CN110747466A - Laser micro-melting continuous casting method for protective coating of water turbine flow surface - Google Patents
Laser micro-melting continuous casting method for protective coating of water turbine flow surface Download PDFInfo
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- CN110747466A CN110747466A CN201911196481.7A CN201911196481A CN110747466A CN 110747466 A CN110747466 A CN 110747466A CN 201911196481 A CN201911196481 A CN 201911196481A CN 110747466 A CN110747466 A CN 110747466A
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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
Abstract
The invention discloses a laser micro-melting continuous casting method of a protective coating on the overflow surface of a water turbine, for example, a composite coating is prepared on the overflow surface of parts such as the water turbine, a water pump and the like, so that the cavitation erosion resistance of the overflow surface of the parts is improved, and the service life of the parts is prolonged; the method comprises the steps of sending out alloy powder through a coaxial powder feeding nozzle, melting the powder and micro-melting a matrix by using a high-energy density laser beam, and spraying molten liquid drops to the surface of the matrix through high-speed airflow to form a micro-melting continuous casting coating, so that a metallurgical bonding organization structure with extremely low heat input and epitaxial growth is realized; compared with the traditional thermal spraying coating, the invention has the advantages of high coating production efficiency, simple process, lower cost, high-strength metallurgical bonding between the coating and the substrate, continuous columnar crystal structure of the tissue, low surface roughness, compact tissue and extremely low porosity, can greatly improve the erosion resistance of the overflow surface, and realizes the high-quality and high-efficiency preparation of the erosion-resistant coating of the overflow surface of the part for the hydraulic and hydro-power junction.
Description
Technical Field
The invention belongs to the field of laser processing, relates to a method for preparing a cladding layer on the surface of an overflowing surface of a part by laser micro-melting continuous casting, and particularly relates to a method for preparing an anti-cavitation coating on the overflowing surface of a stainless steel part by laser micro-melting continuous casting Ni-based alloy powder.
Background
Hydroenergy is one of the economic and pollution-free green energy sources for sustainable development, and is more and more favored and valued by various countries. However, the key flow passage component of the hydraulic machine is easy to generate cavitation abrasion in a multiphase flow state, so that the service life of the flow passage component of the hydraulic machine is greatly shortened, the operation efficiency is reduced, the vibration is aggravated, and the safety and the reliability of the operation of a hydropower station are directly threatened. For example, turbine flow components such as runner blades, vanes, head and bottom ring liners, spray needles, inlet valve seals, and the like, are subject to significant damage due to cavitation and erosion by the slurry. The cavitation erosion and the mortar erosion abrasion of the water turbine can cause the change of the blade profile, influence the service efficiency of the water turbine, seriously aggravate the vibration of a hydroelectric generating set, even cause the machine set to stop and cause huge economic loss, and thus the cavitation erosion abrasion becomes one of the technical problems which are urgently needed to be solved by the current water conservancy machinery. Cavitation abrasion refers to the phenomenon that cavitation bubbles are formed and collapsed due to local pressure change in a liquid medium, and a material is continuously impacted by high-pressure and high-speed micro jet flow to generate surface damage, is a complex physical process with multiple phases, transients, microcosmics and randomness, appears on the surface of a component and is closely related to the surface performance of the material, so that the method has important significance for improving the cavitation erosion resistance of a flow passage component by preparing a high-performance coating through an advanced surface engineering technology. Therefore, a plurality of methods are adopted at home and abroad to improve the cavitation erosion resistance of the hydraulic machinery flow passage component, such as coating by using a polymer synthetic material, hard alloy surfacing, embedding a stainless steel plate on the surface, wire spraying, alloy powder spray welding, thermal spraying, traditional laser cladding and the like. But the high polymer material coating and wire spraying are difficult to form high-strength combination with the base material; large thermal deformation and thermal stress are easily generated by overlaying welding, embedding and spray welding; the hot spraying also has the problems that the coating is combined with a substrate to be mechanically combined, the strength is not high, the coating has certain porosity, the complete compactness cannot be achieved, and the like; the traditional laser cladding has low production efficiency, large coating dilution rate and large heat input of the base material, and the base material is easy to generate large thermal deformation. Therefore, each of the above methods needs to be further improved.
Disclosure of Invention
The prior method generally has the defects of low bonding strength between the coating and a matrix, incompact coating, or larger thermal stress and thermal deformation of a base material in the aspect of preparing the overflow surface cavitation erosion resistant coating. These defects will severely reduce the service life of the coating and limit the performance of the coating in terms of cavitation erosion resistance. The invention provides a laser micro-melting continuous casting method of a protective coating on the overflow surface of a water turbine, the coating treated by the method is metallurgically bonded with a base material and cannot fall off, and the method has the advantages of wide processing range, high cladding efficiency, simple process, lower cost and the like.
In order to achieve the purpose, the invention adopts the technical scheme that:
the method comprises the following steps: assembling the coaxial powder feeding nozzle and the powder feeder into a coaxial powder feeding device;
step two: the surface of the base material is cleaned and clamped on a machine tool, the cleaning of the surface of the base material is to prevent oil stains and embroidery stains on the surface of the base material from generating impurities which deteriorate the performance of a coating under the heating of laser in the laser cladding process, and the clamping of the base material on the machine tool is to ensure that the base material obtains higher linear speed under the driving of the machine tool and moves at high speed instead of a cladding head, so that the uniformity of coaxial powder feeding is ensured;
step three: the alloy powder is dried and then is loaded into a powder feeder, and the drying of the alloy powder is beneficial to improving the fluidity of the alloy powder and avoiding the phenomenon of uneven powder feeding in the cladding process;
step four: starting a powder feeder to enable cladding alloy powder to be delivered out from a coaxial powder feeding nozzle under the wrapping of carrier gas through the powder feeder, and starting a machine tool to enable a base material to start rotating;
step five: adjusting the distance between the coaxial powder feeding nozzle and the base material, namely the defocusing amount to be 10-25mm, the laser power to be 100W-10KW, the powder flow to be 1r/min-10r/min, the machine tool rotating speed to be 5r/min-1000r/min, the base material rotating speed, namely the linear speed to be 200mm/min-32000mm/s, and the moving speed and the scanning speed of the powder feeding nozzle to be 0.1mm-30 mm/s; defocusing amount influences heat input of a base body and coupling of a powder focal plane and a laser focal plane, influences utilization rate of cladding powder, and further influences laser cladding effect. The laser power directly affects the indexes of the coating such as dilution rate, thickness, heat input and the like. The line speed affects the thickness of the coating, the uniformity of the texture, the heat input to the substrate, etc. The combination of the scanning speed and the linear speed can obviously influence the dilution rate, the thickness, the tissue uniformity, the heat input and the like of the coating, and each process parameter has obvious influence on the performance of the coating, so that the proper process parameters are matched to ensure that each parameter is in the most proper range, thereby preparing the coating with the best performance;
step six: starting a laser to carry out laser cladding, enabling the laser to synchronously move with a powder feeding nozzle under the driving of a manipulator, heating and melting cladding alloy powder sent out from the coaxial powder feeding nozzle under the irradiation of laser, simultaneously melting the alloy powder and the surface of a base material by utilizing the irradiation of the laser, forming a cladding layer with lower dilution rate and metallurgical bonding with the base body after rapid cooling and solidification, and preparing an anti-cavitation coating on the surface of the base material, namely the flow surface of the water turbine.
Compared with the prior art, the invention has the following effects:
the invention aims to provide a laser micro-melting continuous casting method of a protective coating on an overflow surface of a water turbine, ultra-high speed laser cladding sends out alloy powder through a coaxial powder feeding nozzle, high-energy-density laser beams are utilized to melt the powder and slightly melt a substrate, molten liquid drops are sprayed to the surface of the substrate through high-speed airflow to form a micro-melting continuous casting coating, through the ingenious design of a laser cladding head, the optimal coupling of the relative position of a powder focal plane and a laser focal plane is realized, most of laser energy acts on the powder above a workpiece, only a small part of laser energy penetrates through the surface of the substrate moving at a high speed, the method can enable the powder and the substrate to be fully metallurgically bonded under the condition of ensuring extremely low heat input of the substrate, compared with the traditional laser cladding, the method has high cladding efficiency, the cladding rate can reach 200m/min, the utilization rate of alloy powder can reach 85% to the maximum, the dilution rate of the coating is low, the coating thickness is generally lower than 5%, the coating thickness is controllable, the coating with the thickness of tens of the thickness to hundreds of micrometers to the hundreds of the substrate is prepared, the coating with the highest degree of the thickness and the surface smoothness of the highest melting point of ①, the coating prepared by the high-speed laser cladding, the high-speed laser-dilution-high-speed laser-heat-dilution-fusion-.
In conclusion, the method has the advantages that ① cooling speed is high, the characteristic of rapid solidification structure is generated, a compact, uniform and high-hardness coating can be obtained, ② heat input and thermal deformation are extremely small, the method is particularly important for water turbine flow passage components and thin-wall components with strict requirements on deformation, the coating after ③ treatment is metallurgically combined with a base material and cannot fall off, ④ light beam aiming can be carried out to select areas to clad and process areas which are difficult to be accessed by other methods, ⑤ process is easy to realize automation and is convenient for quality control, the method has the advantages of wide processing range, high cladding efficiency, simple process, low cost and the like, the defects of low bonding strength between the coating and a base body, incompact coating, high thermal stress, high thermal deformation, high dilution rate and the like in the traditional preparation method are overcome, and the method is an ideal new process for preparing the cavitation erosion resistant coating on the surface of the flow passage.
Drawings
FIG. 1 is a schematic diagram of the preparation of a coating by ultra-high speed laser cladding.
FIG. 2 is the surface topography of the Ni-based WC coating prepared on the surface of 304 stainless steel in example 1.
Fig. 3a and 3b are morphology diagrams of BSE photographs of the prepared Ni-based WC coating cross-section at 100 x and 1000 x on the surface of 304 stainless steel of example 1, respectively.
Fig. 4a and 4b are the morphology of SEM photographs of example 2 at 200 x and 500 x of the cross-section of Ni60 coating prepared on the surface of 304 stainless steel, respectively.
Detailed Description
The invention is described in further detail below with reference to the figures and specific examples.
The invention relates to a laser micro-melting continuous casting method of a protective coating of a water turbine flow surface, which comprises the following steps of:
the method comprises the following steps: assembling the coaxial powder feeding nozzle and the powder feeder into a coaxial powder feeding device;
step two: the surface of the base material is cleaned and clamped on a machine tool, the cleaning of the surface of the base material is to prevent oil stains and embroidery stains on the surface of the base material from generating impurities which deteriorate the performance of a coating under the heating of laser in the laser cladding process, and the clamping of the base material on the machine tool is to ensure that the base material obtains high linear speed under the driving of the machine tool and moves at high speed instead of a cladding head, so that the uniformity of coaxial powder feeding is ensured;
step three: the alloy powder is dried and then is loaded into a powder feeder, and the drying of the alloy powder is beneficial to improving the fluidity of the alloy powder and avoiding the phenomenon of uneven powder feeding in the cladding process;
step four: starting a powder feeder to enable cladding alloy powder to be delivered out from a coaxial powder feeding nozzle under the wrapping of carrier gas through the powder feeder, and starting a machine tool to enable a base material to start rotating;
step five: adjusting the distance between the coaxial powder feeding nozzle and the base material, namely the defocusing amount to be 10-25mm, the laser power to be 100W-10KW, the powder flow to be 1r/min-10r/min, the machine tool rotating speed to be 5r/min-1000r/min, the base material rotating speed, namely the linear speed to be 200mm/min-32000mm/s, and the moving speed and the scanning speed of the powder feeding nozzle to be 0.1mm-30 mm/s; the scan speed in combination with the line speed significantly affects the dilution rate, thickness, tissue uniformity and heat input of the coating.
Step six: starting a laser to carry out laser cladding, enabling the laser to synchronously move with a powder feeding nozzle under the driving of a manipulator, heating and melting cladding alloy powder sent out from the coaxial powder feeding nozzle under the irradiation of laser, simultaneously melting the alloy powder and the surface of a base material by utilizing the irradiation of the laser, forming a cladding layer with lower dilution rate and metallurgical bonding with the base body after rapid cooling and solidification, and preparing an anti-cavitation coating on the surface of the base material, namely the flow surface of the water turbine.
As a preferred embodiment of the present invention, the alloy powder described in step three is a Ni-based intermetallic compound or Ni-based cermet alloy powder in which the mass fraction of Ni is 50% to 99%, the balance being one or more of C, Cr, B, Si, Ti, Fe, Cu and ceramic particles such as WC, SiC, CrC, etc., and the mass fraction of the balance being 1% to 50%; the granularity of the alloy powder is 10-300 mu m, and the shape is spherical, nearly spherical, polygonal or irregular; drying the gold powder at 100-200 deg.C for 15-120 min.
In a preferred embodiment of the present invention, the carrier gas in step four is an inert gas, the inert gas is Ar gas, He gas, or a mixture of Ar gas and He gas, and the flow rate of the carrier gas is 2 to 15L/min.
In the fifth step, the included angle between the coaxial powder feeding nozzle and the base material is 70-90 degrees.
As a preferred embodiment of the invention, the laser cladding head of the laser adopted in the sixth step is a rectangular light spot, the size of a single side of the light spot is not less than 10mm, and the defocusing amount is 0-80 mm.
In the sixth step, the protective gas of the coaxial powder feeding nozzle is inert gas during laser cladding, and the inert gas is Ar gas, He gas or a mixed gas of Ar gas and He gas; the pressure of the protective gas is 0.01-1MPa, and the flow of the protective gas is 0.1-30L/min.
As a preferred embodiment of the present invention, the surface melting thickness of the substrate in the sixth step is not more than 0.5 mm.
As shown in fig. 1, the coupling relationship between the powder feeding track and the laser is studied through simulation, the positions of the laser focal plane and the powder focal plane are adjusted to realize the optimal coupling of the laser and the powder, and the high-speed laser cladding head designed on the basis can enable most of laser energy to act on the powder instead of the substrate. The powder can be injected into the molten pool in a liquid state, the surface smoothness of the coating is good, the utilization rate of the powder is high, and the heat input of the matrix is small.
Example 1:
the Ni-based WC overflow surface protective coating is prepared by the laser micro-melting continuous casting method of the overflow surface protective coating of the water turbine, which comprises the following steps:
1) a304 stainless steel tube is selected as a substrate for laser micro-melting continuous casting, the size of the substrate is phi 60mm multiplied by 400mm, and the wall thickness is 3 mm. Before use, the surface is cleaned by ethanol and dried for standby.
2) And (3) placing the prepared Ni-based WC spherical alloy powder into a forced air dryer for drying treatment, wherein the drying temperature is 100 ℃, and the drying time is 15 min.
3) And (3) clamping the 304 stainless steel pipe in a machine tool, adjusting the rotating speed of the machine tool to 72r/min, pouring the dried Ni-based powder into a powder feeder, and connecting the powder feeder with a coaxial powder feeding nozzle.
4) A fiber laser is used for micro-melting continuous casting, the power is 1.5KW, the linear speed is 226mm/s, the defocusing amount is 7mm, the powder feeding amount is 3r/min, the carrier gas pressure is 0.4MPA, the carrier gas flow is 5L/min, the protective gas pressure is 0.5MPa, the protective gas flow is 15L/min, and the protective gas and the carrier gas are argon.
5) In example 1, the surface appearance of the Ni-based WC coating prepared on the surface of 304 stainless steel is shown in FIG. 2, the surface is smooth and flat, no sticky powder exists, and the surface quality is high. The section morphology is shown in fig. 3a and fig. 3b, and it can be seen from BSE photographs that the Ni-based WC coating prepared by laser micro-melting continuous casting is combined with the stainless steel of the substrate 304 for metallurgical bonding, WC particles are uniformly distributed in the coating and the coating is dense without defects such as cracks, pores and the like, and the wear resistance of the substrate can be greatly improved.
Example 2:
the Ni60 overflow surface protective coating is prepared by laser micro-melting continuous casting method of the overflow surface protective coating of the water turbine by the method of the embodiment:
1) a304 stainless steel tube is selected as a substrate of the laser micro-melting continuous casting coating, the size of the substrate is phi 60mm multiplied by 400mm, and the wall thickness is 3 mm. Before use, the surface is cleaned by ethanol and dried for standby.
2) Putting Ni60 spherical alloy powder (powder particle size 40-150 μm) into a forced air drier for drying treatment, wherein the drying temperature is 130 ℃, and the drying time is 30 min.
3) And (3) clamping the 304 stainless steel pipe in a machine tool, adjusting the rotating speed of the machine tool to 100r/min, pouring dried Ni60 alloy powder into a powder feeder, and connecting the powder feeder with a coaxial powder feeding nozzle.
4) A fiber laser is used for carrying out laser micro-melting continuous casting, the power is 1.8KW, the linear speed is 314mm/s, the defocusing amount is 7mm, the powder feeding amount is 2.5r/min, the carrier gas pressure is 0.4MPA, the carrier gas flow is 6L/min, the protective gas pressure is 0.5MPa, the protective gas flow is 15L/min, and the protective gas and the carrier gas are argon.
5) Example 2 the cross-sectional morphology of the Ni60 coating prepared on the surface of 304 stainless steel is shown in fig. 4a and 4b, and SEM photographs show that the Ni60 coating is metallurgically bonded to the 304 stainless steel substrate, the bonding strength is high, and the coating is dense and has no defects such as pores and cracks. The cavitation erosion resistance of the matrix can be greatly improved.
Claims (7)
1. A laser micro-melting continuous casting method for a protective coating of a water turbine flow surface is characterized by comprising the following steps:
the method comprises the following steps: assembling the coaxial powder feeding nozzle and the powder feeder into a coaxial powder feeding device;
step two: the surface of the base material is cleaned and clamped on a machine tool, the cleaning of the surface of the base material is to prevent oil stains and embroidery stains on the surface of the base material from generating impurities which deteriorate the performance of a coating under the heating of laser in the laser cladding process, and the clamping of the base material on the machine tool is to ensure that the base material obtains high linear speed under the driving of the machine tool and moves at high speed instead of a cladding head, so that the uniformity of coaxial powder feeding is ensured;
step three: the alloy powder is dried and then is loaded into a powder feeder, and the drying of the alloy powder is beneficial to improving the fluidity of the alloy powder and avoiding the phenomenon of uneven powder feeding in the cladding process;
step four: starting a powder feeder to enable cladding alloy powder to be delivered out from a coaxial powder feeding nozzle under the wrapping of carrier gas through the powder feeder, and starting a machine tool to enable a base material to start rotating;
step five: adjusting the distance between the coaxial powder feeding nozzle and the base material, namely the defocusing amount to be 10-25mm, the laser power to be 100W-10KW, the powder flow to be 1r/min-10r/min, the machine tool rotating speed to be 5r/min-1000r/min, the base material rotating speed, namely the linear speed to be 200mm/min-32000mm/s, and the moving speed and the scanning speed of the powder feeding nozzle to be 0.1mm-30 mm/s; the scan speed in combination with the line speed significantly affects the dilution rate, thickness, tissue uniformity and heat input of the coating.
Step six: starting a laser to carry out laser cladding, enabling the laser to synchronously move with a powder feeding nozzle under the driving of a manipulator, heating and melting cladding alloy powder sent out from the coaxial powder feeding nozzle under the irradiation of laser, simultaneously melting the alloy powder and the surface of a base material by utilizing the irradiation of the laser, forming a cladding layer with lower dilution rate and metallurgical bonding with the base body after rapid cooling and solidification, and preparing an anti-cavitation coating on the surface of the base material, namely the flow surface of the water turbine.
2. The laser microfusion continuous casting method of the protective coating of the flow surface of the water turbine as claimed in claim 1, characterized in that the alloy powder in the third step is Ni-based intermetallic compound or Ni-based cermet alloy powder, wherein the mass fraction of Ni is 50% -99%, the balance is one or more of C, Cr, B, Si, Ti, Fe, Cu and ceramic particles, and the mass fraction of the balance is 1% -50%; the granularity of the alloy powder is 10-300 mu m, and the shape is spherical, nearly spherical, polygonal or irregular; drying the gold powder at 100-200 deg.C for 15-120 min.
3. The laser micro-melting continuous casting method of the protective coating on the flow surface of the water turbine as claimed in claim 1, wherein the carrier gas in the fourth step is inert gas, the inert gas is Ar gas, He gas or a mixed gas of Ar gas and He gas, and the flow rate of the carrier gas is 2-15L/min.
4. The laser micro-melting continuous casting method for the protective coating of the flow surface of the water turbine as claimed in claim 1, wherein in the fifth step, the included angle between the coaxial powder feeding nozzle and the base material is 70-90 degrees.
5. The laser micro-melting continuous casting method of the protective coating on the flow surface of the water turbine as claimed in claim 1, wherein the laser cladding head of the laser adopted in the sixth step is a rectangular light spot, the unilateral dimension of the light spot size is not less than 10mm, and the defocusing amount is 0-80 mm.
6. The laser micro-melting continuous casting method for the protective coating of the flow surface of the water turbine as claimed in claim 1, wherein the protective gas of the coaxial powder feeding nozzle during laser cladding in the sixth step is inert gas, and the inert gas is Ar gas, He gas or a mixed gas of Ar gas and He gas; the pressure of the protective gas is 0.01-1MPa, and the flow of the protective gas is 0.1-30L/min.
7. The laser micro-melting continuous casting method for the protective coating of the flow surface of the water turbine as claimed in claim 1, wherein in the sixth step, the melting thickness of the surface of the base material is not more than 0.5 mm.
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