CN108456879B - Method for strengthening steel rail by efficient composite cladding of laser-auxiliary heat source - Google Patents
Method for strengthening steel rail by efficient composite cladding of laser-auxiliary heat source Download PDFInfo
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- CN108456879B CN108456879B CN201810063575.6A CN201810063575A CN108456879B CN 108456879 B CN108456879 B CN 108456879B CN 201810063575 A CN201810063575 A CN 201810063575A CN 108456879 B CN108456879 B CN 108456879B
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
- C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
- C23C24/106—Coating with metal alloys or metal elements only
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/06—Surface hardening
- C21D1/09—Surface hardening by direct application of electrical or wave energy; by particle radiation
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/04—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for rails
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D2211/00—Microstructure comprising significant phases
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D2211/00—Microstructure comprising significant phases
- C21D2211/009—Pearlite
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Abstract
The invention discloses a method for strengthening a steel rail by high-efficiency composite cladding through a laser-auxiliary heat source, wherein the laser and the auxiliary heat source simultaneously act on a region to be clad on the surface of the steel rail, the laser is used as a main heat source to simultaneously and rapidly melt a cladding layer material and a partial substrate material on the surface of the steel rail to form a molten pool, the auxiliary heat source and the laser heat source move in the same direction and at the same speed to synchronously preheat or/and post-heat the laser molten pool, a heat affected zone and the surface layer of the steel rail substrate, so that the temperature gradient is reduced, the cooling rate is reduced, and the martensitic transformation and cracking phenomena. The invention can lead the cooling time of the heat affected zone to be larger than the critical cooling time of the transformation from austenite to pearlite in a CCT curve or a TTT curve through the composite action, lead the mechanical properties of the cladding layer, the heat affected zone and the substrate to be reasonably matched, lead the hardness curve to be smoothly distributed and lead the whole fatigue property to be good. The method can be used for cladding the metal layer on the surface of the railway steel rail on site on line, and can also be used for cladding the surface of the steel rail in a production workshop.
Description
Technical Field
The invention belongs to the field of material processing, and particularly relates to a method for efficiently preparing a metal cladding layer on the surface of a steel rail by adopting laser-auxiliary heat source composite cladding. The method can be used for improving the wear resistance and the contact fatigue performance of the steel rail, and can also be used for solving the problems of poor railway shunting, repairing of damaged steel rails and the like.
Background
China has rapid rail transit development, and the national railway operation mileage reaches 12.4 kilometers by 2016. With the increase of railway traffic and train speed and axle weight, the problem of rail damage, such as rail wear, rolling contact fatigue, rail corrosion, etc., is increasingly prominent. The damage of the steel rail mainly occurs on the surface, so the preparation of the coating on the surface of the steel rail has important significance for prolonging the service life of the steel rail.
Thermal spraying, electroplating and surfacing are the main methods for preparing metal coatings on the surfaces of steel rails at present. The thermal spraying and electroplating coating is mechanically combined with the steel rail substrate, the binding force is weak, and the coating is easy to fall off in the friction process of the wheel rail. The surfacing layer and the steel rail substrate are metallurgically bonded, but the method has large heat input and heat affected zone, the surfacing layer has poor structure and performance uniformity, and martensite structure is easily induced in the steel rail substrate.
Compared with plasma arc and electric arc surfacing, laser cladding has the advantages of high energy density, small heat affected zone, small heat input, low residual stress, small substrate penetration, high cladding efficiency and the like, is widely applied to preparation of surface strengthening coatings of metal parts, additive manufacturing and the like, and Chinese invention patent No. CN 107099793A discloses a method for improving the wear resistance of heavy-duty wheel rails by laser cladding cobalt alloy coatings, and the method utilizes high-power laser to clad cobalt alloy powder on the surfaces of the wheel rails so as to reduce the surface friction coefficient, improve the wear resistance and prolong the service life of the wheel rails. However, due to the rapid heating and cooling effect of the laser, a high-carbon acicular martensite structure is generated in the heat affected zone of the rail. The martensite structure has high hardness, but the toughness is low, so that the rail fracture risk is easily caused, and the martensite structure in the steel rail is prohibited in the standard TB/T2344-2003 of the railway industry. Secondly, under the high laser scanning speed, the cladding layer and the heat affected zone are easy to crack due to the high cooling speed and the large temperature gradient between the cladding layer and the steel rail substrate, and the safe operation of the train is influenced.
The high-energy laser beam and the auxiliary heat source are combined to realize composite processing, so that the problems can be effectively solved. Patent document (publication No. CN101125394A) discloses an automatic powder feeding laser induction hybrid cladding method and device, which adopts laser and induction heat source hybrid processing, not only can greatly improve cladding efficiency, but also can solve the problem that an alloy material with poor weldability is easy to crack in the laser cladding process. However, the method does not consider the problems of how to reduce and avoid the martensite transformation of the heat affected zone when cladding the coating on the large-sized high-carbon steel substrate (such as a steel rail), and the technical problems of matching the mechanical properties of the cladding layer, the heat affected zone and the substrate in a specific service environment (rolling contact of a wheel rail).
Disclosure of Invention
The invention provides a method for efficiently preparing a high-performance cladding layer on the surface of a steel rail by adopting a laser-auxiliary heat source so as to fulfill the aims of strengthening and repairing the surface of the steel rail and the like. The laser and the auxiliary heat source act on the steel rail to-be-clad processing surface simultaneously, so that the cracking phenomenon of a cladding layer and a heat affected zone at a high scanning speed can be avoided, the generation of harmful tissues such as martensite in the heat affected zone can be avoided, and the good matching of the mechanical properties of the cladding layer, the heat affected zone and a substrate is ensured. The invention can be used for preparing the high-performance cladding layer on the surface of the steel rail so as to improve the wear resistance and the contact fatigue performance of the steel rail, and can also be used for solving the problems of poor shunting of the railway, repair of damaged steel rails and the like.
The invention provides a method for strengthening a steel rail by high-efficiency composite cladding by using a laser-auxiliary heat source, which is characterized in that the laser and the auxiliary heat source simultaneously act on a region to be clad on the surface of the steel rail, the laser is used as a main heat source to rapidly melt a cladding layer material and a partial substrate material on the surface of the steel rail to form a molten pool, the auxiliary heat source is positioned in front of or/and behind the laser heat source and moves in the same direction and at the same speed as the laser heat source to synchronously preheat or/and post-heat the laser molten pool, a laser heat affected zone and the surface layer of the steel rail substrate so as to reduce the cooling rate of the laser molten pool and the heat affected zone and avoid the phenomena of martensite transformation of the.
As an improvement of the technical scheme, the laser and the auxiliary heat source reasonably regulate and control the temperature cycle curve of the heat affected zone under the action of the laser through composite action, so that the cooling time of the heat affected zone is longer than the critical cooling time for the transformation from austenite to pearlite in a continuous cooling curve (CCT curve) and an isothermal transformation curve (TTT curve) of a steel rail material, the critical condition for the complete transformation from austenite to pearlite is met, the interval between sheets of the heat affected zone is smaller than or equal to the sheet pearlite of a steel rail substrate, the hardness is between a cladding layer and the substrate, the mechanical properties of the cladding layer, the heat affected zone and the substrate are reasonably matched, the hardness curve is distributed smoothly, and the overall fatigue performance is good.
As a further improvement of the technical proposal, the auxiliary heat source adopts any one or the combination of any several of induction heating, oxyacetylene flame and propane blowtorch; preheating at 100-1000 deg.C, and post-heating at 300-700 deg.C; the thickness of the metal cladding layer obtained by single processing is 0.1-2mm, the width is 3-20mm, and the hardness of the cladding layer can be adjusted within the range of HV250-HV500 according to the specific requirements of the track; the width of the laser heat affected zone is less than 1mm, the hardness is HV250-HV400, and the martensitic transformation of the heat affected zone can be avoided; the induction heating is realized by adopting an induction power supply and an induction coil. Wherein, the induction coil is formed by bending and welding a copper pipe, a magnetizer is embedded on the copper pipe in a working area, the lower surface of the copper pipe is parallel to a cladding surface of the steel rail, and the gap is 0.5-15 mm; the heating surface is in a straight-line structure along the length direction of the steel rail, and the length of the heating surface is 10-500 mm.
The method comprises the following concrete implementation steps:
(1) firstly, polishing the area to be clad on the surface of the steel rail to remove rust and pollutants on the surface;
(2) adjusting the defocusing amount of a laser beam, and setting a laser spot into a round shape with the diameter of 3-10 mm or a rectangular shape with the diameter of (1-3) mmx (6-30) mm;
(3) adjusting the relative position of the laser spot and the auxiliary heat source to enable the laser spot to be in front of, in the middle of or behind the auxiliary heat source;
(4) starting a laser and an auxiliary heat source, synchronously feeding or presetting a coating material in a laser irradiation area on the surface of the steel rail by adopting an automatic powder feeder, focusing a laser beam and then injecting the laser beam onto a steel rail substrate to form a molten pool, and forming a cladding layer on the surface of the steel rail after the molten pool is solidified; the auxiliary heat source has the effects of preheating, post-heating and preheating and post-heating on the steel rail, wherein the preheating temperature is 100-1000 ℃, and the post-heating temperature is 300-700 ℃;
(5) after a metal cladding layer is cladded, judging whether the thickness of the cladding layer meets the requirement of a working condition, if so, ending the cladding process; if not, repeating the steps (2), (3) and (4) until the required thickness is reached;
(6) after cladding, detecting the surface of the corrosion-resistant cladding layer by adopting penetration or ultrasonic flaw detection to ensure that the cladding layer has no metallurgical defects;
(7) according to application requirements, the tread of the steel rail is selected to be cleaned and profile-trimmed, so that the surface is smooth.
The cladding layer material can be an iron-based alloy, and the main chemical components are (Wt.%): C (0.01-0.60), (10-40) Cr, (5-18) Ni, (0.1-3.0) Si, (0-3) B, (0-3) Mo, (1-3) Mn and the balance Fe;
the cladding layer material can be nickel-based alloy, and comprises the following main chemical components (Wt.%): (0.01-0.50) C, (20-30) Cr, (5-10) W, (3-5) Si, (0-3) B, (5-10) Fe, and the balance of Ni;
the cladding layer material can be a cobalt-based alloy, and the main chemical components are (Wt.%): (0.01-0.5) C, (20-35) Cr, (1-10) Ni, (1-3) Si, (5-15) W, (0-3) B, (0.5-2) Mn and the balance of Co.
The invention has the following advantages:
the method comprises the following steps that firstly, laser and an auxiliary heat source act on a region to be clad on the surface of a steel rail at the same time, a cladding layer material and a thin layer material on the surface of the steel rail are rapidly melted to form a molten pool by a high-energy laser beam, the auxiliary heat source synchronously preheats and afterheats the laser molten pool, a heat affected zone and the surface of a steel rail substrate, and the temperature gradients of the molten pool, the heat affected zone and a steel rail substrate are reduced, so that the cooling rate is reduced, and the cracking and peeling phenomena of a metal cladding layer and the;
② the relative position of the laser and the auxiliary heat source, the laser processing power, the laser scanning rate and the heating temperature of the auxiliary heat source to the steel rail, reasonably controlling the temperature cycle curve of the heat affected zone, ensuring that the cooling time is longer than the critical cooling time for transforming austenite to pearlite in a CCT curve and a TTT curve, meeting the critical condition for completely transforming austenite to pearlite, transforming the heat affected zone into a fine lamellar pearlite structure with the lamellar spacing smaller than or equal to that of the steel rail substrate, and ensuring that the hardness is between the cladding layer and the substrate, so that the cladding layer, the heat affected zone and the substrate are reasonably matched in mechanical properties, the hardness curve is smoothly distributed, and the overall fatigue performance is good.
compared with other methods such as plasma arc, electric arc and the like, the laser energy density is high, the heat affected zone is small, the martensite structure of the induction coil and other auxiliary heat sources can be eliminated only by heating the width and the depth of the induction coil and other auxiliary heat sources to be larger than the width of the heat affected zone, the whole heat input is small, the residual stress and the deformation of the steel rail in machining are small, the stability is high, the flexibility of the device is good, the machining precision is high, and the steel rail damaged in different degrees can be repaired.
and fourthly, the dilution rate of the cladding layer is low, and the coating is particularly effective for cladding of a thinner coating, and when the thickness of the cladding layer is less than 0.5mm, the dilution rate of the coating is less than 5 percent, so that the wear resistance and the corrosion resistance of the cladding layer can be ensured.
when the laser power is 1-20kW, the deposition rate of the cladding layer can reach 10-250g/min, and the scanning speed reaches 0.4-30m/min, compared with the pure laser cladding process, the deposition efficiency is improved by 3-15 times;
the method has strong universality, can directly and efficiently prepare the wear-resistant and corrosion-resistant cladding layer, the fatigue-resistant cladding layer and the like with uniform components and matched mechanical properties on the surface of the steel rail, and can also repair the locally damaged steel rail. The reinforced or repaired steel rail has smooth hardness distribution curve along the depth direction, the mechanical properties of the cladding layer, the heat affected zone and the substrate are mutually matched, the integral fatigue performance is good, and the coating can not fall off in the service process. Meanwhile, each process assembly adopted by the method is high in integration level, is convenient to integrate with a related processing platform, can be used for a fixed laser processing machine tool to perform off-line processing, and can also be applied to mobile laser processing equipment (such as a mobile laser processing vehicle) to perform on-line processing strengthening or repairing on a railway site.
Drawings
FIG. 1 is a top view of laser-induction post-thermal composite cladding of a rail surface before laser spots are positioned on induction heating;
FIG. 2 is a top view of the steel rail surface laser-induction preheating and post-induction thermal composite cladding with laser spots positioned in the middle of induction heating;
FIG. 3 is a top view of the laser-induction heating + oxyacetylene flame (or laser-induction heating + propane torch) heating composite cladding on the surface of the steel rail;
FIG. 4 is a top view of the laser-oxyacetylene flame (or laser-propane torch) heating composite cladding on the surface of the steel rail;
FIG. 5 is a hardness distribution diagram of a steel rail with a Fe-based metal cladding layer prepared by laser-induction post-thermal composite cladding along the depth direction;
FIG. 6 is a hardness distribution diagram of a Ni-based metal cladding layer steel rail prepared by laser-induction preheating and induction post-thermal composite cladding along the depth direction;
fig. 7 is a hardness distribution diagram of a Co-based metal cladding layer steel rail prepared by laser-induction heating and oxyacetylene flame (or laser-induction heating and propane torch) heating composite cladding along the depth direction.
FIG. 8 is a depth-direction hardness distribution diagram of a Fe-based metal cladding layer steel rail prepared by laser-oxyacetylene flame (or laser-propane torch) composite cladding;
in the figure, 1, laser spot, 2, induction heating coil, 2(a), induction preheating coil, 2(b), induction post-heating coil, 3, oxyacetylene (or propane torch) flame.
Detailed Description
The following further describes embodiments of the present invention with reference to the drawings. It should be noted that the description of the embodiments is provided to help understanding of the present invention, but the present invention is not limited thereto. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
The invention takes laser as a main heat source to clad alloy materials on the surface of the steel rail, the auxiliary heat source preheats or/and afterheats the steel rail to reduce the cooling rate of a cladding layer and a heat affected zone, a functional cladding layer with wear resistance, fatigue resistance and corrosion resistance can be efficiently prepared on the surface of the steel rail or the damaged steel rail can be repaired, the thickness of the cladding layer obtained by single processing is 0.1-2mm, the hardness can be adjusted in the range of HV250-HV500 according to the specific requirements of a track. Meanwhile, by adopting the technical route provided by the invention, martensite is not generated in the heat affected zone of the steel rail, and the cladding layer is reasonably matched with the mechanical property of the steel rail substrate, so that the steel rail has better bending fatigue and contact fatigue properties while being reinforced and repaired. The invention is further illustrated with reference to the figures and examples.
The invention provides a method for strengthening a steel rail by efficient composite cladding of a laser-auxiliary heat source. The method can be integrated with fixed laser processing equipment to process the steel rail off line, and can also be integrated with a vehicle-mounted laser processing platform to process, reinforce or repair the steel rail on line on a railway site. The implementation steps comprise:
(1) firstly, polishing the area to be clad on the surface of the steel rail to remove rust and pollutants on the surface;
(2) adjusting the defocusing amount of a laser beam, and setting a laser spot into a round shape with the diameter of 3-20mm or a rectangular shape with the diameter of (1-3) mmx (6-30) mm;
(3) adjusting the relative position of the laser spot and the auxiliary heat source to enable the laser spot to be in front of, in the middle of or behind the auxiliary heat source;
(4) starting a laser and an auxiliary heat source, synchronously feeding (or pre-arranging) alloy powder materials into a laser irradiation area on the surface of the steel rail by adopting an automatic powder feeder, focusing a laser beam, then injecting the laser beam onto a steel rail substrate to form a molten pool, and forming a metal coating on the surface of the steel rail after the molten pool is solidified; the auxiliary heat source has the effects of preheating, post-heating and preheating and post-heating on the steel rail, wherein the preheating temperature is 100-1000 ℃, and the post-heating temperature is 300-700 ℃;
(5) after a metal cladding layer is cladded, judging whether the thickness of the cladding layer meets the requirement of a working condition, if so, ending the cladding process; if not, repeating the steps (2), (3) and (4) until the required thickness is met;
(6) after cladding, detecting the surface of the corrosion-resistant cladding layer by adopting penetration or ultrasonic flaw detection to ensure that the cladding layer has no metallurgical defects;
(7) and (4) selecting to clean and trim the tread of the steel rail according to application requirements, and flattening the surface to obtain a finished product.
Example (c):
the first embodiment is as follows: railway online laser-induction post-heating efficient composite cladding
The steel rail repairing method is used for efficiently strengthening and repairing a service steel rail on a railway site, induction heating is used as an auxiliary heat source, and an industrial manipulator or a three-dimensional motion shaft is adopted as a processing motion and position control unit. And heating the area to be clad on the surface of the steel rail through the induction heating assembly and the temperature control mechanism, and controlling the heating temperature and time. The induction heating assembly comprises an induction power supply and an induction coil, the temperature control mechanism comprises an infrared thermometer and a temperature controller, the induction coil is connected with the induction power supply, the infrared thermometer is connected with the temperature controller, and the temperature controller is connected with the induction power supply through a data line. And a detection signal of the infrared thermometer is input into the temperature controller, and after operation, the temperature controller outputs a control signal to adjust the output power of the induction heating power supply, so that the control of the induction heating temperature of the steel rail is realized. The laser spot is focused in front of the induction coil as shown in fig. 1. Preparing a metal cladding layer on the surface of a steel rail by laser-induction post-thermal composite cladding, which basically comprises the following implementation steps:
(1) the iron-based alloy powder is selected as a cladding material, and the main chemical components (Wt.%) are (0.01-0.60) C, (10-40) Cr, (5-18) Ni, (0.1-3.0) Si, (0-3) B, (0-3) Mo, (1-3) Mn and the balance Fe.
(2) Firstly, polishing a cladding area on the surface of the steel rail to remove rust and pollutants on the surface;
(3) adjusting the position of the induction coil to enable the lower surface of the induction coil to be parallel to the region to be cladded on the surface of the steel rail, wherein the gap is 5 mm; aiming at the induction heating area on the surface of the rail by an infrared thermometer, connecting the infrared thermometer with a temperature controller and an induction power supply, detecting and controlling the induction heating temperature, and setting the induction heating temperature to 700 ℃;
(4) and adjusting the defocusing amount of the laser beam and the relative position of the laser spot and the induction coil to focus the laser spot on the surface of the steel rail in front of the induction coil. The laser facula is a circular facula with the diameter of 3mm, the powder feeding amount of the powder feeder is 10g/min, the laser power is 1kW, and the laser scanning speed is 0.4 m/min.
(5) And starting the motion control unit, the laser and the induction heating power supply. Synchronously feeding powder (or pre-arranging) to a laser irradiation area on the surface of the steel rail by adopting an automatic powder feeder, focusing a laser beam, then injecting the laser beam onto a steel rail substrate to form a molten pool, and forming a metal coating on the surface of the steel rail after the molten pool is solidified;
(6) after cladding a layer, judging whether the thickness of the cladding layer meets the requirement of the working condition, if so, ending the cladding process; if not, repeating the processes (2), (3), (4) and (5) until the thickness requirement is met;
(7) after cladding, detecting the surface of the metal coating by adopting penetration or ultrasonic flaw detection to ensure that the cladding layer has no metallurgical defects;
(8) and according to application requirements, cleaning and profile trimming are carried out on the tread of the steel rail, so that the surface is smooth, and a finished product is obtained.
The thickness of the iron-based metal cladding layer prepared in the example is 0.1mm, the mechanical properties of the cladding layer, the heat affected zone and the steel rail substrate are reasonably matched, and the hardness distribution along the depth direction of the steel rail is shown in figure 5.
Example two: railway online laser-induction preheating and post-induction heat efficient composite cladding
In the embodiment, the service steel rail is efficiently strengthened and repaired on the railway site, induction heating is used as an auxiliary heat source, the induction heating control mechanism is the same as that in the first embodiment, and the machining motion and position control unit adopts an industrial manipulator or a three-dimensional motion shaft. Focusing laser spots on the middle of the induction coil, as shown in fig. 2, preparing a metal cladding layer on the surface of the steel rail by laser-induction preheating and post-induction thermal composite cladding, which basically comprises the following implementation steps:
(1) the nickel-based alloy powder is selected as a cladding material, and the main chemical components are as follows (Wt.%): (0.01-0.50) C, (20-30) Cr, (5-10) W, (3-5) Si, (0-3) B, (5-10) Fe, and the balance of Ni;
(2) firstly, polishing a cladding area on the surface of the steel rail to remove rust and pollutants on the surface;
(3) adjusting the position of the induction coil to enable the lower surface of the induction coil to be parallel to the region to be cladded on the surface of the steel rail, wherein the gap is 0.5 mm; aiming at the induction heating area on the surface of the rail by an infrared thermometer, connecting the infrared thermometer with a temperature controller and an induction power supply, detecting and controlling the induction heating temperature, and setting the induction heating temperature to be 500 ℃;
(4) and adjusting the defocusing amount of the laser beam and the relative position of the laser spot and the induction coil to focus the laser spot on the surface of the steel rail in front of the induction coil. The laser facula is a rectangle with the diameter of 1 multiplied by 6mm, the powder feeding quantity of the powder feeder is 50g/min, the laser power is 5kW, and the laser scanning speed is 2 m/min.
(5) And starting the motion control unit, the laser and the induction heating power supply. Synchronously feeding powder (or pre-arranging) to a laser irradiation area on the surface of the steel rail by adopting an automatic powder feeder, focusing a laser beam, then injecting the laser beam onto a steel rail substrate to form a molten pool, and forming a metal cladding layer on the surface of the steel rail after the molten pool is solidified;
(6) after cladding one layer, judging whether the thickness of the cladding layer meets the requirement of the working condition, if so, ending the cladding process; if not, repeating the processes (2), (3), (4) and (5) until the thickness requirement is met;
(7) after cladding, detecting the surface of the metal coating by adopting penetration or ultrasonic flaw detection to ensure that the cladding layer has no metallurgical defects;
(8) and according to application requirements, cleaning and profile trimming are carried out on the tread of the steel rail, so that the surface is smooth, and a finished product is obtained.
In this example, the induction coil is composed of two parts, 4(a) and 4(b), and the two parts are connected by a copper pipe, 4(a) plays a role in preheating the steel rail, and 4(b) plays a role in delaying the cooling rate of the steel rail. In practical application, on the premise of reasonable matching of mechanical properties, cladding efficiency can be effectively improved, and energy conservation is facilitated. The thickness of the prepared nickel-based metal cladding layer is 0.5mm, the mechanical properties of the cladding layer, the heat affected zone and the steel rail substrate are reasonably matched, and the hardness distribution along the depth direction of the steel rail is shown in figure 6.
Example three: off-line type steel rail surface laser-induction heating and oxyacetylene flame (propane torch) heating efficient composite cladding
This example provides off-line rail reinforcement and repair with induction heating and oxyacetylene flame (or propane torch) as the auxiliary heat source. The laser spot is focused in front of the induction coil, the oxyacetylene flame (or propane torch) preheats the surface of the steel rail to be clad, as shown in fig. 3, the laser and the induction coil move in the same direction and at the same speed, and the induction heating synchronously heats the steel rail laser melting pool and the heat affected zone, and the basic implementation steps are as follows:
(1) selecting cobalt-based alloy powder as a cladding material, wherein the main chemical components are as follows (Wt.%): (0.01-0.5) C, (20-35) Cr, (1-10) Ni, (1-3) Si, (5-15) W, (0-3) B, (0.5-2) Mn, and the balance of Co;
(2) firstly, polishing a cladding area on the surface of the steel rail to remove rust and pollutants on the surface;
(3) adjusting the position of the induction coil to enable the lower surface of the induction coil to be parallel to the region to be cladded on the surface of the steel rail, wherein the gap is 15 mm; aiming at the induction heating area on the surface of the rail by an infrared thermometer, connecting the infrared thermometer with a temperature controller and an induction power supply, detecting and controlling the induction heating temperature, and setting the induction heating temperature to be 300 ℃;
(4) and adjusting the defocusing amount of the laser beam and the relative position of the laser spot and the induction coil to focus the laser spot on the surface of the steel rail in front of the induction coil. The laser beam is a rectangle of 3 multiplied by 30mm, the powder feeding quantity of the powder feeder is 250g/min, the laser power is 20kW, and the laser scanning speed is 30 m/min;
(5) preheating the surface to be clad of the steel rail by adopting an oxyacetylene flame/propane blast burner, aiming an infrared thermometer 6-2 at a heating area on the surface of the steel rail, monitoring the preheating temperature of the surface of the steel rail to reach 100-200 ℃, and then closing the oxyacetylene flame/propane blast burner device;
(6) starting a laser and an induction heating power supply, synchronously feeding powder (or pre-arranging) to a laser irradiation area on the surface of the steel rail by adopting an automatic powder feeder, focusing a laser beam, then injecting the laser beam onto a steel rail substrate to form a molten pool, and forming a metal cladding layer on the surface of the steel rail after the molten pool is solidified;
(7) and after cladding one layer, judging whether the thickness of the cladding layer meets the working condition requirement. If yes, finishing the cladding process; if not, repeating the processes (3), (4), (5) and (6) until the required thickness is met;
(8) after cladding, detecting the surface of the metal coating by adopting penetration or ultrasonic flaw detection to ensure that the cladding layer has no metallurgical defects;
(9) and according to application requirements, cleaning and profile trimming are carried out on the tread of the steel rail, so that the surface is smooth, and a finished product is obtained.
The thickness of the cobalt-based metal cladding layer prepared in the example is 2mm, the mechanical properties of the cladding layer, the heat affected zone and the steel rail substrate are reasonably matched, and the hardness distribution along the depth direction of the steel rail is shown in figure 7.
Example four: off-line steel rail surface laser-oxyacetylene flame (propane torch) heating efficient composite cladding
This example was used for off-line rail reinforcement and repair, with an oxyacetylene flame (or propane torch) as the auxiliary heat source. Preparing a metal cladding layer on the surface of the steel rail by laser-oxyacetylene flame (or laser-propane torch) composite cladding, as shown in fig. 4, the basic implementation steps are as follows:
(1) selecting iron-based alloy powder as a cladding material, wherein the main chemical components comprise (Wt.%) C (0.01-0.60), (10-40) Cr, (5-18) Ni, (0.1-3.0) Si, (0-3) B, (0-3) Mo, (1-3) Mn and the balance Fe;
(2) firstly, polishing a cladding area on the surface of the steel rail to remove rust and pollutants on the surface;
(3) adjusting the laser beam to be in a circular shape with the diameter of 20mm, wherein the power of a laser is 15kW, the powder feeding speed is 180g/min, and the scanning speed is 10 m/min;
(4) preheating the surface of the steel rail to be clad by adopting an oxyacetylene flame/propane blast burner, aiming an infrared thermometer at a heating area on the surface of the steel rail, and monitoring the preheating temperature of the surface of the steel rail to be 800-1000 ℃;
(5) starting a laser, synchronously feeding alloy powder materials into (or pre-arranging in) a laser irradiation area on the surface of the steel rail by adopting an automatic powder feeder, focusing a laser beam, then injecting the laser beam onto a steel rail substrate to form a molten pool, and forming a metal coating on the surface of the steel rail after the molten pool is solidified; simultaneously, heating the steel rail cladding surface by using an oxyacetylene flame/propane torch, monitoring the post-heating temperature by using an infrared thermometer to be 300-400 ℃, and turning off the oxyacetylene flame/propane torch after the heat preservation time is reached;
(6) after cladding one layer, judging whether the thickness of the cladding layer meets the requirement of the working condition, if so, ending the cladding process; if not, repeating the processes (3), (4) and (5) until the thickness requirement is met;
(7) after cladding, detecting the surface of the metal coating by adopting penetration or ultrasonic flaw detection to ensure that the cladding layer has no metallurgical defects;
(8) and (4) selecting to clean and trim the tread of the steel rail according to application requirements, and flattening the surface to obtain a finished product.
The thickness of the iron-based metal cladding layer prepared in the example is 2mm, the mechanical properties of the cladding layer, the heat affected zone and the steel rail substrate are reasonably matched, and the hardness distribution along the depth direction of the steel rail is shown in figure 8.
The above description is a preferred embodiment of the present invention, but the present invention should not be limited to the disclosure of the embodiment and the drawings. Therefore, it is intended that all equivalents and modifications which do not depart from the spirit of the invention disclosed herein are deemed to be within the scope of the invention.
Claims (6)
1. A method for strengthening a steel rail by high-efficiency composite cladding by using a laser-auxiliary heat source is characterized in that the method utilizes the laser and the auxiliary heat source to simultaneously act on a region to be clad on the surface of the steel rail, the laser is used as a main heat source to simultaneously and rapidly melt an added powder material and a partial substrate material on the surface of the steel rail to form a molten pool and form a cladding layer, the auxiliary heat source is positioned in front of or/and behind the laser heat source and moves in the same direction and at the same speed as the laser heat source to synchronously preheat or/and post-heat the laser molten pool, a laser heat affected zone and the surface layer of the substrate of the steel rail, reduce the temperature gradient and the cooling rate between the laser molten pool, the heat affected zone and the substrate of the steel rail, ensure that the cooling time of the heat affected zone is longer than the critical cooling time for converting austenite to pearlite in a CCT curve or a TT, the steel rail is converted into a fine lamellar pearlite structure with the lamellar spacing smaller than or equal to that of the steel rail substrate, so that the mechanical properties of the cladding layer, the heat affected zone and the substrate are reasonably matched, the hardness curve is smoothly distributed, and the overall fatigue performance is good; the powder material is synchronously fed or preset in a laser irradiation area on the surface of the steel rail, the preheating temperature is 100-1000 ℃, the post-heating temperature is 300-700 ℃, the laser power is 1-20kW, the powder feeding speed is 10-250g/min, the scanning speed is 0.4-30m/min, the thickness of a cladding layer obtained by single processing is 0.1-2mm, the width is 3-20mm, the hardness is HV250-HV500, the width of a heat affected zone is less than 1mm, the hardness is HV250-HV400, the cladding layer is arranged between a cladding layer and a substrate, the heating surface on the surface of the steel rail is of a linear structure, the heating surface is parallel to the length direction of the steel rail, and the length is 10-500 mm.
2. The method for strengthening the steel rail by the high-efficiency composite cladding of the laser-auxiliary heat source according to claim 1, is characterized in that: the auxiliary heat source adopts any one or combination of induction heating, oxyacetylene flame and propane blowtorch.
3. The method for high-efficiency composite cladding strengthening of the steel rail by the laser-auxiliary heat source according to claim 1 or 2, is characterized in that: the method comprises the following concrete implementation steps:
(1) firstly, polishing the area to be clad on the surface of the steel rail to remove rust and pollutants on the surface;
(2) adjusting the defocusing amount of a laser beam, and setting a laser spot into a round shape with the diameter of 3-20mm or a rectangular shape with the diameter of (1-3) mmx (6-30) mm;
(3) adjusting the relative position of the laser spot and the auxiliary heat source to enable the laser spot to be in front of, in the middle of or behind the auxiliary heat source;
(4) starting a laser and an auxiliary heat source, synchronously feeding or presetting a coating material in a laser irradiation area on the surface of the steel rail by adopting an automatic powder feeder, focusing a laser beam and then injecting the laser beam onto a steel rail substrate to form a molten pool, and forming a metal cladding layer on the surface of the steel rail after the molten pool is solidified; the auxiliary heat source has the effects of preheating, post-heating and preheating and post-heating on the steel rail, wherein the preheating temperature is 100-1000 ℃, and the post-heating temperature is 300-700 ℃;
(5) after a metal cladding layer is cladded, judging whether the thickness of the cladding layer meets the requirement of a working condition, if so, ending the cladding process; if not, repeating the steps (2), (3) and (4) until the required thickness is reached;
(6) after cladding, detecting the surface of the corrosion-resistant cladding layer by adopting penetration or ultrasonic flaw detection to ensure that the cladding layer has no metallurgical defects;
(7) according to application requirements, the tread of the steel rail is selected to be cleaned and profile-trimmed, so that the surface is smooth.
4. The method for high-efficiency composite cladding strengthening of the steel rail by the laser-auxiliary heat source according to claim 1 or 2, is characterized in that: the method is integrated with a fixed processing platform to realize off-line processing of the steel rail, or is integrated with a steel rail on-line mobile laser processing vehicle to perform on-line laser cladding strengthening or repairing on the steel rail on a railway site.
5. The method for the high-efficiency composite cladding strengthening of the steel rail by the laser-auxiliary heat source as claimed in claim 2, wherein the induction heating is realized by adopting an induction power supply and an induction coil, wherein the induction coil is formed by bending and welding a copper pipe, a magnetizer is embedded on the copper pipe in the working area, the lower surface of the copper pipe is parallel to the cladding surface of the steel rail, and the gap is 0.5-15 mm.
6. The method for high-efficiency composite cladding of steel rail by laser-auxiliary heat source as claimed in claim 1 or 2, characterized in that the cladding material is iron-based alloy, the main chemical composition is (Wt.%); or
The cladding material is nickel-based alloy or cobalt-based alloy, and the nickel-based alloy comprises the following main chemical components (Wt.%): (0.01-0.50) C, (20-30) Cr, (5-10) W, (3-5) Si, (0-3) B, (5-10) Fe, and the balance of Ni; the main chemical composition of cobalt-based alloys is (Wt.%): (0.01-0.5) C, (20-35) Cr, (1-10) Ni, (1-3) Si, (5-15) W, (0-3) B, (0.5-2) Mn and the balance of Co.
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201810063575.6A CN108456879B (en) | 2018-01-23 | 2018-01-23 | Method for strengthening steel rail by efficient composite cladding of laser-auxiliary heat source |
| US16/639,746 US20200199698A1 (en) | 2018-01-23 | 2019-01-18 | Method for reinforcing rail by laser and auxiliary heat source efficient hybrid cladding |
| PCT/CN2019/072300 WO2019144843A1 (en) | 2018-01-23 | 2019-01-18 | Method for laser-assisted heat source efficient hybrid cladding reinforcing steel rail |
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| CN201810063575.6A CN108456879B (en) | 2018-01-23 | 2018-01-23 | Method for strengthening steel rail by efficient composite cladding of laser-auxiliary heat source |
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