CN1022895C - Fabrication of component by laser layered doposition - Google Patents

Fabrication of component by laser layered doposition Download PDF

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Publication number
CN1022895C
CN1022895C CN89109405A CN89109405A CN1022895C CN 1022895 C CN1022895 C CN 1022895C CN 89109405 A CN89109405 A CN 89109405A CN 89109405 A CN89109405 A CN 89109405A CN 1022895 C CN1022895 C CN 1022895C
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China
Prior art keywords
section
overlay cladding
welding
goods
cross
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CN89109405A
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Chinese (zh)
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CN1044777A (en
Inventor
万农·戴维·普拉特
韦尔伯·道格拉斯
艾力克·詹姆斯·惠特尼
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General Electric Co
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General Electric Co
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/005Repairing methods or devices
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20Direct sintering or melting
    • B22F10/22Direct deposition of molten metal
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/14Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
    • B23K26/144Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor the fluid stream containing particles, e.g. powder
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20Bonding
    • B23K26/32Bonding taking account of the properties of the material involved
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20Bonding
    • B23K26/32Bonding taking account of the properties of the material involved
    • B23K26/324Bonding taking account of the properties of the material involved involving non-metallic parts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34Laser welding for purposes other than joining
    • B23K26/342Build-up welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0255Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/30Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3033Ni as the principal constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/30Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3046Co as the principal constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/30Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053Fe as the principal constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/32Selection of soldering or welding materials proper with the principal constituent melting at more than 1550 degrees C
    • B23K35/325Ti as the principal constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/006Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine wheels
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00Restoring or reconditioning objects
    • B23P6/002Repairing turbine components, e.g. moving or stationary blades, rotors
    • B23P6/007Repairing turbine components, e.g. moving or stationary blades, rotors using only additive methods, e.g. build-up welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10Processes of additive manufacturing
    • B29C64/106Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00Articles made by soldering, welding or cutting
    • B23K2101/001Turbines
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/02Iron or ferrous alloys
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/08Non-ferrous metals or alloys
    • B23K2103/14Titanium or alloys thereof
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/18Dissimilar materials
    • B23K2103/26Alloys of Nickel and Cobalt and Chromium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/30Organic material
    • B23K2103/42Plastics
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/50Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00Materials to be soldered, welded or cut
    • B23K2103/50Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
    • B23K2103/52Ceramics
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/45Nc applications
    • G05B2219/45164Laser refurbish with laser beam and metal powder
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/45Nc applications
    • G05B2219/45238Tape, fiber, glue, material dispensing in layers, beads, filling, sealing
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/50Machine tool, machine tool null till machine tool work handling
    • G05B2219/50214Refurbish, refinish, reprofile, recondition, restore, rebuild profile
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00Aeronautics or air transport
    • Y02T50/60Efficient propulsion technologies, e.g. for aircraft

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Manufacturing & Machinery (AREA)
  • General Engineering & Computer Science (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Laser Beam Processing (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Powder Metallurgy (AREA)
  • Mounting, Exchange, And Manufacturing Of Dies (AREA)

Abstract

A component is fabricated by depositing a succession of overlying beads of a material, the pattern and position of the beads being assigned the proper characteristics of the corresponding section of the desired component. Shape definition is accomplished by characterizing the component as a series of sections or slices having the thickness of the bead, and programming a computer-controlled deposition head to deposit a succession of beads with the respective patterns and positions. Deposition is preferably by precision laser welding. Complex shapes having properties comparable to properties of forged or cast material are readily prepared. The material used in successive beads may be varied, producing a component of graded composition to achieve particular properties in various regions.

Description

Fabrication of component by laser layered doposition
The present invention relates to the goods manufacturing, relate in particular to and utilize the built-up welding of laser stratification to make the method for goods.
Improving manufacturing technology and material is the key of enhancing product performance and reducing cost.As an example, the mutual improvement in the constant ground of technology and material has caused the bigger raising of aircraft gas turbines performance.
Aircraft gas turbines or jet engine suck and compressed air by axial-flow compressor, with this compressed air and fuel mix, and this mixture that burns, and discharge this combustion product through the axial flow gas turbine that drives this compressor.This compressor comprises a wheel disc, and many blades extend from its circumference.This wheel disc rotates rapidly on an axle, thereby the blade of curved surface a bit sucks as electric fan and compressed air.
In present manufacturing practice, this compressor is made by this compressor disk of solid forging, and many grooves are arranged on its circumference.This compressor blade is cast separately or is swaged into has the root shape that is called " dovetail ", and they are complementary with groove in this wheel disc.Assembling is that the dovetail part slippage of blade is finished in the wheel disc groove.If certain blade also not exclusively is fit to, breaks down during running or impaired, linkage editor is reversed pulls down this blade and prepare a new blade, it can be replaced rapidly.
Recently, the someone advises blade and wheel disc integral body are together manufactured the system that is called " blisk " (blade and disk are formed a new word blisk-agent to be annotated), and this blisk manufacture method provides by reduction weight and improved potential of performance.This product can be cast or forge into a big trochal disc, at periphery additional metal is arranged.Then, these additional metals are processed into blade, it links to each other with described wheel disc is whole.These final products are made expensive, because it requires the operation of high accuracy processing widely.Even a processing of leaves error also can cause fault and the scratch of whole blisk.
With regard to this manufacture method, the replacing of the injured blade-section of blisk or repairing are difficult problems.If between on-stream period, for example, owing to all or part of that has sucked that outside impurity makes blade fractures, then this blisk becomes uneven.Will be with the method that does not cause that mode that performance reduces is come repairing damaged blade, it is reported does not at present also have.Therefore, need a kind of like this method.Adopt this method to reduce cost in blisk makes, this is desirable.The present invention satisfies this requirement, and relevant benefit is provided.
The object of the present invention is to provide a kind of method of utilizing the built-up welding of laser stratification to make goods, utilizing this method to make goods can reduce cost, also can improve Products Quality, control shape of products and profile easily, and allow the composition gradual change of goods.
The invention provides an a kind of part that is suitable for making with repaired item and product, such as the process of the blade of blisk.This process except have with another parts extra benefit made in one piece, can also produce a kind of on performance can with casting or the comparable product of product that forges.Previously use the impaired product made from quadrat method if utilize this process to repair one, then repaiied product and original in fact also indistinction.This process can be controlled simple and complicated shape and profile admirably, also allows the gradual change of product composition.The control that this composition changes designs a kind of property product that is suitable for the zones of different performance requirement that has for the designer offers an opportunity again conversely.
According to the present invention, a kind of method of utilizing the built-up welding of laser stratification to make goods is provided, these goods have reservation shape and are characterized by and have a plurality of parallel cross sections, and its each cross section has predetermined curve shape and thickness, said method comprising the steps of:
Utilize laser beam that dusty material is melted, and the material of fusion is piled coated with forming first overlay cladding by the curve shape in goods first cross section, the thickness of first overlay cladding is corresponding with the thickness in first cross section;
Utilize laser beam that dusty material is melted, and the material of fusion piled coated with forming second overlay cladding by the curve shape in goods second cross section and local at least first weld overlay materials that covers, the thickness of second overlay cladding is corresponding with the thickness in second cross section; And
Utilize laser beam that dusty material is melted, and the material of fusion piled coated with forming continuous overlay cladding by the curve shape in each corresponding cross section of goods, the local cross section of its lower floor and the cross section of its lower floor of local offset of covering, at least one cross section in the continuous cross section, therefore, the original relatively resurfacing welding material of overlay cladding at least one place, cross section in the continuous cross section is local not supported, formed the part that overhangs, and, the thickness in the corresponding cross section on the thickness of each overlay cladding and each overlay cladding about equally, on each continuous cross section, form each overlay cladding continuously, until finishing goods.
According to the preferential special applications of the present invention, make the process that becomes the compressor blade of integral body with compressor disk and comprise and be provided at some steps that it has the compressor disk of a stromal surface on every side; The built-up welding first welding bead material is in stromal surface, and this welding bead has the aerofoil profile and the position of the compressor blade of contiguous compressor disk; The a series of welding bead materials of built-up welding, each welding bead is overlapped in a built-up welding welding bead, and each welding bead has the aerofoil profile and the position of compressor blade corresponding position.If the section of blade is thicker than single welding bead, then can constitute one deck by two or more welding beads side by side of built-up welding, the more then overlapping built-up welding of welding bead group forms several layers subsequently in this layer.
Many products can be decomposed into the sub-assembly of some sections that are parallel to each other or section, are its shape and size by the aerofoil profile of stipulating each section, and the position of each section, and promptly the correlation of it and adjacent section has been determined this product with regard to monodrome ground.The aerofoil profile of each section is by means of the resurfacing welding material of welding bead, can controlled formation, and wherein welding bead generally is to rely on respect to thermal source to move basic unit and the built-up welding of the elongation that forms.Situation since it is so, just can manufacture a product: by a certain section wing shape built-up welding one welding bead (if needs with such method, several roads of built-up welding welding bead side by side), then build-up welding apparatus is upwards raised this welding bead height, another welding bead of built-up welding subsequently, it has the aerofoil profile of needed next section and with respect to the position of last bead welding.This process repeats many times by the needs of making product.
For example, certain compressor blade width is narrow, is in 1/8 inch magnitude, is a kind of weld width of the easy built-up welding of laser soldering device.Each section is with the single pass welding built-up welding of laser soldering device.One works as this welding bead is welded into, and this soldering tip is upwards raised this welding bead height, generally is about 0.015 inch, and next section is by the built-up welding of single laser weld welding bead.During each welding bead built-up welding, the top of the last built-up welding welding bead of laser weld build-up welding apparatus fusing (under the first welding bead situation is matrix), and add more material through its powder feeder unit and form overlapping welding bead.The new interpolation material of overlapping welding bead and the melt portions of last bead welding are partly mixed mutually and are solidified togather, and have guaranteed that whole welding bead has a continuous strong tissue.
Can make many kinds of shapes and profiled outline by means of this method.Solid shape can be stacked in that method of bead welding obtains on another by one.Increase width can by in each layer abreast a few row's welding beads of built-up welding, increase more welding bead more than the layer at this then and obtain.The parts of varied in thickness can obtain by the number of weld passes in changing certain layer.The airfoil fan of hollow or other hollow shape can by along its outer wall shape bead welding, then one on another other welding bead of built-up welding make.Hollow section with internal structure such as the cooling duct, is made by rib in adding on each section and analog.In fact, it is the set of a series of welding beads that Any shape can both be defined as, thereby method of the present invention has the versatility of making these multiple shapes.General aircraft engine is used and is comprised that compressor blade, gas turbine blades, propeller blade, housing and casing, the latter are square, rectangle or irregular cross section.
With the privileged components that the present invention makes, promptly compressor blade generally has complicated air foil shape, comprises two-dimensional curvature.During each welding bead built-up welding, parts are moved with respect to welding built-up welding head along a certain curved path, and this moves by moving these parts and reaches, or reach by mobile welding bead build-up welding apparatus, or by moving both reach, just can easily introduce this product to one dimension curvature.Another dimension curvature is introduced from a last section one in a small amount by being displaced sideways each section.
The control of built-up welding be by will such as the blade on the figure or by the shape of product of more traditional parts of preparing such as machine-tooled method in addition numerical characteristicization finish.In case the shape of these parts is by after the numerical characteristicization, utilize existing digital control computer program these parts move (the built-up welding head moves too) compiled program, with obtain during each welding bead built-up welding about this part displacements and welding bead between the instruction image of lateral displacement.The product that is obtained has very accurately reproduced the shape of numerical characteristicization, comprises the curvature of the complexity of aerofoil profile or analog.
Laser welding technology is sprayed on the powder feed fusing and the material that will melt on a certain surface.This method is controlled, and has produced the high-precision result that can reproduce.In the process that manufactures a product with this method, the composition of the powder that supplies can remain unchanged on entire product.Perhaps also can make the composition of the powder that supplies in arbitrary welding bead or between continuous welding bead, have a mind to change, on entire product, produce controlled composition and change.For example, in a compressor blade, the place can adopt tough and tensile alloy near blade root, and the hard antifriction alloy that close blade tip place adopts.
For repaired item, need only repeat the built-up welding characterization program of the previous establishment of a part.For example, if a compressor blade fractures in nearly center, need only grinding one plane, the built-up welding of the blade remainder of repetitive computer control then on corresponding to the most close remaining blade that does not decrease section.Blade through repairing is in fact as broad as long with original blade of making, and makes because it uses the same method, and has same shape control aerofoil profile.Position through repairing is not aware of the fusion boundary line from microphoto after polishing, also can't see the discontinuity with the blade root position, because the two is to be used in the same quadrat method that is adopted when making this blade to weld together.
Adopt the method for the present invention can be with various material built-up welding.For example, can the built-up welding titanium alloy, nickel alloy, cobalt alloy, ferroalloy, pottery and plastics.
The present invention has advanced a great step manufacturing technology.Complicated parts can be made with another parts are whole together, after adding through machine, have been not aware of the fusion boundary line with photomicrography.Shape and its local composition with regard to product have great adaptability.Employing same process when original the manufacturing, the built-up welding of computerizeing control helps repairing.Its its feature of the present invention and advantage are used for the more detailed narration following preferential embodiment carried out together with accompanying drawing and can be obviously, and it illustrates principle of the present invention by example.
The accompanying drawing summary
Fig. 1 is the blade of whole compressor disk, i.e. the perspective view of blisk;
Fig. 2 is the enlarged perspective of Fig. 1 blade-section;
Fig. 3 is the front view of Fig. 2 blade;
Fig. 4 is the top view of Fig. 2 blade;
Fig. 5 represents at the summary of the representational welding bead A of 4 shown in Fig. 3, B, C and D;
Fig. 6 is the front view in order to the laser soldering device of implementing process of the present invention.
The present invention preferentially is implemented in the technical process of making or repairing with the whole compressor blade of compressor disk one-tenth, but the present invention is not limited to this.With reference to Fig. 1, the entire combination of a compressor disk 10 and many compressor blades 12 has constituted a blade/wheel disc sub-assembly, and promptly blisk 14.This is taken turns disc portion 10 and is general garden cylindricality wheel disc, and a wheel rim 16 is arranged around it.Some blades 12 16 are sentenced correct position and method is connected in the wheel disc portion at the edge, when blisk 14 rotates, suck and compressed air (in Fig. 1 for for the purpose of clear, at a small amount of blade 12 that only draws on every side of wheel disc portion.The littler blade of many spacings is arranged usually).
Fig. 2 has represented blade-section 12 in further detail.Blade-section 12 integral body are connected in wheel rim 16.Be that manufacturing is not connected on the wheel rim blade then as single-piece.Blade and wheel rim 16 structurally are whole, and 12 form a kind of continuous tissue from wheel rim 16 to blade.
Blade 12 is normally according to the aerofoil profile to the determined a kind of complexity of detailed calculated of the best mode of air compression.The axial-flow compressor of gas turbine generally includes many level compressors, and the accurate shape and size of each blade-section are different between at different levels.Yet in general, blade-section 12 is along two direction bendings.That is, if constitute a rectangular coordinate system by the radius 18 of wheel disc 10 and the tangent to periphery 20 of wheel rim 16, then at least some part of blade 12 with respect to separately radius 18 and tangent line 20 bendings.In addition, the chord length of blade is not the same everywhere with curvature, and across the span of wing with along its length, its curvature normally changes, and, change along its length string.The curve form of making this complexity with traditional processing, forging or casting require careful and also cost high.
The design feature of blade-section 12 is that the section line got through blade 12 is perpendicular to radially 18.In Fig. 3,4 exemplary section A, B, C and D have been gone out with the radius distance table that increases.The curvature of the complexity of blade 12 also can be found out from the top view of Fig. 4.
Fig. 5 represents to have represented with abstract concept figure and the relative position of section line A, B, C and D, does not consider the correlation of they and blade 12.Blade is such shown in figure A in the shape at section A place, and blade is such shown in figure B in the shape at section B place, and the rest may be inferred.In the method, blade 12 be by along the figure A built-up welding first welding bead metal, be overlapped in first welding bead and make along figure B built-up welding second welding bead metal and method by that analogy., forming near blade root or bottom usually usually greater than the thickness of the blade at section B place at the thickness of the blade at section A place because increase the round-corner transition part of width.Therefore, for example, near basic unit, it is wide that blade can be made 4 welding beads, and it is wide to make 3 welding beads toward last layer, and 2 welding beads of last layer are wide again, and welding bead of one deck subsequently is wide.Different layers or section part vane thickness can the number of welding bead obtains controlled variation in each layer by changing.
The shape of blade (as different with its thickness) is to change by shape and the aerofoil profile that changes welding bead., can obviously find out with different along the weld bead shape of aerofoil profile B from the aerofoil profile A of Fig. 5 and the different curvature of B along the weld bead shape of aerofoil profile A.Curvature also can be offset a welding bead by the welding bead from the previous built-up welding of bottom and controllably change.For example aerofoil profile B from aerofoil profile A by laterally offset one displacement 22, this displacement is along with along the position of welding bead and change.That is to say that aerofoil profile B not only has different shapes, and aerofoil profile A there is different interval locations relatively.Therefore, directly be not overlapped in along the welding bead of aerofoil profile B, but be displaced to a different position a little along the welding bead of aerofoil profile A.This skew also can form a forniciform shape with respect to this blade along this aerofoil profile length.Though it is bigger that shown skew may seem, yet, should expect in the accompanying drawings shown in aerofoil profile A and B be to take from the section of suitable separation for illustrated purpose.In fact, the displacement H between two adjacent welding beads is little, generally is about 0.015 inch, and is in fully in the maintenance blade 22 successional limit.
In order to make blade 12, the characteristics of blade shape at first are to adopt the method for a series of sections.Be the aerofoil profile of each section and position or calculate or according to the careful record of preprepared parts according to figure.For each section, its data necessary data is with a kind of can the obtaining in two kinds of methods.In the relative positioning method, must know the aerofoil profile of (1) section, promptly along the coordinate of aerofoil profile line (such as B) each point and (2) this section position (such as the skew 22 that between aerofoil profile B and A, obtains) with case-by-point algorithm with respect to last section.Also can be with a kind of absolute positioning mode, it must know the position of each built-up welding point of welding bead material with respect to some outside reference system.In arbitrary situation, the data information that constitutes the blade 3D shape on the whole is determined at an easy rate and stores in the mode that is used for the numerical control metalworking machinery.
After the detail shape of blade or other products was determined, the metal welding bead was with overlapping mode built-up welding, to reproduce the data mode that stores.Must adopt and produce completely specified welding bead, can also controllably copy the device of desired data mode.Studied a kind of laser soldering device already to satisfy these requirements, and can describe in detail below.Yet the present invention does not but comprise this device itself, and replaces the method that relates to a kind of application.
More particularly, first welding bead 24 along aerofoil profile A as the bottom built-up welding on wheel rim 16.Sufficient amount of heat is transmitted on the wheel rim 16, so that some surface melting of base material, and when the material of welding bead 24 arrives this base material, melted significantly.These materials that are melted mix mutually and solidify soon.First welding bead 24 is fused on the wheel rim 16 thus, forms the welding bead band of an integral body immediately.On photomicrography, can't see or detect less than welding boundary line or layering.After final machined and polishing, for all practical occasions, first welding bead 24 and wheel rim 16 are fully integrated.If wheel rim 16 is different with the material composition of first welding bead 24, then these compositions have some and mix mutually in the fusion area.
After the welding bead that forms first welding bead 24 was finished, build-up welding apparatus carried out second welding bead with built-up welding second welding bead 26.In second welding bead, this device is from the aerofoil profile of section A to the next section in upper edge, and this section wing has slightly different aerofoil profile (curvature), position and length usually, and may be by laterally offset, and these parameters before were determined already, and were stored.Characterizing that distance between each sections of blade 12 shapes is taken as usually approximately is height H by the welding bead of build-up welding apparatus built-up welding, and it depends on type of device, by the material of built-up welding, deviation ratio and other factors, but generally is approximately 0.015 inch for laser weld.When second welding bead, 26 built-up welding thereon the time, first welding bead 24 is by local melting.Thereby the same manner that second welding bead 26 melts by above-mentioned first welding bead 24 and matrix is fused to first welding bead 24 of bottom, forms global tissue completely again.
The program of built-up welding stack welding bead repeats to till the whole height formation of blade 12 always.By copying pre-determined aerofoil profile to pile up welding bead, blade is duplicated accurately.Because the continuous blade record any coarse injustice of blade surface that imperfection caused can be ground and be polished, and finishes the integral blade manufacturing.
This method also provides some great advantages except the many-sided adaptability pointed out above and overall structure.Supply with material in the build-up welding apparatus along the length of arbitrary welding bead or between continuous welding bead, can be changed, to change the composition of the product between its zones of different.Since by the material composition of built-up welding, as shape, can be by numerical control, the zone that just might form special composition is to reach special purpose.For example, it is high and flexible to can be made into intensity near the part (being section A) of blade 12 bottoms, and that the part (being section D) at close blade 12 tops can be made is hard and wear-resistant.The part of bearing pneumatic heat heating at most can give special composition.In addition, the metallographic structure of this blade is different from the blade metallographic structure of being made by any other method, and it has a kind of molten more continuously structure.
Repairing after blade 12 is in use impaired also is easily with this method.For example, if the blade tip of blade 12 is fractureed along the jagged line with digital 28 expressions among Fig. 3,, blade 12 grindings do not exist the section of damage to come place under repair by being returned.Such section may be section C.Then according to as make the built-up welding that the duplicate mode of blade is superimposed on the new blade tip of section C at first with this method.Owing to can keep the possibility of the numerical characteristic of blade, new blade tip can be become the same with original impaired blade tip by built-up welding.If this improvement can not be changed the performance of blisk 14 because other blade is not improved equally, any feature of having improved, such as a kind of new improvement wing shapes or in the different materials composition can both be included in.Under any circumstance, because fusion of welding bead subsequently or fusing, the blade that is repaired can keep complete integral body along its length, and does not have the significantly plane of weakening.
The known technology that the welding bead of many different deposited metals and other matrix is arranged.Some produces the diffusion spraying, and this technology generally can not be used for practice of the present invention.Have found that, a kind of is laser soldering device in order to implement satisfied especially device of the present invention, wherein a laser beam melts the lip-deep zone of being aimed at by laser beam, and the material of finally cutting apart of augmenting is transported to the fusion zone is called " welding bead " with increase new resurfacing welding material.By moving this parts, form a kind of careful welding bead of determining and being shaped along controlled route.
The welding build-up welding apparatus 38 that the controlled laser welding is carried out in a kind of useful in the embodiment of this invention being used for is illustrated in Fig. 6.This device has been done extremely detailed description in U.S. Pat-4,730 in 093, here, and it disclosing as a comparison file and introducing.Yet enforcement of the present invention is not limited to the application of this special device.
Device 38 comprises a sealing powder groove with 40 summary expressions, and for powder humidity is controlled at certain low value, it is subjected to heater coil 42 heating.Comprising also have a gas inlet port 44, a kind of preferential dried inert gas such as argon with arrow 46 expressions, is introduced into through this mouth, so that the powder 48 in the groove 40 remain on pressure state and help the powder conveying.A mechanical positive displacement powder feed mechanism that links to each other with this powder groove is such as the powder delivery wheel 50 that can buy on a kind of market.For example, this model that is used for a kind of device form of the present invention is a kind of Metco L type powder delivery wheel that has improved.
The downstream of wheel 50 is vibrators, and such as pneumatic vibrator 50, it links to each other with conduit 54, is bonded to mutually on conduit 54 walls to be limited in the powder particle that moves in the conduit 54.The water-cooled powder of conduit 54 terminations one guiding powder is carried shower nozzle 56, is accelerated into a stationary flow by means of pressurized inert gas, for example, and the matrix on the blade 12 or the welding bead of previous built-up welding.The reflection that has found that laser beam can cause the flowing through powder of shower nozzle 56 stops up.Therefore, this shower nozzle preferably has at least by certain material, as the portion of chewing that the red copper or the aluminium of the used optical maser wavelength of high reflection are made, and liquid body, as water, cooling avoiding the problems referred to above, and is accelerated into stable powder stream.This stable powder stream is because following integrated application is caused: be maintained at the powder under the low temperature state, under the inert gas pressure of regulation, by the loosening device of mechanical positive displacement powder feed mechanism and powder and the shower nozzle that cooled off feed together, powder leads to product surface in laser beam irradiation point through shower nozzle.
It is contemplated that if desired, the additional conduits 56 of some phase class profiles to be arranged, dispose at interval in powder supplies point periphery.Powder stream by some conduit 54 supplies will dispose to such an extent that it is focused on the surface of the work.
5 kilowatts of carbon dioxide of Device 38 comprises that a branch of emission has the laser, 58 of the light beam 60 of beam axis 62.Laser, 58 has the power output that is enough to finish its fusion function.The embodiment that can carry out operation of the present invention has adopted one laser to make compressor blade, but can adopt big or little laser instrument on demand.Light beam 60 has a focussing plane 64, and being in welding bead will be by below the built-up welding surface 66 thereon, so that form the generally light beam spot 68 in 0.005~0.2 inch scope of size on surface 66.Although these sizes are illustrated once more, however unrestricted.This laser energy uses about 10 usually3~10 6Watt/centimetre 2Power density melt the material sections that coincides with light beam spot 68.
The welding bead of resurfacing welding material relies on powder is come built-up welding through conduit 54 supplies in the fusion zone at light beam spot 68 places.Powder is supplied with by spout 56, and nozzle preferably becomes about 35 °~60 ° angles with product surface, and is more preferably and is in about 40 °~55 ° scopes.To avoid concerning shower nozzle and powder greater than about 60 ° of angles that too early interaction is very difficult with laser beam, and make laser beam be focused at that desirable position is difficult on the product surface simultaneously to carrying powder less than about 35 ° of angles.Be displaced sideways relatively owing to producing, can produce fusing in turn, cooling and the curing of the interaction area of fusion, formed a welding bead at laser beam spot with between bearing by the product of shop powder.
Blade 12 and wheel rim 16 is supported in one movably on the support 80 as the blisk 14 of parts wherein, it is along two direction moving blades 12, directions X 70(and-directions X) and Y direction 71(come out from plane, Fig. 6 place, and-the Y direction, enter from plane, Fig. 6 place).By the control X of support 80 with the Y direction is synthetic moves, keep conduit 54 and laser 58 highly constant simultaneously, have for the completely specified welding bead of the desired aerofoil profile of specific section of blade 12 just built-up welding become.
The laser instrument 58 of conduit 54 is bearing on the appliance stand 82 rigidly.This support 82 can along Z direction 84(and-the Z direction) move, to raise or to reduce conduit 54 and laser instrument 58.By means of support 80 and 82, laser instrument 58 and conduit 54 can move with respect to blade 12 on all three directions.Move by the synthetic of control X of support 80 and Y direction, keep conduit 54 and laser instrument 58 height Z constant simultaneously, have for the completely specified welding bead of the desired aerofoil profile of specific section of blade 12 just built-up welding become.(similarly, X, Y and Z's can be by along X and Y direction traversing carriage 82 relative to synthetic moving, and along Z direction traversing carriage 80, or any other similarly synthetic moving is satisfied).
At welding bead (as first welding bead 24) when finishing, device 38 upwards increases, with conduit 54 and laser beam 58 are brought up to general selected be that the H of welding bead height or thickness measures.Like this, another welding bead (as second welding bead 26) can superimposed built-up welding on first welding bead.Fig. 6 illustrates at first welding bead 24 and has finished and second welding bead 26 is in this bead-welding technology process in part built-up welding stage.When second welding bead 26 during by built-up welding, the top of first welding bead 24 has been guaranteed the mixing and the continuous tissue of two welding beads 24 and 26 by refuse.
For several application of the present invention aspect is described, introduce several examples below, yet in office where face should not be regarded as limitation of the present invention.
Example 1, matrix.3 kilowatt of CO of above-mentioned device have been used makes the compressor blade that becomes integral body with2It is on 0.356 centimetre the luminous point that laser beam focuses on diameter; 30 kilowatts of .The hyperboloid of thereby reaches the power density of every square centimeter compressor blade that has in the general shape shown in Fig., 1~5 has been become by built-up welding.About, 3 inch of the length of this blade.About, 0.015 inch of the height of each welding bead.Make the blade demand and add up to, 200 welding bead; Use matrix linear mobility with respect to laser beam per minute 50 inch when powder during by built-up welding.By the alloy of built-up welding is titanium-6Al-4V; Supplying duct be-35/+230 order powder that with the feeding speed of about per minute 10 grams, matrix is titanium-6Al-4V.Blade and peripheral region are in the argon gas during the built-up welding.
Example 2 is except being that inconel (Inconel) 718 alloys, matrix are that inconel (Inconel) 718 alloys and mobility are that all the other are with example 1 per minute 80 inch by the alloy of built-up welding.
Example 3, except matrix was Rene 95 alloys, all the other were with example 2.
Like this, the invention provides a kind of method that is used to make with the highly versatile of repaired item.Although in conjunction with special case and embodiment the present invention is described, all persons skilled in the art can understand, under situation about not deviating from by the spirit and scope of the present invention of additional claims defined, can make various changes.

Claims (20)

1, a kind of method of utilizing the built-up welding of laser stratification to make goods, these goods have reservation shape and are characterized by and have a plurality of parallel cross sections, and its each cross section has predetermined curve shape and thickness, said method comprising the steps of:
Utilize laser beam that dusty material is melted, and the material of fusion is piled coated with forming first overlay cladding by the curve shape in goods first cross section, the thickness of first overlay cladding is corresponding with the thickness in first cross section;
Utilize laser beam that dusty material is melted, and the material of fusion piled coated with forming second overlay cladding by the curve shape in goods second cross section and local at least first weld overlay materials that covers, the thickness of second overlay cladding is corresponding with the thickness in second cross section; And
Utilize laser beam that dusty material is melted, and the material of fusion piled coated with forming continuous overlay cladding by the curve shape in each corresponding cross section of goods, the local cross section that covers cross section its lower floor of local offset of its lower floor, at least one cross section in the continuous cross section, therefore, the original relatively resurfacing welding material of overlay cladding at least one place, cross section in the continuous cross section is local not supported, formed the part that overhangs, and, the thickness in the corresponding cross section on the thickness of each overlay cladding and each overlay cladding about equally, on each continuous cross section, form each overlay cladding continuously, until finishing goods.
2, method according to claim 1 is characterized in that these goods are curve form.
3, method according to claim 1, it is characterized in that, in utilizing laser beam that dusty material is melted and the material of fusion being piled coated with the step that forms continuous overlay cladding, overlay cladding is piled the material that covers and overlay cladding formerly to pile the material that covers different continuously.
4, method according to claim 1 is characterized in that these goods are compressor blade, gas turbine blades or propeller blade.
5, method according to claim 1, it is characterized in that, in utilizing laser beam that dusty material is melted and piling the material of fusion coated with the step that forms continuous overlay cladding, the part of formerly piling the cover material material is melted, thereby forms the welding fused portion between two overlay claddings.
6, method according to claim 1, the material that it is characterized in that being used for overlay cladding is selected from titanium alloy, nickel alloy, cobalt alloy, ferroalloy, pottery or plastics.
7, method according to claim 1, it is characterized in that, in utilizing laser beam that dusty material is melted and piling the material of fusion coated with the step that forms second overlay cladding, the part of first overlay cladding is melted, and forms the welding fused portion between two overlay claddings.
8, method according to claim 1 is characterized in that the reservation shape of goods is the compound curved surface shape, and first overlay cladding is that heap overlays in the substrate.
9, method according to claim 8, it is characterized in that, dusty material is melted and the material of fusion is piled the step of covering by the curve shape in each corresponding cross section of goods controlled by computer, the curve shape in each parallel cross section is stored in the computer.
10, method according to claim 8 is characterized in that, these goods have the shape of two-dimensional curvature.
11, method according to claim 8 is characterized in that, under at least a situation, is melting and is piling in the step of the continuous weld overlay materials that covers mutual covering, and the material of continuous overlay cladding is different with the material of overlay cladding formerly.
12, method according to claim 8 is characterized in that, these goods are compressor blades that fuse with compressor disk.
13, method according to claim 8, it is characterized in that, cover in the step of continuous weld overlay materials of mutual covering in fusing and heap, heap cover cladding material during, formerly the part of overlay cladding is melted, and is formerly forming fused portion between overlay cladding and the cover layer.
14, method according to claim 8 is characterized in that, the used material of overlay cladding is selected from titanium alloy, nickel alloy, cobalt alloy or ferroalloy.
15, method according to claim 8 is characterized in that, these goods are blades, and this substrate is a wheel disc, and blade utilizes Laser Welding and wheel disc to form one.
16, method according to claim 15 is characterized in that, first weld overlay materials heap is being layed onto in the step of substrate surface, and the part of substrate surface is melted, and forms fused portion between the substrate surface and first overlay cladding.
17, method according to claim 8 is characterized in that, at least one overlay cladding, the dusty material of different component is melted and heap overlays in the same overlay cladding.
18, method according to claim 8 is characterized in that, and is at least one overlay cladding, different and be that the continually varying component material is overlayed in the same overlay cladding by heap.
19, method according to claim 8 is characterized in that, these goods are gas turbine blades, and substrate is a gas turbine wheel disk.
20, method according to claim 8 is characterized in that, these goods are propeller blades, and substrate is the propeller wheel disc.
CN89109405A 1989-02-08 1989-12-20 Fabrication of component by laser layered doposition Expired - Fee Related CN1022895C (en)

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CN1044777A (en) 1990-08-22
DE3942051A1 (en) 1990-08-09
JP2599804B2 (en) 1997-04-16
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GB2228224A (en) 1990-08-22
IL92428A0 (en) 1990-07-26
GB2228224B (en) 1993-09-01
FR2642690B1 (en) 1997-07-18
CA2005527A1 (en) 1990-08-08
JPH02251389A (en) 1990-10-09
IL92428A (en) 1992-12-01
IT1237856B (en) 1993-06-18
IT8922603A0 (en) 1989-12-04
DE3942051B4 (en) 2006-07-27
FR2642690A1 (en) 1990-08-10

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