweep speed is 0.5～2m/min.
A kind of manufacturing installation of composite roll; comprise laser instrument; focusing system 1; mechanical arm 12, workbench 7, motor 9; powder feed system and computer programming system; described mechanical arm 12 is connected with laser instrument, and described motor 9 is connected with roll 6 and is positioned on the workbench 7, and described powder feed system comprises that protective gas interface 3, powder interface 4, left side powder shower nozzle 10, right side powder shower nozzle 11 and cooling system 5 form.
Described roll 6 is by anchor clamps 8 controls of being fixed on the workbench.
The manufacturing installation of a kind of composite roll as shown in Figure 1, after the laser beam 2 process focusing system shapings, shine on the roll 6, powder is via 4 inputs of powder feeding mouth, wherein dust mouth through 10,11 powder of sending are controlled the proportioning of powder in real time according to the reaction-injection moulding demand, anchor clamps 8 controls that roll 6 rotation is vertically driven by the motor 9 that is fixed on the Digit Control Machine Tool.
The detailed process of reaction-injection moulding is as follows: after having determined initialization point, the arm 12 of machining makes working head deposit to (x direction) along roll mandrel, after depositing a roll axial length, by motor 9 drives roll 6 is rotated to an angle, make follow-up passage Ln and front passage Ln-1 carry out tower and connect, mechanical arm 12 control working head motions deposit successively then; After depositing complete roll 6 sides, raise the thickness of 12 1 working linings of mechanical arm, rotary work head, rectangular light spots is revolved to be turn 90 degrees, change the mass percent of roller core material and working layer, deposit successively then, along roll mandrel after finishing reaction-injection moulding, motor 9 drives roll 6 rotations, makes follow-up passage and front passage carry out tower and connects.Once carry out reaction-injection moulding then, until the thickness that reaches required processing.
Concrete case study on implementation: high ferrochrome coating
At first, use gasoline, alcohol etc. are removed the greasy dirt and the rust on roll 6 surfaces, and use the grinder buffing roller surface, further remove the dirt on surface so that the deposition of sedimentary deposit.Then will be respectively with Fe powder and the high chrome iron powder powder feed system of packing into; regulate the flow velocity and flow and the proportioning of powder mass flow control system of protective gas and powder feeding gas to obtain required powder; open laser instrument; carry out the laser reaction-injection moulding on the roller core surface; earlier along roll 6 axial deposition, follow-up passage Ln and front passage Ln-1 carry out tower and connect, deposit complete roll 6 sides after; begin to rotate square operation light spot 90 degree in end point, adjust powder mixture ratio and deposit successively.Follow-up passage Mn and front passage Mn-1 carry out the tower that identical tower connects rate and connect.
Concrete technological parameter is as follows: laser power 4kw, and the light spot shape rectangle, long 10mm, wide 1mm, tower meet width 0.4mm, scan velocity V=0.6m/min.Layer thickness 0.3mm up and down.
High chrome iron powder composition is: C 2.7%, and Si 0.6%, and Mn 1.1%, P＜0.04, and S＜0.04, Cr 16%, Mo＜1.5%, Ni 1% surplus is Fe.
The above; it only is the specific embodiment of the present invention; but protection scope of the present invention is not limited thereto; any those of ordinary skill in the art are in the disclosed technical scope of the present invention; variation or the replacement that can expect without creative work all should be encompassed within protection scope of the present invention.Therefore, protection scope of the present invention should be as the criterion with the protection domain that claims were limited.
Claims (7)
1. high-performance composite roll laser reaction-injection moulding manufacturing and restorative procedure and equipment utilize the laser reaction-injection moulding to make the transition zone and the working lining of roll, it is characterized in that its concrete grammar step is as follows:
A) remove the greasy dirt on the surface of roll core body, and with sand papering with its greasy dirt of further removal;
B) powder of working layer and the powder of roller core are respectively charged in the powder feed system, begin laser by roller surface and spray the intermediate layer that the synchronous powder feeding system direct metal is made roll by mechanical arm control stroke;
C) deposited after one deck, realized intertonguing by the direction of change square focus spot and the direction of motion of mechanical arm;
D) after transition zone was shaped, being shaped at the transition zone jet surface constituted working lining by the functional material that is added fully again.
2. a kind of high-performance composite roll laser according to claim 1 reaction-injection moulding manufacturing and restorative procedure and equipment, it is characterized in that, in the transition zone, the layer of injection and the mass percent of working layer between the layer and roller core material are between 10%～100%.
3. a kind of high-performance composite roll laser according to claim 1 reaction-injection moulding manufacturing and restorative procedure and equipment, it is characterized in that, before depositing, can change the proportioning of powder feeding by the control feeding head, the excessive layer material of shaping different materials proportioning next time.
4. a kind of high-performance composite roll laser according to claim 1 reaction-injection moulding manufacturing and restorative procedure and equipment, it is characterized in that, described dusty material is a Ni base alloy composite powder, wherein powder Ni base alloy powder granularity is 100 ± 20 μ m, and the WC powder granularity is 90～180 μ m, and Ni base alloy composite powder composition is by weight: WC 20%, Cr 15%, B 3.0%, and Si 3.5%, and C 0.7%.Fe 14%, and surplus is Ni.
5. a kind of high-performance composite roll laser according to claim 1 reaction-injection moulding manufacturing and restorative procedure and equipment is characterized in that, the power of described laser is 4KW; Spot size is: circular light spot diameter 0.2m～2mm, square focus spot size 1 * 5mm to 2 * 30mm; Connect width 20%～50% with front and back passage tower in the layer, every layer thickness is 0.2～0.8mm; Sweep speed is 0.5～2m/min.
6. the manufacturing installation of a composite roll; it is characterized in that; described device comprises laser instrument, focusing system, mechanical arm; workbench; motor, powder feed system and computer programming system, described mechanical arm is connected with laser instrument; described motor is connected with roll and is positioned on the workbench, and described powder feed system comprises that protective gas interface, powder interface, left side powder shower nozzle, right side powder shower nozzle and cooling system form.
7. the manufacturing installation of composite roll according to claim 6 is characterized in that, described roll is by the anchor clamps control of being fixed on the workbench.
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| CN2011100818011A CN102259187A (en) | 2011-04-01 | 2011-04-01 | Method and device for manufacturing and repairing composite roll with high performance through laser spray forming |
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