CN109338357B - Laser melting deposition repair method for metal casting defect part - Google Patents
Laser melting deposition repair method for metal casting defect part Download PDFInfo
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- CN109338357B CN109338357B CN201811409438.XA CN201811409438A CN109338357B CN 109338357 B CN109338357 B CN 109338357B CN 201811409438 A CN201811409438 A CN 201811409438A CN 109338357 B CN109338357 B CN 109338357B
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- 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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Abstract
The invention discloses a laser melting deposition repair method for a defective part of a metal casting, and belongs to the technical field of metal forming. The method comprises the following steps: carrying out nondestructive testing on the metal casting, and determining the corresponding part of the internal defect; removing the corresponding part of the internal defect to form a groove-shaped area to be repaired with an upward opening on the metal casting; processing the area to be repaired to ensure that the bottom surface of the area to be repaired is horizontal and the section of the area to be repaired is gradually enlarged along the bottom surface towards the opening direction; three-dimensional scanning is carried out on the processed area to be repaired, and a three-dimensional model of the area to be repaired is obtained; and according to the three-dimensional model of the area to be repaired, performing laser melting deposition repair on the processed area to be repaired by adopting metal powder. Compared with the manual repair welding repair efficiency, the repair efficiency is improved by more than 2 times, the labor intensity and the workload of operators are greatly reduced, the primary repair qualification rate is greatly improved, the reliability of the repair process is high, the quality stability is good, and a large amount of unnecessary production cost in the manual repair welding repair and secondary repair welding process is avoided.
Description
Technical Field
The invention relates to a laser melting deposition repair method for a defective part of a casting, and belongs to the technical field of metal forming.
Background
The turbopump is a key component of the liquid oxygen kerosene rocket engine and is called as the engine heart. Wherein, the oxygen pump casing in the turbopump works in special environment such as low temperature liquid oxygen high speed erodees, big vibration for a long time, and is higher to the mechanical properties requirement. At present, an oxygen pump shell casting manufactured by a precision casting method is influenced by factors such as a high-strength stainless steel vacuum melting process and a complex shell structure, the internal quality of a product is difficult to control, defects such as looseness and shrinkage cavities are easy to occur, the area of a defect area is large, the delivery progress of the product is guaranteed, and the defects at the non-key position of the oxygen pump shell casting are repaired in a manual repair welding mode.
The manual repair welding method removes the defect part by polishing, and then adopts the manual argon arc welding process to repair the defect, which is influenced by factors such as a defect groove, welding wire materials, process parameters and the like, and easily generates defects such as cracks, air holes and the like in the repair welding process, so that part of the defect part needs to be repaired repeatedly, the repair welding period is long, the labor intensity is high, and the product reliability is difficult to ensure; meanwhile, the excessive heat input in the repair welding area coarsens the grain structure, reduces the mechanical property and further reduces the reliability and stability of the product quality.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides a laser melting deposition repairing method for the defect part of a metal casting, which is characterized in that an area corresponding to the internal defect of the metal casting is processed, and the metal casting is repaired by using the laser melting deposition method, compared with the manual repair welding repairing efficiency, the repairing efficiency is improved by more than 2 times, the labor intensity and the workload of operators are greatly reduced, the primary repairing qualification rate of the defect part is greatly improved, the reliability of the repairing process is high, the quality stability is good, and a large amount of unnecessary production cost in the manual repair welding repairing and secondary repair welding processes is avoided.
In order to achieve the above purpose, the invention provides the following technical scheme:
a laser melting deposition repair method for a metal casting defect part comprises the following steps:
(1) carrying out nondestructive testing on the metal casting, and determining the corresponding part of the internal defect;
(2) removing the corresponding part of the internal defect to enable the metal casting to form a groove-shaped to-be-repaired area with an upward opening;
(3) processing the area to be repaired to enable the bottom surface of the area to be repaired to be horizontal and gradually expand the cross section along the direction of the opening from the bottom surface;
(4) three-dimensional scanning is carried out on the processed area to be repaired, and a three-dimensional model of the area to be repaired is obtained;
(5) and according to the three-dimensional model of the area to be repaired, performing laser melting deposition repair on the processed area to be repaired by adopting metal powder.
In an alternative embodiment, the determining the corresponding portion of the internal defect in step (1) includes:
when at least one defect is detected in the metal casting, marking the corresponding position on the surface of the metal casting according to the distribution information of the at least one defect, and taking the marked position as the corresponding position of the internal defect.
In an optional embodiment, the removing the internal defect corresponding portion in step (2) includes:
and polishing the corresponding part of the internal defect until the defect is eliminated completely.
In an optional embodiment, an included angle between the sidewall of the region to be repaired and the vertical plane in step (3) is 45 ° to 60 °.
In an alternative embodiment, the pair of metal castings of step (1) is a 06Cr14Ni7Mo stainless steel casting.
In an alternative embodiment, the non-destructive testing of the metal casting in step (1) comprises:
and performing ultrasonic nondestructive detection on the metal casting by adopting a pulse reflection method, wherein vaseline is adopted as a coupling agent, the ultrasonic frequency is 1 MHz-5 MHz, the scanning speed is not more than 150mm/s, and the mutual overlapping area of two adjacent scans is 10% -15% of the size of the probe wafer.
In an optional embodiment, in the step (5), laser melting deposition repair is carried out on the processed to-be-repaired area by using 06Cr14Ni7Mo stainless steel spherical powder with the grain diameter of 50-180 microns.
In an alternative embodiment, the laser fused deposition repair is performed under an inert atmosphere, wherein: the laser power is 1000W-3000W, a Zigzag scanning mode is adopted, the scanning speed is 500 mm/min-1100 mm/min, the scanning interval is 1.5 mm-2.5 mm, the layering thickness is 0.5 mm-1 mm, the spot diameter of the laser cladding head is 3 mm-5 mm, and the powder feeding amount is 20 g/min-30 g/min.
In an optional embodiment, after performing laser melting deposition repair on the processed region to be repaired by using metal powder in the step (5), the method further includes:
the repaired metal casting is processed under the pressure of not more than 10 DEG C-3Keeping the temperature for 2 to 4 hours in a vacuum environment of Pa at the temperature of 1050 to 1130 ℃, and filling argon back to cool to the room temperature; then cooling to-70-80 ℃ by cold treatment, preserving heat for 1.5-2.5 h, recovering the temperature to the room temperature in the air, then heating to 250-320 ℃, preserving heat for 3-6 h, and cooling in the air.
In an alternative embodiment, the metal casting is an oxygen pump housing.
The invention has the following beneficial effects:
(1) according to the method, the area corresponding to the internal defect of the metal casting is processed, and the metal casting is repaired by using a laser melting deposition method, so that compared with the manual repair welding repair efficiency, the efficiency is improved by more than 2 times, the labor intensity and the workload of operators are greatly reduced, the primary repair qualification rate of the defect part is greatly improved, the reliability of the repair process is high, the quality stability is good, and a large amount of unnecessary production cost in the manual repair welding repair and secondary repair welding process is avoided;
(2) the laser melting deposition repair process parameters provided by the invention have high controllability of energy on power density and space-time distribution, can reduce the influence of warping deformation, coarse grain structure and the like on a matrix casting caused by heat input to the maximum extent, have no macrosegregation in the self structure, have fine grains, and can completely reach or exceed the performance level of the matrix of the casting on the mechanical property of a repair area;
(3) the method has the advantages that the defects of the oxygen pump shell are repaired by a laser melting deposition method, the feasibility of the technology in repairing the defects of the oxygen pump shell of the key part of the turbopump of the liquid oxygen kerosene rocket engine is verified, the excellent technical potential is shown, and a great amount of technical experience is accumulated for realizing the efficient and high-performance repair and remanufacture of damaged parts of the liquid oxygen kerosene rocket engine.
Drawings
FIG. 1 is a schematic diagram of an oxygen pump housing and defects according to an embodiment of the present invention;
fig. 2 is a schematic diagram of laser melting repair of a defect of an oxygen pump case according to an embodiment of the present invention.
Detailed Description
The following detailed description of embodiments of the invention will be made with reference to the accompanying drawings and specific examples.
The invention provides a laser melting deposition repair method for a metal casting defect part, which comprises the following steps: step (1): carrying out nondestructive testing on the metal casting, and determining the corresponding part of the internal defect;
specifically, the internal quality of the metal casting can be detected by nondestructive detection means such as X-ray or ultrasonic wave, and the internal defect can be determined; determining the corresponding part of the internal defect according to the distribution information such as the area, the depth, the position and the like of the internal defect; in an optional embodiment, for convenience of subsequent operation, when at least one defect is detected to exist in the metal casting, marking a corresponding position on the surface of the metal casting according to the distribution information of the at least one defect, and taking a marked position as a corresponding position of the internal defect;
in the embodiment of the invention, the metal casting can be 00Cr13Ni5Co9Mo5 high-strength stainless steel, GH4169 high-temperature alloy and other metal castings, and 06Cr14Ni7Mo stainless steel castings are preferred. Further, in an optional embodiment, a pulse reflection method is adopted to carry out ultrasonic nondestructive detection on the metal casting, vaseline with high viscosity is adopted as a coupling agent during detection, the ultrasonic frequency is 1-5 MHz, the scanning speed is not more than 150mm/s, the overlapping area of two adjacent scanning is 10-15% of the size of a probe wafer, and the detection sensitivity is adjusted by adopting a flat-bottom hole contrast test block made of 06Cr14Ni7Mo stainless steel material. In other embodiments, the metal casting can be subjected to subarea division and marking when the X-ray detection is adopted, the image quality meter is placed at the position with the worst sensitivity prediction in the effective transillumination area, proper exposure is selected according to an exposure curve and the transillumination thickness, and then voltage parameters are selected;
step (2): removing the corresponding part of the internal defect to enable the metal casting to form a groove-shaped to-be-repaired area with an upward opening;
specifically, according to the embodiment of the invention, a reasonable metal casting placing mode can be determined according to the shape of the metal casting and the corresponding part of the defect, in combination with the problems of the size of a cladding head used for subsequent laser melting deposition forming, the interference condition and the like, after the metal casting is placed, the corresponding part of the internal defect is removed, and in order to avoid excessive removal, the defect is preferably removed completely by a polishing mode.
And (3): processing the area to be repaired to enable the bottom surface of the area to be repaired to be horizontal and gradually expand the cross section along the direction of the opening from the bottom surface;
specifically, in the implementation of the invention, a milling machine is preferably adopted to mill most of the to-be-repaired areas, so that the bottom surfaces of the to-be-repaired areas are horizontal, and the side walls of the to-be-repaired areas are expanded outwards, wherein the included angle between the side walls of the to-be-repaired areas and the vertical plane is preferably 45-60 degrees, when the depth of the to-be-repaired areas is less than 25mm, the included angle between the side walls of the to-be-repaired areas and the vertical plane is preferably 45-50 degrees, and when the depth of the to-be-repaired areas is more than 25; the angle can ensure that the laser cladding head is well matched with the matrix region without interference, the volume of the repair region is reduced to the maximum extent, and the repair time is shortened.
And (4): three-dimensional scanning is carried out on the processed area to be repaired, and a three-dimensional model of the area to be repaired is obtained;
specifically, before scanning a processed area to be repaired by using a three-dimensional scanner, firstly pasting mark points on the surface of the processed area to be repaired, wherein the mark points are random as much as possible, the minimum distance between every two adjacent mark points is kept between 20mm, then starting scanning measurement, rotating a metal casting according to a certain angle, and finally obtaining complete point cloud data of the area to be repaired; and importing the obtained point cloud data into reverse engineering software Geomagic Studio to carry out preprocessing and polygon processing, and storing the processed point cloud data as an stl format model.
And (5): and according to the three-dimensional model of the area to be repaired, performing laser melting deposition repair on the processed area to be repaired by adopting metal powder.
In an optional embodiment, in order to ensure good metallurgical bonding with the bevel of the base groove during repair and avoid poor lapping caused by positioning or machining errors, the obtained three-dimensional model of the repair area is modified, so that the oblique side of the model is outwardly biased by 1-2 mm.
Specifically, clamping the metal casting according to the placing position in the step (2), so that the bottom surface of the area to be repaired is parallel to the forming platform, and the forming direction is the normal direction of the bottom surface;
when the laser melting deposition repair is carried out, the modified model is stored again and then is guided into the set slicing software platform for slicing treatment, and the processing program can be obtained.
Further, the machining program positions: importing the modified model into Magics software, selecting three feature points in a bottom surface area, setting one feature point as an origin, and recording coordinates of the other two feature points; and (3) importing the machining program into equipment forming control software, positioning the machining program to the characteristic points by using red light, setting a program origin, moving the laser cladding head to the coordinates of the remaining two characteristic points, and starting the red light to check whether the positions of the theoretical characteristic points are overlapped with the positions of the actual characteristic points.
In an alternative embodiment, a 06Cr14Ni7Mo stainless steel spherical powder with a particle size of 50 to 180 μm is used for laser fused deposition repair, said powder obeying a normal distribution and being free of satellite powder and foreign inclusions, the repair being performed under an inert atmosphere wherein: the laser power is 1000W-3000W, a Zigzag scanning mode is adopted, the scanning speed is 500 mm/min-1100 mm/min, the scanning interval is 1.5 mm-2.5 mm, the layering thickness is 0.5 mm-1 mm, the laser cladding head spot scale is 3-5 mm, and the powder feeding amount is 20 g/min-30 g/min; the controllability of energy in power density and space-time distribution in the laser melting deposition repair process is high, the influences of warping deformation, large grain structure and the like caused by heat input on a matrix casting can be reduced to the maximum extent, no macrosegregation exists in the self structure, the grains are fine, and the mechanical property of a repair area can completely reach or exceed the performance level of the matrix of the casting. Argon is preferably selected as the inert gas, the oxygen content of the atmosphere in the forming process is required to be less than 1000PPM, and 06Cr14Ni7Mo stainless steel powder is added into the powder feeder every 1.5 hours in the forming process, so that the normal operation of the oxygen pump shell repairing process is ensured.
In order to ensure the profile precision of the repaired metal casting, the repaired metal casting is preferably polished or machined;
in an alternative embodiment, the repaired metal casting is heat treated after grinding or machining to remove internal stresses and improve texture to achieve mechanical properties in the repaired area that are well within or better than the base properties of the casting.
The adopted heat treatment mode is solution cold treatment tempering.
Wherein the solid solution treatment system comprises the following steps: at a pressure of not more than 10-3Keeping the temperature for 2 to 4 hours in a Pa vacuum environment at 1050 to 1130 ℃, and then filling argon back for cooling; the cold treatment system is as follows: keeping the temperature at-70 ℃ to-80 ℃ for 2h +/-30 min, and recovering the temperature to the room temperature in the air; the tempering treatment system is as follows: keeping the temperature at 250-320 ℃ for 3-6 h, and cooling in air.
The following is a specific embodiment of the present invention:
example 1
The embodiment provides a laser melting deposition repairing method for an oxygen pump shell casting, wherein the oxygen pump shell is made of a 06Cr14Ni7Mo stainless steel material as shown in FIG. 1, and the repairing method specifically comprises the following steps:
(1) and carrying out internal quality detection on the oxygen pump shell by using an X-ray detection method, recording the area, depth and position information of the detected internal defect, and marking the corresponding part of the internal defect.
(2) According to the shape of the oxygen pump shell and the position of the defect a, the position of the oxygen pump shell is determined to be placed as shown in figure 1 by combining the size of the laser cladding head and the interference condition, and the corresponding part of the defect is polished to remove the defect after the placement, so that the to-be-repaired area of the groove structure is obtained.
(3) And processing the area to be repaired by using a milling machine, so that the bottom surface of the area to be repaired is horizontal, the included angle alpha between the side wall and the vertical plane is 50 degrees, and the processing of the area to be repaired is completed.
(4) And performing three-dimensional scanning measurement on the processed to-be-repaired area to obtain point cloud data, and introducing the point cloud data into the reverse engineering software Geomagic Studio to process to obtain a stl format to-be-repaired area three-dimensional model. The laser melting deposition repair process parameters of the 06Cr14Ni7Mo stainless steel material in the slicing software platform are set as follows: the laser power is 2000W, the scanning speed is 800mm/min, and the scanning interval is as follows: 2.5mm and the lamination thickness is 0.9 mm. Selecting a scanning mode: zigzag. Wherein, the 06Cr14Ni7Mo stainless steel powder is spherical powder, the particle size range is 75-180 μm, the normal distribution is obeyed, and satellite powder and special-shaped impurities do not exist in the powder. And (3) placing the three-dimensional model of the area to be repaired at the position in the step (2), wherein the repairing direction is the normal direction of the plane of the bottom surface of the area to be repaired, and cutting the area to be repaired after the set slicing software platform is introduced to obtain the processing program. Clamping an oxygen pump shell according to the determined placing mode, adjusting the light spot scale on a laser cladding head to be 3mm, moving each shaft of a machine tool to close a forming cabin door after confirming that the mechanical movement process of the machine tool is abnormal, returning to zero for a machine tool of laser melting deposition forming equipment, setting a program origin according to the position of a repairing area, setting the powder feeding amount to be 20g/min, introducing a subdivision program into equipment forming control software, starting red light to carry out idle stroke check, opening the equipment cleaning function after confirming that no error exists, starting repairing the oxygen pump shell when the atmospheric oxygen content in a forming cabin is less than 1000PPM, and adding 06Cr14Ni7Mo stainless steel powder into a powder feeder every 1.5 hours. And after the repairing is finished, polishing or machining the repairing part of the oxygen pump shell according to the technical requirements of the drawing of the oxygen pump shell to obtain the repaired oxygen pump shell.
Further, carrying out heat treatment on the repaired oxygen pump shell: at a pressure of 10-3Keeping the temperature for 3 hours in a vacuum environment of Pa at the temperature of 1100 ℃, and then filling argon back for cooling; the cold treatment system is as follows: keeping the temperature at-75 ℃ for 2h, and recovering the temperature to the room temperature in the air; then raising the temperature to 300 ℃, preserving the heat for 4 hours, and cooling in air.
Example 2
The embodiment provides a laser melting deposition repairing method for an oxygen pump shell casting, wherein the oxygen pump shell is made of a 06Cr14Ni7Mo stainless steel material as shown in FIG. 1, and the repairing method specifically comprises the following steps:
(1) and (3) carrying out internal quality inspection on the oxygen pump shell by using an ultrasonic detection method, recording the detected defect area, depth and position information, and marking the defect area.
(2) According to the shape and the defect position of the oxygen pump shell, the position of the oxygen pump shell is determined to be placed as shown in figure 1 by combining the size and the interference condition of the laser cladding head, and the corresponding part of the defect is polished to remove the defect after the placement, so that the to-be-repaired area of the groove structure is obtained.
(3) And processing the area to be repaired by using a milling machine, so that the bottom surface of the area to be repaired is horizontal, an included angle alpha between the side wall and the vertical plane is 65 degrees, and the processing of the area to be repaired is completed.
(4) And performing three-dimensional scanning measurement on the processed to-be-repaired area to obtain point cloud data, and introducing the point cloud data into the reverse engineering software Geomagic Studio to process to obtain a stl format to-be-repaired area three-dimensional model. The laser melting deposition repair process parameters of the 06Cr14Ni7Mo stainless steel material in the slicing software platform are set as follows: laser power 2800W, scanning speed 1000mm/min, scanning pitch: 2.5mm and the layering thickness is 1 mm. Selecting a scanning mode: zigzag. Wherein, the 06Cr14Ni7Mo stainless steel powder is spherical powder, the particle size range is 50-180 μm, the normal distribution is obeyed, and satellite powder and special-shaped impurities do not exist in the powder. And (3) placing the three-dimensional model of the area to be repaired at the position in the step (2), wherein the repairing direction is the normal direction of the bottom surface of the area to be repaired, and cutting the three-dimensional model after the set slicing software platform is led in to obtain the processing program. Clamping an oxygen pump shell according to the determined placing mode, adjusting the diameter of a light spot on a laser cladding head to be 4mm, moving each shaft of a machine tool to close a forming cabin door after confirming that the mechanical movement process of the machine tool is abnormal, returning to zero for a machine tool of laser melting deposition forming equipment, setting a program origin according to the position of a repair area, setting the powder feeding amount to be 25g/min, introducing a subdivision program into equipment forming control software, starting red light to carry out idle stroke check, opening the equipment cleaning function after confirming that no error exists, starting to repair the oxygen pump shell when the atmospheric oxygen content in a forming cabin is less than 1000PPM, and adding 06Cr14Ni7Mo stainless steel powder into a powder feeder every 1.5 hours. And after the repair is finished, polishing or machining the repaired part of the oxygen pump shell according to the technical requirements of a product drawing to obtain the repaired oxygen pump shell.
Further, carrying out heat treatment on the repaired oxygen pump shell: at a pressure of 10-3Keeping the temperature for 4 hours in a vacuum environment of Pa at 1050 ℃, and then filling argon back for cooling; the cold treatment system is as follows: keeping the temperature at-80 ℃, keeping the temperature for 1.5h, and recovering the temperature to the room temperature in the air; then raising the temperature to 250 ℃, preserving the heat for 5 hours, and cooling in air.
Table 1 mechanical properties parameters of repair area provided by each example
The above description is only one embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention.
The invention has not been described in detail in part of the common general knowledge of those skilled in the art.
Claims (1)
1. A laser melting deposition repairing method for an oxygen pump shell casting is characterized by comprising the following steps:
the oxygen pump shell is made of a 06Cr14Ni7Mo stainless steel material, and the repairing method specifically comprises the following steps:
(1) performing internal quality detection on the oxygen pump shell by using an X-ray detection method, recording the area, depth and position information of the detected internal defect, and marking the corresponding part of the internal defect;
(2) determining to place the oxygen pump shell according to the shape of the oxygen pump shell and the position of the defect and by combining the size of the laser cladding head and the interference condition, polishing the part corresponding to the defect after placement to remove the defect, and obtaining a to-be-repaired area of the groove structure;
(3) processing the area to be repaired by using a milling machine, so that the bottom surface of the area to be repaired is horizontal, and the included angle alpha between the side wall and the vertical plane is 50 degrees, thereby finishing the processing of the area to be repaired;
(4) the method comprises the following steps of performing three-dimensional scanning measurement on a processed to-be-repaired area to obtain point cloud data, introducing the point cloud data into reverse engineering software Geomagic Studio to process the point cloud data to obtain a stl format to-be-repaired area three-dimensional model, and setting laser melting deposition repair process parameters of a 06Cr14Ni7Mo stainless steel material in a slicing software platform as follows: the laser power is 2000W, the scanning speed is 800mm/min, and the scanning interval is as follows: 2.5mm, the lamination thickness is 0.9mm, and the scanning mode is selected as follows: zigzag; wherein, the 06Cr14Ni7Mo stainless steel powder is spherical powder, the particle size range is 75-180 μm, the powder obeys normal distribution, and no satellite powder and special-shaped impurities exist in the powder; placing the three-dimensional model of the area to be repaired at the position in the step (2), wherein the repairing direction is the normal direction of the plane of the bottom surface of the area to be repaired, and cutting the area to be repaired after the set slicing software platform is introduced to obtain a processing program; clamping an oxygen pump shell according to the determined placing mode, adjusting the light spot scale on a laser cladding head to be 3mm, moving each shaft of a machine tool to close a forming cabin door after confirming that the mechanical movement process of the machine tool is abnormal, returning to zero for a machine tool of laser melting deposition forming equipment, setting a program origin according to the position of a repair area, setting the powder feeding amount to be 20g/min, introducing a subdivision program into equipment forming control software, starting red light to perform idle stroke check, opening the equipment cleaning function after confirming that no error exists, starting to repair the oxygen pump shell when the atmospheric oxygen content in a forming cabin is less than 1000PPM, and adding 06Cr14Ni7Mo stainless steel powder into a powder feeder every 1.5 hours; after the repair is finished, polishing or machining the repaired part of the oxygen pump shell according to the requirement of the drawing of the oxygen pump shell to obtain the repaired oxygen pump shell;
carrying out heat treatment on the repaired oxygen pump shell: at a pressure of 10-3Keeping the temperature for 3 hours in a vacuum environment of Pa at the temperature of 1100 ℃, and then filling argon back for cooling; the cold treatment system is as follows: keeping the temperature at-75 ℃ for 2h, and recovering the temperature to the room temperature in the air; then raising the temperature to 300 ℃, preserving the heat for 4 hours, and cooling in air.
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