CN104878380A - Laser remanufacturing and reinforcing method of mine car wheel set - Google Patents
Laser remanufacturing and reinforcing method of mine car wheel set Download PDFInfo
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Abstract
The invention relates to a laser remanufacturing and reinforcing method of a mine car wheel set. The laser remanufacturing and reinforcing method is characterized in that nickel-based alloy powder is adopted for a fusion covering middle buffer layer, and the nickel-based alloy powder comprises the following chemical components in percentage by weight: 0.33%-0.50% of carbon, 0.32%-3.8% of silicon, 0.65%-7.5% of chromium, 0.25%-3.5% of iron, 0.10%-1.5% of boron, 0.10%-0.2% of vanadium and the balance of nickel and inevitable impurities; iron-based alloy powder is adopted for a fusion covering strengthening layer, and the iron-based alloy powder comprises the following components in percentage by weight: 0.10%-1.5% of carbon, 0.22%-2.8% of silicon, 4.5%-6.0% of chromium, 4.5%-5.0% of molybdenum, 1.5%-2.0% of boron, 3.0%-3.5% of manganese, 2.0%-2.5% of vanadium, 6.5%-7.5% of tungsten and the balance of iron and inevitable impurities. Thus, the laser remanufacturing and reinforcing method disclosed by the invention can be used for effectively prolonging the service life of the mine car wheel set and reducing the replacement frequency of the mine car wheel set.
Description
Technical field
The present invention relates to laser processing technology, the laser remanufacturing that particularly a kind of mine tram wheel is right and enhancement method.
Background technology
Mine tram wheel is to the major parts being mining rail transport trolley, long term operation, under high impact loads, repeated load and humidity and acid or alkali environment, is mainly generation stress crack, wearing and tearing or corrosion by the failure mode that field investigation discovery mine tram wheel is right and causes losing efficacy.At present, mine tram wheel is to work-ing life generally at 3500-4000 km, and as some high-sulfur ore deposits because corrosives exists, its life-span is lower, uses substantially to scrap process afterwards.With the citing of Anshan iron and steel plant Dagushan Iron Ore Mine, mine tram wheel is 12000-13000 unit/part to new product procurement price, is about 3500-4000 kilometer work-ing life, amounts to only about 1-2 month working time.And mine car deadweight nearly 10 tons, when borehole operation change mine tram wheel quite loaded down with trivial details to program, time-consuming, effort, add mining cost.Therefore, being directed to the right one of mine tram wheel and effectively manufacturing and enhancement method again, is current problem urgently to be resolved hurrily.
At present, about utilizing laser melting and coating process manufacture the patent of workpiece again and report a lot, be now exemplified below:
1, CN102615431A discloses a kind of Gray Iron Cylinder Head automatic laser cladding reproducing method, and its feature is: step 1), preparation graphitic cast iron laser melting coating repair materials; Step 2), nondestructive testing is done to the degree of depth of " rhinoschisis " crackle on Gray Iron Cylinder Head; Step 3), preprosthetic pre-treatment is done to " rhinoschisis " position on Gray Iron Cylinder Head, in described pre-treatment, according to step 2) the crack depth detected result that obtains removes the crackle at " rhinoschisis " position, form a groove, then utilize until expose fresh metal surface around the grinder buffing groove of angle, by acetone soln cleaning groove and circumferential surface thereof; Step 4), by laser melting coating, profiling reparation is done to " rhinoschisis " position on described Gray Iron Cylinder Head; This step comprises: step 4.1), described groove place on described Gray Iron Cylinder Head does the cladding of single track individual layer; Step 4.2), described groove place on described Gray Iron Cylinder Head forms intermediate buffer layer; Step 4.3), in step 4.2) on the basis of intermediate buffer layer that generates, do multilayer and pile up profiling reparation; Step 5), to reparation position remove stress.
2, CN 1932082 discloses and a kind of prepares wear-resisting heat resistanceheat resistant composite cladding layer process at crystallizer surface laser quick cladding, its feature is to utilize superpower laser, become the good toughness bottoming transition layer of metallurgical binding by laser rapid scanning at copper plate of crystallizer surface cladding with matrix, and prepare cobalt base alloy that is wear-resisting and heat resistanceheat resistant excellent property by laser wide-band cladding at bottoming alloy surface.
3, CN101338427 discloses the laser melting and coating process of a kind of hydraulic support column cylinder, piston rod wear-resisting erosion resistance cladding layer, and it comprises following technological process: first column cylinder barrel, piston rod surface pre-treatment; Then the selection of powdered alloy and the adjustment of automatic powder feeding device: select and there is good wear etch resistant properties and the iron(-)base powder good with the metallurgical consistency of matrix, main containing Fe, C, Cr, Ni, Mo, Si, N, Nb, Ta, B in the composition of iron(-)base powder; When regulating automatic powder feeding device, automatic powder feeding head powdered alloy out is just in time dropped in laser molten pool, regulate powder sending quantity, make the thickness of powdered alloy cladding layer reach 0.6-1.2mm.
4, CN 103320787A discloses a kind of inefficacy bar rolling guide and manufactures restorative procedure again, comprising: step 1), choose coated material; Step 2), according to laser melting coating watt level, spot size, sweep velocity and amount of lap, select laser cladding technological parameter; Coated material selected in step 3), employing step 1), according to step 2) determined laser cladding technological parameter, adopt the repair surface of laser melting coating re-manufacturing technology to the guide and guard of bar roller to repair.
In sum, it is a lot of that workpiece based on laser melting and coating process manufactures restorative procedure again, to some extent solve short problem in the work-ing life of part workpiece, but retrieve verification through the applicant, because workpiece self character is different, Working environment is different, the not equal reason of damage situations, also be not applicable to the right laser melting coating of mine tram wheel at present manufacture and enhancement method, this is also the problem putting forth effort in the application to solve again.
Summary of the invention
The object of the invention is in order to provide a kind of extend mine tram wheel to work-ing life, reduce the right laser remanufacturing of the mine tram wheel of mine tram wheel to replacement frequency and enhancement method.
Technical scheme of the present invention is:
The laser remanufacturing that a kind of mine tram wheel is right and enhancement method, comprise and impaired mine tram wheel measured carrying out flaw detection, remove damaged layer according to result of detection, adopted laser melting coating mode at mine tram wheel, cladding intermediate buffer layer on matrix to be carried out to size restoration, in intermediate buffer layer top cladding and hardening layer and sequent surface process, it is characterized in that:
Co-based alloy powder is adopted during laser melting coating intermediate buffer layer, this powder chemistry composition by weight percent is: carbon 0.33-0.50%, silicon 0.32-3.8%, chromium 0.65-7.5%, iron 0.25-3.5%, boron 0.10-1.5%, vanadium 0.10-0.2%, all the other are nickel and inevitable impurity, the mine tram wheel after recovery to outside dimension compared with the little 1.8-2.2mm of new product;
Iron(-)base powder is adopted during laser melting coating strengthening layer, this powder chemistry composition by weight percent is: carbon 0.10-1.5%, silicon 0.22-2.8%, chromium 4.5-6.0%, molybdenum 4.5-5.0%, boron 1.5-2.0%, manganese 3.0-3.5%, vanadium 2.0-2.5%, tungsten 6.5-7.5%, all the other are iron and inevitable impurity, and described strengthening layer thickness is 2.5-3.0mm.
The laser remanufacturing that above-mentioned mine tram wheel is right and enhancement method, multifunctional numerical control laser-processing system and gravity synchronous powder feeding system mode is adopted to carry out cladding, under high power focused laser beam effect, form laser intermediate buffer layer at mine tram wheel to matrix surface, individual layer cladding thickness is 1.2-1.5mm, processing parameter is as follows: condensing lens f=300mm, 15*1 integration condensing lens, cladding power P=4000-4500W, spot size D=12*2, scan velocity V=400-600mm/min, overlapping rate is 35-40%.
The laser remanufacturing that above-mentioned mine tram wheel is right and enhancement method, multifunctional numerical control laser-processing system and the preset automatic powder feeding system of gravity is adopted to carry out cladding, under high power focused laser beam effect, at intermediate buffer layer surface cladding Laser Strengthening Layer, processing parameter is as follows: condensing lens f=300mm, cladding power P=4200-4500W, spot size D=3mm, scan velocity V=850-1050mm/min, overlapping rate is 45-55%.
The invention has the beneficial effects as follows:
In the present invention, consider that wheel is to original material ZG45, and cause the right dominant failure reason of wheel to be impact the fatigue cracking and common formation of wearing and tearing that cause, if adopt single material cladding can cause base material and cladding material difference of hardness excessive, cracking is easily caused under thump effect, and due to No. 45 steel plasticity poor, the hardened layer difference that thermal expansivity is formed with iron-based tungsten system strengthening powder is too much, so take the process program of nickel-base alloy intermediate buffer layer and iron-based tungsten system alloy enhanced layer in the present invention, and in the configuration of iron(-)base powder, increase the ratio of Si and B element, to form good low-melting-point eutectic, well metallurgical binding can be formed with primary substrate, stable eutectic structure can be formed again with the Ni-based tungsten system powder of strengthening layer, and the coefficient of expansion reducing strengthening layer and base material is poor, make use of the good elasticity that nickel-base alloy has absorb and cushion the comparatively thump run in use procedure simultaneously, reduce the formation of fatigue cracking, further enhance the work-ing life of strengthening layer, improve the bonding strength of strengthening layer, improve strengthening layer tungsten system alloy and easily occur crackle, the defect of cladding poor performance.
The mine tram wheel pair after strengthening is manufactured again by powdered alloy of the present invention and technique, to impact when running, there is good shock absorption, and the alloy hardening layer of surperficial tungsten system has splendid wear resistance, and due to the existence of bottoming buffer layer, effectively improve the anti-fatigue performance of wheel to entirety, substantially stop the situation that fatigue cracking occurs causing scrapping to occur, thus increase substantially wheel right work-ing life.
Experiment proves that mine tram wheel after this patented method remediation intensification improves about 1500-2000 kilometer to comparatively new product work-ing life, and can reach 5000-6000 km, and can repeated multiple timesly repair, result of use is good.While saving enterprise mine tram wheel is to purchase cost, also slow down mine tram wheel to replacement frequency, saves a large amount of man power and materials, there is higher economic worth and practical value.
Embodiment
In view of mine tram wheel to inefficacy abrasion loss usually at more than 5mm, and have a large amount of stress crack, fatigue cracking to exist, the present invention adopts and first measures fatigue layer thickness by nondestructiving inspecting equipment, then machine adds and removes fatigue layer, use high tenacity antifatigue primer to carry out size restoration in laser melting coating mode again, the mine tram wheel after recovery to outside dimension compared with the little 1.8-2.2mm of new product; Then laser melting coating mode is adopted to carry out the thick wear and shock-resistant strengthening layer of cladding 2.5-3.0mm, wherein, reserved 0.7-0.8mm is as machining allowance, and after cladding, machine adds resizing and smooth finish, thus realizes whole again manufacture and the strengthening process right to mine tram wheel.Now illustrated by two embodiments.
embodiment 1
The laser remanufacturing that this mine tram wheel is right and enhancement method, specifically comprise the steps.
1, flaw detection and process in early stage:
(1) remove rusty stain, the greasy dirt of mine tram wheel effects on surface, carry out size, inner carrying out flaw detection;
(2) according to result of detection, the turning of surface fatigue layer is removed, meets local corrosion, lesion depths exceedes the fatigue layer degree of depth, determine Lathe quantity according to corrosion or damage full depth, in the present embodiment, determine that Lathe quantity is 7mm.
2, laser intermediate buffer layer cladding
(1) previous work
Remove cutting surface greasy dirt, carry out dimensional measurement, determine that external diameter damage amount is 14mm;
(2) preparation of intermediate buffering layer material
Intermediate buffer layer selects Co-based alloy powder, this powder chemistry composition by weight percent is: carbon 0.44%, silicon 3.6%, chromium 7.2%, iron 3.0%, boron 1.3%, vanadium 0.2%, all the other are nickel and inevitable impurity, get this powder of 8Kg adopt in drying baker after 100 mesh sieve sieves 200 DEG C dry 2-3 hour for subsequent use;
(3) laser cladding method
Adopt HGL-5000 type multifunctional numerical control laser-processing system to carry out cladding, regulate powder feeding rate, individual layer cladding layer thickness is 1.2mm, five layers of cladding, adopt gravity synchronous powder feeding system mode, under high power focused laser beam effect, at mine tram wheel, laser intermediate buffer layer is formed to matrix surface, concrete technology parameter is: condensing lens f=300mm, 15*1 integration condensing lens, cladding power P=4100-4300W, spot size D=12*2, scan velocity V=450-470mm/min, overlapping rate 40%.
3, Laser Strengthening Layer cladding
(1) previous work
Angle is used to grind off except intermediate buffer layer surface scale;
(2) preparation of strengthening layer powder
Strengthening layer selects the wear-resisting powder of iron-based, and this powder chemistry composition by weight percent is carbon 1.2%, silicon 2.7%, chromium 5.5%, molybdenum 4.8%, boron 1.8%, manganese 3.2%, vanadium 2.2%, tungsten 7.0%, and all the other are iron and inevitable impurity.Before using, get this powder of 1.5Kg through 100 mesh sieve sieve after in drying baker adopt 200 DEG C dry 2-3 hour for subsequent use;
(3) laser cladding method
HGL-5000 type multifunctional numerical control laser-processing system is adopted to carry out cladding, regulate powder feeding rate, make individual layer cladding layer thickness be 1.5mm, two-layer cladding, adopt the preset automatic powder feeding system of gravity, under high power focused laser beam effect, at intermediate buffer layer surface cladding Laser Strengthening Layer, concrete technology parameter is: condensing lens f=300mm, cladding power P=4200-4500W, spot size D=3mm, scan velocity V=1050mm/min, overlapping rate 50%.
4, subsequent disposal
Carry out machine to strengthening layer surface to add, meet surface smoothness and dimensional requirement.
embodiment 2
The laser remanufacturing that this mine tram wheel is right and enhancement method, specifically comprise the steps.
1, flaw detection and process in early stage
(1) remove rusty stain, the greasy dirt of mine tram wheel effects on surface, carry out size, inner carrying out flaw detection;
(2) according to result of detection, Lathe quantity is set as 4 (the existing certain wearing and tearing of external diameter before turning, so Lathe quantity is not equal to external diameter loss amount) mm.
2, laser intermediate buffer layer cladding
(1) previous work
Remove cutting surface greasy dirt, carry out dimensional measurement, determine external diameter loss 11mm;
(2) preparation of intermediate buffer layer powder
Intermediate buffer layer selects Co-based alloy powder, and this powder chemistry composition by weight percent is: carbon 0.40%, silicon 3.5%, chromium 7.5%, iron 3.0%, boron 1.5%, vanadium 0.15%, and all the other are nickel and inevitable impurity.Before using, get this powder of 6Kg through 100 mesh sieve sieve after in drying baker adopt 200 DEG C dry 2-3 hour for subsequent use;
(3) laser cladding method
Adopt HGL-5000 type multifunctional numerical control laser-processing system to carry out cladding, regulate powder feeding rate, individual layer cladding layer thickness is 1.5mm, three layers of cladding, adopt gravity synchronous powder feeding system mode, under high power focused laser beam effect, at mine tram wheel, laser intermediate buffer layer is formed to matrix surface, concrete technology parameter is: condensing lens f=300mm, 15*1 integration condensing lens, cladding power P=4000 ~ 4100W, spot size D=12*2, scan velocity V=500-520mm/min, overlapping rate 38%.
3, Laser Strengthening Layer cladding
(1) previous work
Angle is used to grind off except intermediate buffer layer surface scale;
(2) preparation of laser cladding powder
Strengthening layer selects iron(-)base powder, and this powder chemistry composition by weight percent is: carbon 1.5%, silicon 2.3%, chromium 5.0%, molybdenum 4.6%, boron 1.6%, manganese 3.5%, vanadium 2.4%, tungsten 7.5%, and all the other are iron and inevitable impurity.Before using, get this powder of 1.5Kg through 100 mesh sieve sieve after in drying baker adopt 200 DEG C dry 2-3 hour for subsequent use;
(3) laser cladding method
HGL-5000 type multifunctional numerical control laser-processing system is adopted to carry out cladding, regulate powder feeding rate, individual layer cladding layer thickness is 1.5mm, two-layer cladding, adopt the preset automatic powder feeding system of gravity, under high power focused laser beam effect, at intermediate buffer layer surface cladding Laser Strengthening Layer, concrete technology parameter is: condensing lens f=300mm, cladding power P=4200-4500W, spot size D=3mm, scan velocity V=1050mm/min, overlapping rate 52%.
4, subsequent disposal
Carry out machine to strengthening layer surface after laser melting coating to add, make any surface finish and guarantee dimensional requirement.
Claims (3)
1. the laser remanufacturing that a mine tram wheel is right and enhancement method, comprise and impaired mine tram wheel measured carrying out flaw detection, remove damaged layer according to result of detection, adopted laser melting coating mode at mine tram wheel, cladding intermediate buffer layer on matrix to be carried out to size restoration, in intermediate buffer layer top cladding and hardening layer and sequent surface process, it is characterized in that:
Co-based alloy powder is adopted during laser melting coating intermediate buffer layer, this powder chemistry composition by weight percent is: carbon 0.33-0.50%, silicon 0.32-3.8%, chromium 0.65-7.5%, iron 0.25-3.5%, boron 0.10-1.5%, vanadium 0.10-0.2%, all the other are nickel and inevitable impurity, the mine tram wheel after recovery to outside dimension compared with the little 1.8-2.2mm of new product;
Iron(-)base powder is adopted during laser melting coating strengthening layer, this powder chemistry composition by weight percent is: carbon 0.10-1.5%, silicon 0.22-2.8%, chromium 4.5-6.0%, molybdenum 4.5-5.0%, boron 1.5-2.0%, manganese 3.0-3.5%, vanadium 2.0-2.5%, tungsten 6.5-7.5%, all the other are iron and inevitable impurity, described strengthening layer thickness is 2.5-3.0mm, and wherein reserved 0.7-0.8mm is as machining allowance.
2. the laser remanufacturing that mine tram wheel according to claim 1 is right and enhancement method, it is characterized in that: adopt multifunctional numerical control laser-processing system and gravity synchronous powder feeding system mode to carry out cladding, under high power focused laser beam effect, at mine tram wheel, laser intermediate buffer layer is formed to matrix surface, individual layer cladding thickness is 1.2-1.5mm, processing parameter is as follows: condensing lens f=300mm, 15*1 integration condensing lens, cladding power P=4000-4500W, spot size D=12*2, scan velocity V=400-600mm/min, overlapping rate is 35-40%.
3. the laser remanufacturing that mine tram wheel according to claim 1 is right and enhancement method, it is characterized in that: adopt multifunctional numerical control laser-processing system and the preset automatic powder feeding system of gravity to carry out cladding, under high power focused laser beam effect, at intermediate buffer layer surface cladding Laser Strengthening Layer, processing parameter is as follows: condensing lens f=300mm, cladding power P=4200-4500W, spot size D=3mm, scan velocity V=850-1050mm/min, overlapping rate is 45 ~ 55%.
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