CN107931827B - High-alloy laser rapid repairing method - Google Patents
High-alloy laser rapid repairing method Download PDFInfo
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- CN107931827B CN107931827B CN201710929524.2A CN201710929524A CN107931827B CN 107931827 B CN107931827 B CN 107931827B CN 201710929524 A CN201710929524 A CN 201710929524A CN 107931827 B CN107931827 B CN 107931827B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/34—Laser welding for purposes other than joining
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/60—Preliminary treatment
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Abstract
The invention discloses a high alloy laser rapid repair method, which belongs to the technical field of laser cladding and comprises the following steps: step 1, machining a nodular cast iron roller to be repaired to remove a fatigue layer; step 2, locally heating the nodular cast iron roller to be repaired; step 3, coating a transition layer by laser, wherein the material of the transition layer is an alloy material with HRC40 degrees; step 4, performing secondary machining on the roller coated with the transition layer in the step 3, and keeping the thickness of 0.5-1.5 mm; step 5, laser coating a surface layer; and 6, machining the roller coated with the surface layer in the step 5 for three times to remove burrs. The invention obviously improves the remanufacturing technical level of the nodular cast iron roller and high-end key parts thereof by the aspects of research and development integration of the complete equipment for the super-thick and large-area laser rapid three-dimensional forming, component design of cladding materials, determination of process parameters and the like.
Description
Technical Field
The invention belongs to the technical field of laser cladding, and particularly relates to a high-alloy laser rapid repair method.
Background
The remanufacturing takes parts of waste products as blanks, mainly takes an advanced surface engineering technology as a repairing means, and prepares a thin layer of wear-resistant, corrosion-resistant and fatigue-resistant surface coating on the surface of the damaged part, so that the performance and the quality of the coating are recovered and even exceed the state of a new product.
The laser rapid stereolithography refers to a large-scale laser Cladding (L ase Cladding) technology, is a novel part manufacturing and remanufacturing technology, relates to a high and new technology of multiple disciplines such as light, machine, electricity, materials, detection and control and the like, is the most important supporting technology of a laser advanced manufacturing technology, can solve the problem that a traditional manufacturing method cannot be completed, and is a high and new technology which is mainly supported and promoted by the country.
With the maturity and development of laser cladding technology, the laser cladding technology is successively and successfully applied to corrugated rollers, cylinder sleeve flame rings, engine parts and the like, and the repair of various key metal parts with high added value by taking laser as a main processing means is realized. With the development and the demand of scientific technology and engineering technology, the working conditions of metal parts are more and more rigorous, and the metal parts often work under extreme conditions of high alternating stress, high temperature, high speed, high corrosion and the like. Therefore, the material for manufacturing the metal component needs to have various properties at the same time to meet the special service conditions of the part. Moreover, the manufacturing cost of the parts is high, the manufacturing period is long, and once the parts fail, huge economic loss and safety accidents are generated. Such as turbine equipment, various important components such as: blades, rotor journals, valve stems, impellers, valves, and the like; aircraft engines, internal combustion engine components, and the like. The technical problems in engineering provide a new challenge for the laser cladding technology. Therefore, how to solve the problem of repairing the failed parts under extreme conditions is urgent.
The most advanced laser cladding technology known in the world today can achieve the ultra-thick, Joining Technologies up to 3 inches (76 mm), large area, Alabama L aser up to 1200mm x18000mm, high speed, and the fastest 6kw fiber laser up to 18 kg/h.
However, it should be noted that the advanced technology is only a single technical index that each company can achieve under different working conditions, and cannot reflect the current situation of the comprehensive technology in the industry, and especially, the technical complexity is further improved under the conditions of different fields and different working conditions.
The failures of the nodular cast iron roller and the high-end key parts thereof mainly comprise three types of fracture, corrosion and abrasion, and the abrasion failure accounts for 80 percent. According to statistics, the economic loss caused by frictional wear in China is more than 1000 million yuan per year, and 300 million tons of metal wear-resistant materials are consumed per year only by abrasive wear. The performance of the nodular cast iron roller as a rolling tool with large consumption affects the quality of steel products, and the cost of the nodular cast iron roller affects the cost of the steel products; the current mainstream manufacturing method of the nodular cast iron roller is centrifugal composite casting, the structure of a working layer is thick, the macrosegregation is serious, the distribution of carbides is not uniform, and a bonding layer is easy to combine badly, so that the performance of the nodular cast iron roller is not good enough and not stable enough; the working layer of the nodular cast iron roller only accounts for about 20 percent of the weight of the whole roller, the part is scrapped after the part is used up, the rest 80 percent of metal is remelted to be used, a large amount of electric power is consumed (at least 1500 degrees of electricity is needed for processing each ton of the nodular cast iron roller), and because the organizational inheritance problem exists in metal smelting, the waste roller used as a return material is easy to inherit some defects into a new roller during smelting, and the performance of the new roller is influenced; therefore, the remanufacturing of the nodular cast iron roller has great significance for energy conservation, emission reduction, cost reduction and efficiency improvement in the roller industry and the steel industry.
The invention patent of China patent application No. 01144662.5, published as 2002, 6.5.a discloses special equipment for manufacturing a high-speed wire rod roller by laser cladding and a cladding method, which are applied to the technical field of laser processing, and the special equipment comprises a roller wheel blank rotary table 1 with a three-jaw chuck 2, a mandrel 3 fixed on the three-jaw chuck 2, a preheating furnace 15 for preheating a roller wheel blank 14 fixed on the mandrel 3, a special laser radiation protection window 6 arranged at the top of the preheating furnace, a thermocouple 12 arranged in the furnace through a thermocouple temperature measuring hole 11 at the upper part of the preheating furnace, an electronic temperature control device 9, a laser working device and a split type powder feeding device. The cladding method is characterized in that metal powder is filled on the arc-shaped curved surface of the steel-based wheel blank, the roller working layer is manufactured by adopting a laser cladding method, 2-5 layers are clad on each rolling channel on the surface of the wheel blank, 11-15 layers are overlapped, the overlapping area between the layers is 40-60%, and the cladding speed is set to be 360-720 DEG/min through a roller wheel blank turntable.
Chinese patent application No. 200810052212.9, published as 2008/7/23, discloses a method for recovering and improving the service life of hot and cold auxiliary rolls. The method is characterized by comprising the following steps: (1) stress detection is carried out on the working roll body of the failed or scrapped roll, and then crack and peeling layer damage degree detection is carried out on the part displaying stress concentration; performing strength analysis and residual life evaluation according to the damage degree; on the basis, remanufacturing manufacturability and economy evaluation are carried out on the roller, and full life prediction and full life cycle design are carried out; (2) the roller with the designed full life is subjected to rapid prototyping by applying a laser entity free forming technology; (3) and after the roller is rapidly deposited and formed by laser, immediately carrying out material strengthening and toughening process treatment on the deposited layer.
From the prior art, in the technical field of nodular cast iron roller repair, the laser cladding technology is difficult to realize the ultra-thick and large-area repair effect, and even has a large barrier in solving the technical problems of cladding cracking, pores of a cladding layer, bonding layer strength and the like, so that the application of the laser cladding technology to the nodular cast iron roller repair and remanufacture is far from the priority.
Disclosure of Invention
1. Problems to be solved
Aiming at the technical problems of cladding cracking, cladding layer air holes, insufficient bonding layer strength and the like in the existing laser cladding technology, the invention provides a high-alloy laser rapid repair method, which remarkably improves the remanufacturing technical level of nodular cast iron rollers and high-end key parts thereof by the aspects of research and development integration of super-thick and large-area laser rapid three-dimensional forming complete equipment, component design of cladding materials, determination of process parameters and the like.
2. Technical scheme
In order to solve the above problems, the present invention adopts the following technical solutions.
A high alloy laser rapid repair method comprises the following steps:
step 1, machining a nodular cast iron roller to be repaired to remove a fatigue layer;
step 2, locally heating the nodular cast iron roller to be repaired;
and 3, coating a transition layer by laser, wherein the material of the transition layer is an alloy material with HRC40 degrees, and the alloy material comprises the following components: al: 11%, Cu: 6 percent, and the balance of Ni; the coating process comprises the following steps: power 3kw-5kw, spot diameter: 10mm2Focal length: 300-: 120-150r/s, lap width: 1-1.5 mm;
step 4, performing secondary machining on the roller coated with the transition layer in the step 3, and keeping the thickness of 0.5-1.5 mm;
step 5, laser coating a surface layer, wherein the surface layer material comprises the following components: mg: 1.2% -1.8%, Zn: 0.25%, Cu: 3.8% -4.4%, Mn: 0.3-0.4%, Si: 0.5%, Fe: 0.8%, Ni: 1.1%, Mo: 0.5 to 0.8 percent of Al, and the balance of Al; the coating process comprises the following steps: power 4kw-6kw, spot diameter: 10mm2Focal length: 280-290mm, workpiece rotation speed: 120-150r/s, lap width: 1-1.5 mm;
and 6, machining the roller coated with the surface layer in the step 5 for three times to remove burrs.
Preferably, the machining in step 1 above is turning.
Preferably, the local heating in step 2 is performed by a coil induction heating method.
Preferably, the laser coating in step 3 and step 5 uses a 4kw-6kw fiber coupled-out welder.
Preferably, the composition of the surface layer material in the step 5 is as follows: mg: 1.5%, Zn: 0.25%, Cu: 4.0%, Mn: 0.35%, Si: 0.5%, Fe: 0.8%, Ni: 1.1%, Mo: 0.65% and the balance of Al.
Preferably, the surface layer material in the step 5 is powder, and the particle diameter of the surface layer material is 600-899 nm.
3. Advantageous effects
Compared with the prior art, the invention has the beneficial effects that:
(1) according to the method, the transition layer is coated before the surface layer is coated, so that the surface layer can be more firmly adhered to the nodular cast iron roller, and meanwhile, the adhesion firmness degree can be improved by machining and heating the surface of the nodular cast iron roller to be repaired;
(2) the method adopts the 4kw-6kw optical fiber coupling output welding machine, the power is high, and simultaneously, because the carbon content of the roller made of nodular cast iron is high, the carbon element is easy to be oxidized during welding, so the surface coating material adopts a special formula, wherein the rare metal element can be combined with the carbon element to form a protective layer, the high-temperature coating process of the welding machine is not influenced, the original high-hardness performance of the nodular cast iron roller is kept, and the surface hardness of the repaired roller reaches more than HRC60 degrees;
(3) the invention adopts a coil electromagnetic induction heating method to locally heat the part to be repaired, has high heating efficiency and uniform heating, and is beneficial to improving the welding performance;
(4) the method adopts the powdery welding coating material with the particle size of 600-899 nanometers, is easy to melt, is more uniformly coated at high temperature, and is favorable for improving the welding quality.
Detailed Description
The invention is further described with reference to specific examples.
Example 1
A high-alloy laser rapid repair method comprises the following steps of:
step 1, machining a nodular cast iron roller to be repaired to remove a fatigue layer;
specifically, a CX5112A/WF type lathe is adopted for turning, and the turning thickness is 10 mm;
step 2, locally heating the nodular cast iron roller to be repaired;
specifically, a coil induction heating method is adopted to heat the surface of the carrier roller to be repaired, and the next step is carried out when the heating temperature is up to 1900 ℃;
and 3, coating a transition layer by laser, wherein the material of the transition layer is an alloy material with HRC40 degrees, and the alloy material comprises the following components: al: 11%, Cu: 6 percent, and the balance of Ni;
the coating process comprises the following steps: fiber coupling output welding machine of power 4kw, the facula diameter: 10mm2Focal length: 310mm, workpiece rotation speed: 135r/s, lap width: 1.2 mm;
step 4, performing secondary machining on the roller coated with the transition layer in the step 3, and keeping the thickness of 0.5-1.5 mm;
the step also adopts turning processing, the lathe is unchanged, and the step 1 is synchronized;
step 5, laser coating a surface layer, wherein the surface layer material comprises the following components: mg: 1.5%, Zn: 0.25%, Cu: 4.0%, Mn: 0.35%, Si: 0.5%, Fe: 0.8%, Ni: 1.1%, Mo: 0.65 percent, the balance being Al, the surface layer material being powder, the particle diameter being 600-899 nanometers;
the coating process comprises the following steps: adjusting the power of the optical fiber coupling output welding machine to 5kw, the diameter of a light spot: 10mm2Focal length: 285mm, workpiece rotation speed: 150r/s, lap width: 1.5 mm;
the key point of the step is that a coating material containing rare metal elements is adopted, and because the carbon content of the roller made of the nodular cast iron is high, the carbon elements are easy to oxidize during welding, so that the surface coating material adopts a special formula, wherein the rare metal elements can be combined with the carbon elements to form a protective layer, the surface coating material is not influenced in the high-temperature coating process of a welding machine, the original high-hardness performance of the nodular cast iron roller is kept, and the surface hardness of the repaired roller reaches more than HRC60 degrees;
step 6, machining the roller coated with the surface layer in the step 5 for three times to remove burrs;
turning is adopted in the step, a lathe is unchanged, and the step 1 is synchronized.
Claims (1)
1. A high alloy laser rapid repair method comprises the following steps:
step 1, machining a nodular cast iron roller to be repaired to remove a fatigue layer;
step 2, locally heating the nodular cast iron roller to be repaired;
and 3, coating a transition layer by laser, wherein the material of the transition layer is an alloy material with HRC40 degrees, and the alloy material comprises the following components: al: 11%, Cu: 6 percent, and the balance of Ni; the coating process comprises the following steps: power 3kw-5kw, spot diameter: 10mm2Focal length: 300-: 120-150r/s, lap width: 1-1.5 mm;
step 4, performing secondary machining on the roller coated with the transition layer in the step 3, and keeping the thickness of 0.5-1.5 mm;
step 5, laser coating a surface layer, wherein the surface layer material comprises the following components: mg: 1.5%, Zn: 0.25%, Cu: 4.0%, Mn: 0.35%, Si: 0.5%, Fe: 0.8%, Ni: 1.1%, Mo: 0.65% and the balance of Al; the coating process comprises the following steps: power 4kw-6kw, spot diameter: 10mm2Focal length: 280-290mm, workpiece rotation speed: 120-150r/s, lap width: 1-1.5 mm;
step 6, machining the roller coated with the surface layer in the step 5 for three times to remove burrs;
the machining in the step 1 is turning;
the local heating in the step 2 adopts a coil induction heating method, and the next step is carried out when the heating temperature is more than 1900 ℃;
in the step 5, the surface layer material is in a powder shape, and the particle diameter of the surface layer material is 600-899 nm.
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| CN201710929524.2A CN107931827B (en) | 2017-10-09 | 2017-10-09 | High-alloy laser rapid repairing method |
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| CN110102878B (en) * | 2019-06-03 | 2020-04-28 | 燕山大学 | CMT and laser cladding composite repair method for inner hole of flat head sleeve of main shaft of rolling mill |
| CN111872633A (en) * | 2020-07-14 | 2020-11-03 | 苏州市鑫渭阀门有限公司 | Valve and shaft surface regeneration strengthening process |
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| CN1796602A (en) * | 2004-12-24 | 2006-07-05 | 李贞� | Method for repairing large-scale roller |
| CN101249510A (en) * | 2008-03-27 | 2008-08-27 | 安徽工业大学 | Repaired roller and method for repairing roller |
| CN102259187A (en) * | 2011-04-01 | 2011-11-30 | 周明 | Method and device for manufacturing and repairing composite roll with high performance through laser spray forming |
| CN102691061A (en) * | 2012-06-11 | 2012-09-26 | 北京大陆天瑞激光工程技术有限公司 | Laser cladding manufacturing process for hot-rolled spheroidal graphite cast iron roller flat head |
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Address after: 243000 No. 4598, Cihu River Road, Cihu high tech Zone, Maanshan City, Anhui Province Patentee after: MAANSHAN Shenma Machinery Manufacturing Co.,Ltd. Address before: 243000 No. 158, Taodian Road, Cihu high tech Development Zone, Maanshan City, Anhui Province Patentee before: MAANSHAN SHENMA MACHINERY MANUFACTURING Co.,Ltd. |