CN111097914B - 镍基高温合金铸件缺陷的修复方法 - Google Patents
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Abstract
本发明公开了一种镍基合金的铸件缺陷修补方法，其特征在于先将缺陷处的孔径进行扩大并贯穿，并对扩孔的孔位进行清洗干燥处理，在镍基合金一面的孔位处贴上挡片，并在其另一面的孔位处及孔位周围铺上相同成分且厚度均匀的镍基合金粉，把合金粉压实，完全覆盖孔位及孔位周围的基材，调节激光光斑，对准孔位中心，且将光斑大小调节到大于扩孔后的孔径，然后开启激光，将镍基合金熔覆到孔位处；将镍基合金贴挡片的一面翻转，钻孔，去除第一面熔覆后孔内的残渣和缺陷，并对扩孔的孔位进行清洗干燥处理，重复上述熔覆步骤；最后进行高温固熔稳定化处理，便完成修复过程。本发明的这种修复方法，修补处的金相结构与原材质完全相同，极大地减少了由于铸造缺陷产生的浪费。
Description
技术领域
本发明涉及一种修补技术，具体涉及的是对镍基合金铸件缺陷进行修补的方法。
背景技术
镍基高温合金用于飞机、船舶、工业和车辆用燃气轮机的最关键的高温部件，如涡轮叶片、导向叶片和整体涡轮等，一般采用铸造工艺制造而成，但是铸造工艺存在很多缺陷，常见的铸造缺陷如气孔、缩孔、砂眼、粘砂和裂纹等，铸造成品率极低，铸造缺陷一直是铸造行业无法避免和难以解决的问题。高温镍基合金修复是困扰行业多年的问题，修复不合格铸件，常规方法主要是采用非同种材料补焊，但高温镍基合金采用传统的电弧焊接时非常容易开裂，需要熟练工人，焊接还会导致损坏加剧，造成部件报废，因此被称为不可焊材料。尤其是高温镍基合金在一些特殊领域应用时修复区必须采用同种材料，成品要求零缺陷，进一步加大了难度，焊接成品率极低。因此，如何将这种带有缺陷的镍基合金铸件进行同种材料修复，以减少浪费，本领域技术人员一直探索寻求解决方案。
发明内容
鉴于背景技术存在的不足，本发明要解决的技术问题是提供一种对镍基合金铸件缺陷进行修补后完好如初的修补方法。
鉴于此，本发明是采用如下技术方案来实现的：
镍基高温合金铸件缺陷的修复方法，其特征在于包括如下步骤：
a）扩孔，将缺陷孔径扩大并贯穿；
b）对扩孔的孔位进行清洗、干燥处理；
c）在镍基合金铸件A面的孔位处贴上挡片；
d）将镍基合金铸件未贴上挡片的B面朝上；
e）调整激光光斑位置，使之对准B面孔位中心，调节光斑大小至大于扩孔后的孔径；
f）在镍基合金铸件的B面孔位处铺上与铸件基材相同成分且厚度均匀的镍基合金粉末，把镍基合金粉压实，以完全覆盖孔位及周围的基材；
g）根据材料的厚度和孔径的大小，设置好激光功率及激光出光持续时间，开启激光，将激光照射工件表面，将镍基合金粉熔覆到孔位中以及基材表面；
h）去除A面挡片，并在A面的孔位处再次进行扩孔，以清除步骤f）熔覆后残留在孔位内的残渣和缺陷；
i）对扩孔的孔位进行清洗、干燥处理；
j）将A面朝上，调整激光光斑位置，使之对准A面孔位中心，调节光斑大小至大于再次扩孔后的孔径；
k）重复步骤f）—g）；
l）将修补过的镍基合金进行高温固溶稳定化处理，便完成镍基高温合金铸件的缺陷修复。
所述步骤f）中铺粉的厚度为0.6mm-1.2mm。
激光照射时间持续500—1500ms。
修复后的镍基合金铸件进行高温固溶稳定化处理后，进行打磨，并采用荧光探伤法进行检查。
本发明的修补方法，是通过人为制造一种可控形控性的缺陷，采用激光熔覆同种材料的方式来修补铸造缺陷，通过对激光输入的功率、光斑大小、激光持续时间进行精确控制，实现高温镍基合金铸件缺陷进行修复，使得修复后的工件性能达到苛刻工况的使用要求，解决长期困扰行业的难题，极大提高的工件成品率，减少了材料的浪费，提升了行业的技术水平。
附图说明
下面再结合附图进一步说明本发明的有关细节。
图1为本发明修补的过程图。
具体实施方式
本发明的这种镍基高温合金铸件缺陷的修复方法，是通过制造可量化的特定缺陷修复铸造缺陷。下面结合一个具体的实施例来详细说明修复的方法，对一个厚度为1mm的镍基高温合金发动机调节片铸件（以下简称调节片铸件），采用荧光探伤法、X光探伤法进行探测缺陷，并加以标记；采用硬质合金钻头将缺陷部分贯穿，完全去除；然后进行扩孔成型，扩孔后的孔径为2mm；而后将扩孔的孔位用丙酮浸泡，去除油污，用酒精浸泡，去除水分；而后进行干燥化处理；干燥后，在所述调节片铸件一面，此面定义为A面，将A面的孔位处贴上挡片，该挡片用以挡住后面将要铺上的镍基合金粉；将调节片铸件未贴上挡片的一面，此面定义为B面，将B面朝上，并将调节片铸件水平安装于工作台夹具上；调整激光光斑位置，使之对准B面孔位中心，并将光斑大小调节到大于扩孔后的孔径，一般来说，其光斑直径大小调节到3-5mm即可；在调节片铸件的B面孔位处铺上与调节片基材相同成分且厚度均匀的镍基合金粉末，粉末粒度为-100—+325目，厚度高出基材表面0.6-1.2mm，铺上的镍基合金粉末覆盖孔位及孔位周围的基材，然后把镍基合金粉压实；根据材料的厚度和孔径的大小，设置好激光功率和激光出光持续时间，激光出光的持续时间设置在500-1200ms。开启激光，将激光照射在工件表面，将镍基合金粉熔覆到孔位中以及基材表面，熔覆后的镍基合金在孔位处形成一个向上凸的圆弧状；然后对熔覆部位进行检查，是否开裂；如果开裂，该铸件就不能再使用；如果完好无损，则去除A面挡片，并在A面的孔位处再次进行扩孔，以清除上述熔覆后残留在孔位内的残渣和缺陷，且在孔的边缘倒角，且在孔的边缘倒角；而后将扩孔的孔位用丙酮浸泡，去除油污，用酒精浸泡，去除水分；而后进行干燥化处理；干燥后，将A面朝上，再将调节片铸件水平安装于工作台，调整激光光斑位置，使之对准A面孔位中心，调节光斑大小至大于再次扩孔后的孔径，且在孔的边缘倒角，此处的孔径指的A面表面的孔径，然后重复上述的铺粉、熔覆以及检查步骤；最后将激光熔覆过的镍基合金铸件进行高温固溶稳定化处理，使得熔覆部位与铸件本体的金相组织一致；最后进行打磨平整，且再次并采用荧光探伤法进行检查其完好性，就完成了镍基合金铸件的修复过程。
本发明的这种修复方法，具有成功率高，质量好的特点，避免了由于镍基合金铸件本身缺陷造成的极大浪费。
Claims (4)
1.镍基高温合金铸件缺陷的修复方法，其特征在于包括如下步骤：
a）扩孔，将缺陷孔径扩大并贯穿；
b）对扩孔的孔位进行清洗、干燥处理；
c）在镍基合金铸件A面的孔位处贴上挡片；
d）将镍基合金铸件未贴上挡片的B面朝上；
e）调整激光光斑位置，使之对准B面孔位中心，调节光斑大小至大于扩孔后的孔径；
f）在镍基合金铸件的B面孔位处铺上与铸件基材相同成分且厚度均匀的镍基合金粉末，把镍基合金粉压实，以完全覆盖孔位及周围的基材；
g）根据材料的厚度和孔径的大小，设置好激光功率和激光出光持续时间，开启激光，将激光照射工件表面，将镍基合金粉熔覆到孔位中以及基材表面；
h）去除A面挡片，并在A面的孔位处再次进行扩孔，以清除步骤f）熔覆后残留在孔位内的残渣和缺陷，且使A面孔位形成锥形孔；
i）将A面朝上，调整激光光斑位置，使之对准A面孔位中心，调节光斑大小至大于再次扩孔后的孔径；
j）重复步骤f）—g）；
k）将修补过的镍基合金进行高温固溶稳定化处理，便完成镍基高温合金铸件的缺陷修复。
2.根据权利要求1所述的镍基高温合金铸件缺陷的修复方法，其特征在于所述步骤f）中铺粉的厚度为0.6mm-1.2mm。
3.根据权利要求1所述镍基高温合金铸件缺陷的修复方法，其特征在于激光照射时间持续500—1200ms。
4.根据权利要求1所述的镍基高温合金铸件缺陷的修复方法，其特征在于修复后的镍基合金铸件进行高温固溶稳定化处理后，进行打磨，并采用荧光探伤法进行检查。
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