CN102615431A - Remanufacturing method for automatic laser cladding of gray cast iron cylinder cover - Google Patents
Remanufacturing method for automatic laser cladding of gray cast iron cylinder cover Download PDFInfo
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- CN102615431A CN102615431A CN2012101060250A CN201210106025A CN102615431A CN 102615431 A CN102615431 A CN 102615431A CN 2012101060250 A CN2012101060250 A CN 2012101060250A CN 201210106025 A CN201210106025 A CN 201210106025A CN 102615431 A CN102615431 A CN 102615431A
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 5
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- 229910018054 Ni-Cu Inorganic materials 0.000 claims description 4
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Abstract
The invention discloses a remanufacturing method for automatic laser cladding of a gray cast iron cylinder cover, which includes preparing a gray cast iron laser cladding repairing material, conducting damage-free detection on crack depth of 'nose cleft' on the gray cast iron cylinder cover, conducting pre-repairing pretreatment on the 'nose cleft' on the gray cast iron cylinder cover and removing stress of the repairing part. The remanufacturing method is accurate in size, requires small postprocessing, and has small heat effects on a base body. Further, three-dimensional formed repairing part is excellent in dynamic performance, is capable of well restraining the combination interface white turning trend and effectively blocks carbon spreading.
Description
Technical Field
The invention relates to the field of equipment remanufacturing, in particular to an automatic laser cladding remanufacturing method for a gray cast iron cylinder cover.
Background
The gray cast iron has the advantages of good casting performance, excellent vibration damping performance, good wear resistance, excellent cutting processing performance, higher tensile strength, low notch sensitivity, good heat conductivity and the like due to low price, and is commonly used for manufacturing large castings in industrial production. The engine cylinder head is one of typical parts manufactured by adopting the material. Such large components typically require complex heat treatments and manufacturing processes, as well as precision machining, require specialized equipment to produce, are expensive, and are costly.
However, in the using process, due to the loose structure characteristic of the gray cast iron and the cutting effect of the flake graphite, the tensile strength, the plasticity and the toughness of the gray cast iron are far lower than those of steel, and the mechanical property is poor. Some impurity components also have certain influence on the structure and structure of the gray cast iron. These characteristics of gray cast iron lead to a high number of defects in the gray cast iron cylinder head, the most common type of defect being the cross-fracture in the "nose bridge" region between the valves, the cause of said cross-fracture being closely related to the structural characteristics and the working environment of this region. The cylinder cover bears high temperature in the working process of an engine and needs timely cooling of an internal circulating water path, so that the structural design of the cylinder cover is complex, the nose bridge part is of a solid structure, the cooling effect of circulating water is weak, and meanwhile, the part bears the action of high-temperature and high-pressure gas and larger mechanical load impact in the working process, and the part is subjected to fatigue fracture under the action of thermal stress.
If the cylinder cover with fatigue fracture is directly scrapped and returned as a waste product, the additional values such as labor value, energy value and the like during component manufacturing are comprehensively lost, and the obtained product can only be used as a raw material, so that great waste is caused. Repair welding is often used in industry, and common repair welding methods include manual arc welding and CO2Gas shielded welding, but these methods have the following problems: heat input quantityThe welding joint has white structure and hardening structure, and the welding joint is easy to crack. Although the use of heterogeneous weld materials can reduce the white-notch tendency of the weld joint structure, effective technical means for controlling residual stress after multi-layer build-up welding are still lacking.
Disclosure of Invention
The invention aims to overcome the defects of easy cracking of a welding seam and large residual stress formed by the conventional welding repair method, and provides an automatic laser cladding remanufacturing method of a gray cast iron cylinder cover, which comprises the following steps:
step 1), preparing a gray cast iron laser cladding repair material; wherein,
the gray cast iron laser cladding repair material has the following physical and chemical properties: the strength is not lower than that of the matrix, the plasticity and the toughness are high, and the anti-cracking performance is outstanding; can block the diffusion of carbon element and has obvious effect of inhibiting interface white mouth; the alloy has good self-deoxidation and slagging capabilities, excellent surface appearance quality and no air holes inside; the material has good wettability with a gray cast iron matrix, and the laser cladding formability is excellent;
step 2), carrying out nondestructive testing on the depth of the nose crack on the gray cast iron cylinder cover;
step 3), preprocessing a nose crack part on the gray cast iron cylinder cover before repairing, removing cracks on the nose crack part according to the crack depth detection result obtained in the step 2) in the preprocessing to form a groove, then polishing the periphery of the groove by using an angle grinding wheel until a fresh metal surface is exposed, and cleaning the groove and the peripheral surface thereof by using an acetone solution;
step 4), carrying out profiling repair on a nose crack part on the gray cast iron cylinder cover through laser cladding; the method comprises the following steps:
step 4-1), performing single-pass single-layer cladding on the slope on the gray cast iron cylinder cover;
step 4-2), forming a priming layer at the groove on the gray cast iron cylinder cover;
step 4-3), performing multilayer accumulation profiling repair on the basis of the base coat generated in the step 4-2);
and 5) removing stress on the repaired part.
In the above technical solution, in the step 1), the gray cast iron laser cladding repair material is Ni — Cu alloy powder, and the alloy powder includes 0.01% to 0.05% by mass of a C element, 2.0% to 4.0% by mass of a Si element, 1.0% to 3.0% by mass of a B element, 0.1% to 1.0% by mass of a Fe element, 10% to 40% by mass of a Cu element, and Bal Ni element.
In the above technical scheme, in the step 3), the groove is a V-shaped groove, the bottom of the V-shaped groove is a rounded corner, and the included angle of the groove is not less than 80 ° for a groove with a depth of 10 mm.
In the above technical solution, in the step 4-1), performing single-pass single-layer cladding at the groove on the gray cast iron cylinder cover comprises: when single-channel single-layer cladding is carried out, a lateral synchronous powder feeding mode is adopted, high-purity nitrogen protection is carried out, the laser power is 800W, the scanning speed is 150mm/min, the powder feeding voltage is 11V, the spot size is 3.5mm, the powder feeding carrier gas flow is 200L/h, and the single-layer thickness of the formed cladding layer is 0.5 mm.
In the technical scheme, in the step 4-2), when a priming layer is formed at the groove on the gray cast iron cylinder cover, a single-pass laser cladding process is adopted, and during cladding, a robot needs to be adjusted, so that the included angle between the axis of a laser beam and the surface of the groove is controlled within the range of 70-90 degrees; the included angle between the laser beam axis and the powder spray gun axis ranges from 10 degrees to 45 degrees, and the lap joint rate of the priming cladding layer is 45 percent.
In the technical scheme, in the step 4-3), when multilayer accumulation profiling repair is carried out, the accumulation coefficient is 0.5mm, the continuous cladding length is less than 50mm when 4 cladding layers are overlapped, and the laser shutter is stopped once; meanwhile, the cladding layer is rapidly hammered by a small hammer to eliminate internal stress; and then continuing to perform laser cladding until the groove part is fully piled up, and always keeping a backward powder feeding mode in the cladding process.
The invention has the advantages that:
the invention has accurate forming size, only needs small post-processing and has small heat influence on the matrix; and the mechanical property of the three-dimensional forming repair part is excellent, the whitening tendency of the bonding interface can be well inhibited, and the carbon diffusion is effectively blocked.
Drawings
Fig. 1 is a flow chart of an automatic laser cladding remanufacturing method of a gray cast iron cylinder cover.
Detailed Description
The invention is described in detail below with reference to the drawings and the detailed description.
In one embodiment of the invention, cracks are initiated at the "nose bridge" part between the cylinder head inlet and the intake valve, the thickness of the material of the nose bridge part is 14mm (distance from the surface to the water jacket), the crack depth is unknown, and the material of the cylinder head is HT 250. The following describes, by taking this embodiment as an example, a process of remanufacturing this cylinder head by using the laser cladding remanufacturing method of the present invention with reference to fig. 1.
Step 1, preparing a special material for laser cladding repair of gray cast iron.
In order to meet the performance requirement of laser cladding, stacking and forming of gray iron castings and avoid the occurrence of common gray iron cladding defects, materials for gray iron laser cladding repair need to have the following physical and chemical properties:
(1) the strength is not lower than that of the matrix, the plasticity and the toughness are high, and the anti-cracking performance is outstanding.
(2) Can block the diffusion of element C and has obvious effect of inhibiting interface whitening.
(3) Has good self-deoxidation and slagging capability, excellent surface appearance quality and no air holes inside.
(4) Has good wettability with the gray cast iron matrix and excellent laser cladding formability.
In view of the above physical and chemical properties, the material for repair used in this example was Ni — Cu alloy powder. The alloy powder contains the elements with the mass fractions shown in Table 1, and the powder particle size is-140 to +325 meshes.
TABLE 1
Wherein Bal represents the balance.
In other embodiments, other materials may be selected as the repair material, as long as the materials satisfy the above-mentioned physicochemical properties.
And 2, carrying out nondestructive testing on the depth of the nose crack.
In the step, in order to more clearly show eddy current detection signals when the crack depths are different, the cracks with different depths are respectively detected by adopting an eddy current method. The eddy current signal amplitude becomes larger with increasing crack depth, but its phase change is not significant. In order to realize the evaluation of the depth of the nose crack of the cylinder cover, a mathematical model between the crack depth and the amplitude of the eddy current signal is established in the step.
y＝8.9334·e0.402·x (1)
Wherein: y represents the eddy current signal amplitude; x denotes the crack depth.
Therefore, when the crack depth is in the eddy current detection range, the actually measured eddy current signal amplitude is substituted into the formula (1), so that the nose crack depth data of the cylinder cover can be obtained preliminarily, and a basis is provided for repairing the cylinder cover.
And 3, preprocessing the 'nasal fissure' part of the cylinder cover before repair.
According to the results of the depth and the trend of the crack of the nose crack of the cylinder cover detected in the step 2, firstly, a V-shaped groove is deepened at the crack part to remove the crack, the bottom of the V-shaped groove is a rounded corner, and in order to ensure the accessibility of laser, the included angle of the groove is not lower than 80 degrees for the groove with the depth of 10 mm. And then, polishing the periphery of the groove by using an angle grinding wheel until a fresh metal surface is exposed, and cleaning the groove and the peripheral surface thereof by using an acetone solution.
And 4, performing profiling repair on the nose crack part on the gray cast iron cylinder cover through laser cladding. This step may include:
and 4-1, performing single-pass single-layer cladding on the nose crack part on the gray cast iron cylinder cover.
And (2) controlling a YAG laser by using an optical fiber conduction robot, synchronously feeding the powder into the Ni-Cu alloy powder prepared in the step (1) in a pneumatic powder feeding mode, and evaluating the forming quality of a single-channel single-layer cladding layer under different cladding process conditions by performing a large number of orthogonal experiments on an HT250 substrate. The evaluation indexes include: the optimal laser cladding process parameters on the HT250 substrate are determined by the quality (whether the cladding layer is bright and continuous, whether cracks or inclusions exist, and the size and the number of air holes) and the microstructure and the performance test (microhardness and residual stress). The method is characterized in that a lateral synchronous powder feeding mode is adopted, high-purity nitrogen protection is adopted, the laser power is 800W, the scanning speed is 150mm/min, the powder feeding voltage is 11V, the spot size is 3.5mm, the flow rate of powder feeding carrier gas is 200L/h, the thickness of a single layer of the cladding layer is 0.5mm, the cladding layer has no air holes or crack defects, the surface of the cladding layer is continuous and bright, and the forming quality is excellent.
And 4-2, forming the bottom layer.
The three-dimensional copying repair usually needs multilayer cladding, and the priming coat is the most important layer. As a layer directly combined with the substrate, the combination strength of the priming coat and the substrate directly determines the combination quality and the anti-cracking performance of the cladding layer; aiming at the laser cladding of gray cast iron, the invention adopts Ni-Cu alloy powder to prepare the priming coat, and aims to ensure that the matrix only generates smaller fusion depth, and utilizes the melted Ni-Cu alloy to block C element in the matrix at an interface, namely a semi-fusion zone at the bottom of a cladding layer, thereby reducing or even eliminating the white cast tendency at the interface.
The single-channel laser cladding process is adopted, a priming layer is prepared along the surface of the groove in advance, and during cladding, in order to ensure that the energy density of a facula area is in standard Gaussian distribution, a robot needs to be adjusted, and the included angle between the axis of a laser beam and the surface of the groove is controlled within the range of 70-90 degrees; the included angle range of the laser beam axis and the powder spray gun axis is 10-45 degrees, the lap joint rate of the priming cladding layer is 45 percent, and the cladding layer has high flatness at the moment.
Step 4-3, multi-layer stacking profiling repair
And (3) on the basis of the priming layer in the step (4-2), accumulating layer by layer along the V-shaped surface, wherein the accumulation coefficient is 0.5mm, the continuous cladding length is less than 50mm when the cladding layer is overlapped for 4 times, the laser optical gate is stopped once, namely, the short-section forming and intermittent cladding mode is adopted, and meanwhile, the cladding layer is rapidly hammered by a small iron hammer to eliminate the internal stress. And then continuing to perform laser cladding until the groove part is fully piled, and always keeping a backward powder feeding mode (the included angle between the axis of the powder spray gun and the axis of the cladding layer is less than 90 degrees) in the cladding process, wherein the mode has higher powder utilization rate on one hand and can effectively prevent the corner size of the piled cladding layer from collapsing on the other hand. In order to reserve the post-processing allowance, the cladding accumulation size is required to be larger than the original size of the nose bridge in each direction; in order to ensure good interface bonding of the cladding layer and the matrix, the cladding layer needs to cross a contact interface with the groove part and extend into the surface of the cylinder cover by 1-3 mm during surface cladding.
And 5, removing stress on the repaired part.
In order to further eliminate residual stress in the accumulated cladding layer, after the integral accumulation is finished, a gasoline blowtorch is used for heating the repaired part and the nearby area, the temperature is increased to 200-400 ℃, the temperature is kept for about 1 hour, and asbestos covers the surface of the repaired part, so that the delayed cracking tendency of the cladding layer is inhibited.
The above is the implementation process of the laser cladding remanufacturing method of the invention. For gray cast iron parts, the technical means of laser cladding adopted in the method can enable the matrix to generate smaller fusion depth, has extremely low dilution influence on the cladding layer, further reduces the diffusion effect of C element, prevents the formation of white cast texture, and simultaneously plugs the C element at the combination interface by matching the immiscible effect of Ni and Cu alloys and C, thereby further inhibiting the white cast trend. Meanwhile, laser cladding heat is concentrated, the heat influence on a matrix is small, slow scanning forming is carried out under low power density, and the residual stress of a cladding layer can be effectively reduced by matching with external hammering and slow cooling measures, so that the purpose of controlling cracking of a thick formed cladding layer is achieved.
Claims (6)
1. An automatic laser cladding remanufacturing method of a gray cast iron cylinder cover comprises the following steps:
step 1), preparing a gray cast iron laser cladding repair material; wherein,
the gray cast iron laser cladding repair material has the following physical and chemical properties: the strength is not lower than that of the matrix, the plasticity and the toughness are high, and the anti-cracking performance is outstanding; can block the diffusion of carbon element and has obvious effect of inhibiting interface white mouth; the alloy has good self-deoxidation and slagging capabilities, excellent surface appearance quality and no air holes inside; the material has good wettability with a gray cast iron matrix, and the laser cladding formability is excellent;
step 2), carrying out nondestructive testing on the depth of the nose crack on the gray cast iron cylinder cover;
step 3), preprocessing a nose crack part on the gray cast iron cylinder cover before repairing, removing cracks on the nose crack part according to the crack depth detection result obtained in the step 2) in the preprocessing to form a groove, then polishing the periphery of the groove by using an angle grinding wheel until a fresh metal surface is exposed, and cleaning the groove and the peripheral surface thereof by using an acetone solution;
step 4), carrying out profiling repair on a nose crack part on the gray cast iron cylinder cover through laser cladding; the method comprises the following steps:
step 4-1), performing single-pass single-layer cladding on the slope on the gray cast iron cylinder cover;
step 4-2), forming a priming layer at the groove on the gray cast iron cylinder cover;
step 4-3), performing multilayer accumulation profiling repair on the basis of the base coat generated in the step 4-2);
and 5) removing stress on the repaired part.
2. The automatic laser cladding remanufacturing method of a gray cast iron cylinder head as claimed in claim 1, wherein in the step 1), the gray cast iron laser cladding repair material is Ni-Cu-based alloy powder including C element with a mass fraction of 0.01 to 0.05%, Si element with a mass fraction of 2.0 to 4.0%, B element with a mass fraction of 1.0 to 3.0%, Fe element with a mass fraction of 0.1 to 1.0%, Cu element with a mass fraction of 10 to 40%, and Ni element with a mass fraction of Bal.
3. The automatic laser cladding remanufacturing method of a gray cast iron cylinder cover according to claim 1, wherein in the step 3), the groove is a V-shaped groove, the bottom of the V-shaped groove is a round angle, and the included angle of the groove is not lower than 80 degrees for a groove with a depth of 10 mm.
4. The automatic laser cladding remanufacturing method of a gray cast iron cylinder head as claimed in claim 1, wherein in the step 4-1), said performing single layer cladding at the groove of the gray cast iron cylinder head comprises: when single-channel single-layer cladding is carried out, a lateral synchronous powder feeding mode is adopted, high-purity nitrogen protection is carried out, the laser power is 800W, the scanning speed is 150mm/min, the powder feeding voltage is 11V, the spot size is 3.5mm, the powder feeding carrier gas flow is 200L/h, and the single-layer thickness of the formed cladding layer is 0.5 mm.
5. The automatic laser cladding remanufacturing method of the gray cast iron cylinder cover according to claim 1, wherein in the step 4-2), when a priming layer is formed at the groove on the gray cast iron cylinder cover, a single-pass laser cladding process is adopted, and during cladding, a robot needs to be adjusted to control an included angle between the axis of a laser beam and the surface of the groove to be within a range of 70-90 degrees; the included angle between the laser beam axis and the powder spray gun axis ranges from 10 degrees to 45 degrees, and the lap joint rate of the priming cladding layer is 45 percent.
6. The automatic laser cladding remanufacturing method of a gray cast iron cylinder cover according to claim 1, wherein in the step 4-3), when multilayer stacking profiling repair is performed, the stacking coefficient is 0.5mm, the continuous cladding length is less than 50mm after every 4 overlapping passes of the cladding layer, and the laser shutter is stopped once; meanwhile, the cladding layer is rapidly hammered by a small hammer to eliminate internal stress; and then continuing to perform laser cladding until the groove part is fully piled up, and always keeping a backward powder feeding mode in the cladding process.
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| CN112025224B (en) * | 2020-09-03 | 2021-11-19 | 河北省瑞兆激光机电设备再制造产业技术研究院 | Carbon dioxide automatic cladding remanufacturing method for nodular cast iron bearing cylinder |
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