CN111607788A - Laser cladding remanufacturing method for dry quenching circulating fan impeller - Google Patents
Laser cladding remanufacturing method for dry quenching circulating fan impeller Download PDFInfo
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- CN111607788A CN111607788A CN202010181912.9A CN202010181912A CN111607788A CN 111607788 A CN111607788 A CN 111607788A CN 202010181912 A CN202010181912 A CN 202010181912A CN 111607788 A CN111607788 A CN 111607788A
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- laser cladding
- laser
- dry quenching
- circulating fan
- fan impeller
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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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
- B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
- B23P6/007—Repairing turbine components, e.g. moving or stationary blades, rotors using only additive methods, e.g. build-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
- B22F2007/068—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts repairing articles
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
The invention belongs to the technical field of dry quenching, and particularly relates to a laser cladding remanufacturing method for a dry quenching circulating fan impeller, which comprises the following specific steps: s1: high-speed laser cladding treatment: on the basis of the traditional laser cladding technology, technological parameters are optimized, the wear resistance of the easily worn part is improved, an industrial camera is used for building a molten pool temperature real-time monitoring system, and images are analyzed through software to guide laser cladding equipment to work; s2: flux-cored wire welding treatment; s3: replacing the high-strength bolt; the flux-cored wire is made of low-carbon steel or low-alloy steel and other materials with better plasticity, has the advantages of wear resistance, heat resistance, corrosion resistance, high strength and the like, and can meet the requirements of remanufacturing and repairing; a real-time monitoring system of the temperature of the molten pool is set up by an industrial camera, images are analyzed through software, the laser cladding equipment is effectively guided to work, and the influence of laser melting deposition process parameters on single-layer organization and performance is effectively avoided.
Description
Technical Field
The invention relates to the technical field of dry quenching, in particular to a laser cladding remanufacturing method for an impeller of a dry quenching circulating fan.
Background
The main dry quenching equipment comprises a lifter system, a dry quenching furnace system, a boiler system, a primary process dedusting system, a secondary process dedusting system, a gas circulation system, coke charging and discharging equipment and the like. Wherein the gas circulating system is an inert gas circulating device communicated between the storage chamber of the coke quenching furnace and the waste heat boiler. The core equipment of the gas circulation system is a circulating fan which is arranged between a boiler and a dry quenching furnace and has the main functions that: circulating gas at about 850 ℃ is pumped into a boiler, is changed into circulating gas below 200 ℃ after heat absorption by the boiler, is blown into a dry quenching furnace by a fan to exchange heat with red coke, is the heart of the dry quenching device, and is in closed cycle operation. The existing fan runs for a long period, and because the inert gas contains coke powder, the volute, the rotor and other parts of the fan are washed for a long time, the volute of the fan is seriously leaked, and potential safety hazards exist.
The typical characteristics of modern chemical equipment are large-scale, high-speed, continuous, precise and automatic, and these characteristics bring many changes to the production, organization and equipment maintenance management business of enterprises: on one hand, the high-speed operation of the equipment causes the abrasion of parts to be aggravated and the service life to be shortened, and on the other hand, the shutdown loss, the maintenance difficulty, the maintenance cost and the like of the equipment are far larger than those of the traditional equipment, so that a series of problems are brought.
Disclosure of Invention
The invention aims to provide a laser cladding remanufacturing method for a coke dry quenching circulating fan impeller, which aims to solve the problems that the wear of parts is aggravated, the service life is shortened, the shutdown loss, the maintenance difficulty, the maintenance cost and the like of equipment are far larger than those of the traditional equipment due to the high-speed operation of modern chemical equipment in the background technology.
In order to achieve the purpose, the invention provides the following technical scheme: a laser cladding remanufacturing method for a coke dry quenching circulating fan impeller comprises the following specific steps:
s1: high-speed laser cladding treatment: the method comprises the steps of adopting a high-speed laser cladding technology, adopting a laser melting deposition system, wherein the laser melting deposition system comprises an 8kW semiconductor laser, a powder feeding system and a numerical control mobile platform, optimizing process parameters on the basis of the traditional laser cladding technology, improving the wear resistance of an easily worn part, building a molten pool temperature real-time monitoring system by using an industrial camera, and analyzing images by software to guide laser cladding equipment to work;
s2: flux-cored wire welding treatment: the flux-cored wire with high wear resistance and corrosion resistance is adopted for additive manufacturing, and is made of low-carbon steel or low-alloy steel and the like with good plasticity;
s3: replacing the high-strength bolt: the bolts which are easy to damage on the fan impeller are all replaced by high-strength bolts.
Preferably, the wavelength output by the 8kW semiconductor laser is 808-940nm, the focal length is 200mm, and the light spots comprise three rectangular light spots of 3 × 12mm, 3 × 18mm and 3 × 24 mm.
Preferably, the light spot is a 3 × 24mm rectangular light spot.
Preferably, the powder feeding system drives the spiral sheet to transmit powder feeding by a motor, the powder feeding speed is controlled by the rotating speed of the motor, and the powder feeding rate is selected to be 15g/min for controlling the thickness of a single layer of a laser deposition layer.
Preferably, the numerical control moving platform consists of an XYZ three-axis translation mechanism.
Compared with the prior art, the invention has the beneficial effects that:
1) on the basis of the traditional laser cladding technology, technological parameters are optimized, and the processing efficiency and the product forming effect are effectively improved;
2) the flux-cored wire is made of low-carbon steel or low-alloy steel and other materials with better plasticity, has the advantages of wear resistance, heat resistance, corrosion resistance, high strength and the like, and can meet the requirements of remanufacturing and repairing;
3) an industrial camera is used for building a molten pool temperature real-time monitoring system, images are analyzed through LabView and other software, the laser cladding equipment is effectively guided to work, and the influence of laser melting deposition process parameters on single-layer organization and performance is effectively avoided.
Drawings
FIG. 1 is a flow chart of the method of the present invention;
FIG. 2 is a diagram of a laser fused deposition coupon in accordance with the present invention;
FIG. 3 is a graph showing cracks generated on the surface of the cladding layer according to the present invention;
FIG. 4 is a parameter diagram of a laser fusion deposition process of the present invention;
FIG. 5 is a graph of laser fluence at different process parameters of the invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the description of the present invention, it is to be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", and the like, indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are merely for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present invention.
The dry quenching circulating fan is mainly driven by a variable frequency motor and mainly comprises a rotor, a shell, an air inlet box, a bearing group and the like;
the fan has high machining precision requirement. Because the blower locks the core component data, the preparation work of the data can only be completed by surveying and mapping the inlet blower in actual operation, so that the performance of the blower can be achieved after the remanufacturing of the rotor (impeller), and the use requirement can be met with lower cost. The main research and modification contents are as follows:
and manufacturing a fan impeller remanufacturing test platform meeting the requirement of the dry quenching circulating fan.
A novel composite manufacturing method based on a laser remanufacturing theory is researched. The method has the advantages of fully playing the advantage of concentrated heat input of the high-speed laser cladding technology, and simultaneously combining the advantages of the flux-cored wire welding technology in an auxiliary way at the position where the individual high-speed laser cladding is difficult to complete. The composite remanufacturing and repairing scheme not only meets the criteria of 'high quality, high efficiency, energy saving, material saving and environmental protection' of green remanufacturing, but also applies the theory to the actual production and obtains excellent actual effect.
The remanufacturing process of the fan is optimized as soon as possible, import is replaced, the service life of equipment is prolonged, the continuous operation of daily production work is guaranteed, and continuous production is guaranteed.
The key technical problems are as follows:
technical problem 1: the welding technology is used for repairing the easily worn part of the fan impeller to generate more cracks, and the requirement on the wear resistance cannot be met.
Technical problem 2: due to the limitation of the size of equipment, parts which are easy to wear can not be repaired by using a laser cladding technology.
Referring to fig. 1-5, the present invention provides a technical solution: a laser cladding remanufacturing method for a coke dry quenching circulating fan impeller comprises the following specific steps:
s1: high-speed laser cladding treatment: the method comprises the steps of adopting a high-speed laser cladding technology, adopting a laser melting deposition system, wherein the laser melting deposition system comprises an 8kW semiconductor laser, a powder feeding system and a numerical control mobile platform, optimizing process parameters on the basis of the traditional laser cladding technology, improving the wear resistance of an easily worn part, building a molten pool temperature real-time monitoring system by using an industrial camera, and analyzing images by software to guide laser cladding equipment to work;
s2: flux-cored wire welding treatment: the flux-cored wire with high wear resistance and corrosion resistance is adopted for additive manufacturing, and is made of low-carbon steel or low-alloy steel and the like with good plasticity;
s3: replacing the high-strength bolt: the bolts which are easy to damage on the fan impeller are all replaced by high-strength bolts.
Furthermore, the wavelength output by the 8kW semiconductor laser is 808-940nm, the focal length is 200mm, and the light spots comprise three rectangular light spots of 3 × 12mm, 3 × 18mm and 3 × 24 mm.
Further, the light spot takes a 3 × 24mm rectangular light spot.
Furthermore, the powder feeding system drives the spiral sheet to transmit and feed powder by a motor, the powder feeding speed is controlled by the rotating speed of the motor, and the powder feeding rate is selected to be 15g/min for controlling the thickness of a single layer of a laser deposition layer.
Further, the numerical control mobile platform consists of an XYZ three-axis translation mechanism.
According to the pre-experimental results, the lapping rate of 50% is selected, and 9 sets of different laser powers and scanning speeds are selected under the condition that the parameters are not changed (see fig. 4).
The laser melting deposition is to prepare parts by layer-by-layer accumulation, and the influence of the surface topography of the deposition layer can be accumulated continuously, so that the forming quality of the parts is influenced finally. FIG. 2 is a graph showing that the laser power and the scanning speed have a large influence on the macroscopic morphology of the deposited layer when the deposited sample is melted by the laser under 9 sets of process parameters.
When the laser power is 3kW, the powder cannot be bonded to the substrate regardless of the scanning speed, because 3kW is lower than the limit power of the laser fusion deposition, that is, at this power, the laser beam can melt only the alloy powder and hardly the substrate, and thus the deposition layer cannot be formed at 3 kW. When the laser power is 5kW, the deposited layer can be formed, but the formability is reduced with the increase of the scanning speed, and when the scanning speed is 2mm/s, the surface of the deposited layer is flat and the forming is better; when the scanning speed is 8mm/s, the spheroidization phenomenon appears at two sides of each pass; when the scanning speed is increased to 10mm/s, the scanning speed is too fast, so that the molten pool holding time is short, the heat input is less, and the deposited layer fails to be formed.
When the laser power is 8kW, the deposited layer is completely formed, but when the scanning speed is 5mm/s, the initial end and the tail end of the deposition pass are collapsed due to large heat, and a large amount of gray black slag exists on the surface, which indicates that the burning loss of alloy elements is caused by the overhigh temperature of a molten pool; when the scanning speed is 8mm/s and 10mm/s, the large temperature gradient and cooling speed in the molten pool cause cracks on the surface of the cladding layer, as shown in FIG. 3.
From the above analysis, it can be seen that the quality of the laser deposition layer formation is affected by the coupling of the laser power and the scanning speed. For further investigation, the laser energy density ρ is introduced below, i.e.:
wherein P is laser power, kW; v is the scanning speed, mm/s, B is the laser width, mm.
And arranging the laser melting deposition samples in sequence from high to low according to the laser energy density. Analysis shows that on the premise that the laser power is greater than the limit power, the heat input is increased along with the increase of the laser energy density, the powder and the matrix are melted, and when the temperature of a molten pool is higher, the fluidity is good, so that the deposited layer is formed. Under the same laser power, cracks are easily generated at a larger scanning speed, and the solidification speed and the cooling speed of a molten pool are increased due to the larger scanning speed. On one hand, a molten pool grows in a dendritic crystal form, a low-melting-point liquid film exists between two adjacent dendritic crystals due to component segregation and becomes a weak area at the later stage of solidification, cracks are generated under large solidification shrinkage stress, and the cracks cannot be backfilled by the liquid under the condition of rapid solidification, so that cracks exist between the dendritic crystals of a room-temperature tissue. On the other hand, the larger cooling speed improves the temperature gradient of the deposition layer, so that the thermal stress is increased, the residual tensile stress in the deposition layer is increased, and the crack sensitivity is improved, therefore, when the laser energy density for forming the deposition layer is met, the smaller scanning speed can inhibit the generation of cracks.
Fig. 5 shows laser fluence under different process parameters.
Remanufacturing an impeller:
and remanufacturing the worn surface of the impeller by using a laser cladding technology. According to the wear amount and the distribution of the main wear area, the wear condition of the blade head is found to be serious, and laser cladding is carried out between the original welding seams through on-site investigation.
In the repairing process, a high-speed laser cladding technology is strictly adopted for the fan impeller, so that the wear resistance of the easily worn part is improved. Meanwhile, a high-wear-resistant and corrosion-resistant flux-cored wire is adopted for material increase manufacturing at a position which is difficult to reach by high-speed laser cladding, so that the wear resistance and the corrosion resistance of the impeller are guaranteed.
While there have been shown and described the fundamental principles and essential features of the invention and advantages thereof, it will be apparent to those skilled in the art that the invention is not limited to the details of the foregoing exemplary embodiments, but is capable of other specific forms without departing from the spirit or essential characteristics thereof; the present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein, and any reference signs in the claims are not intended to be construed as limiting the claim concerned.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (5)
1. A laser cladding remanufacturing method for an impeller of a dry quenching circulating fan is characterized by comprising the following steps of: the laser cladding remanufacturing method of the dry quenching circulating fan impeller comprises the following specific steps:
s1: high-speed laser cladding treatment: the method comprises the steps of adopting a high-speed laser cladding technology, adopting a laser melting deposition system, wherein the laser melting deposition system comprises an 8kW semiconductor laser, a powder feeding system and a numerical control mobile platform, optimizing process parameters on the basis of the traditional laser cladding technology, improving the wear resistance of an easily worn part, building a molten pool temperature real-time monitoring system by using an industrial camera, and analyzing images by software to guide laser cladding equipment to work;
s2: flux-cored wire welding treatment: the flux-cored wire with high wear resistance and corrosion resistance is adopted for additive manufacturing, and is made of low-carbon steel or low-alloy steel and the like with good plasticity;
s3: replacing the high-strength bolt: the bolts which are easy to damage on the fan impeller are all replaced by high-strength bolts.
2. The laser cladding remanufacturing method of the dry quenching circulating fan impeller according to claim 1, characterized in that: the wavelength output by the 8kW semiconductor laser is 808-940nm, the focal length is 200mm, and the light spots comprise three rectangular light spots of 3 × 12mm, 3 × 18mm and 3 × 24 mm.
3. The laser cladding remanufacturing method of the dry quenching circulating fan impeller according to claim 2, characterized in that: the light spot takes a 3 × 24mm rectangular light spot.
4. The laser cladding remanufacturing method of the dry quenching circulating fan impeller according to claim 1, characterized in that: the powder feeding system drives the spiral sheet to transmit and feed powder by a motor, the powder feeding speed is controlled by the rotating speed of the motor, and the powder feeding rate is selected to be 15g/min for controlling the single-layer thickness of the laser deposition layer.
5. The laser cladding remanufacturing method of the dry quenching circulating fan impeller according to claim 1, characterized in that: the numerical control mobile platform consists of an XYZ three-axis translation mechanism.
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| CN202010181912.9A CN111607788A (en) | 2020-03-16 | 2020-03-16 | Laser cladding remanufacturing method for dry quenching circulating fan impeller |
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| CN202010181912.9A CN111607788A (en) | 2020-03-16 | 2020-03-16 | Laser cladding remanufacturing method for dry quenching circulating fan impeller |
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Application publication date: 20200901 |