CN111676477B - Ultrahigh-speed laser-induction composite cladding method and device - Google Patents

Ultrahigh-speed laser-induction composite cladding method and device Download PDF

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CN111676477B
CN111676477B CN202010528638.8A CN202010528638A CN111676477B CN 111676477 B CN111676477 B CN 111676477B CN 202010528638 A CN202010528638 A CN 202010528638A CN 111676477 B CN111676477 B CN 111676477B
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cladding
workpiece
induction heating
laser
powder
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CN111676477A (en
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曾晓雁
孟丽
胡乾午
王邓志
郭平华
许晓明
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Wuhan Flex Laser Technology Co ltd
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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
    • 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

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  • Engineering & Computer Science (AREA)
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  • Mechanical Engineering (AREA)
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  • Organic Chemistry (AREA)
  • Laser Beam Processing (AREA)

Abstract

The invention belongs to the field of surface coating processing, and particularly discloses an ultrahigh-speed laser-induction composite cladding method and device, aiming at a workpiece to be clad as a processing object, an induction heating coil for preheating the workpiece is arranged nearby the workpiece, and a region of the workpiece to be clad is heated to a set temperature through the shape of the induction heating coil and the spatial arrangement of the induction heating coil relative to the workpiece to be clad; and performing ultrahigh-speed laser-induction hybrid cladding on the region to be clad of the workpiece by adopting an ultrahigh-speed laser cladding and induction heating mode, so that a laser beam spot and a powder beam interact at the target position of the cladding region to heat the alloy powder to a molten drop or semi-molten drop state, and spraying the alloy powder to a micro-molten pool on the preheating surface of the workpiece in a liquid or semi-solid mode to prepare the required cladding layer. The invention can realize the ultra-high-efficiency deposition of the metal cladding layer of various materials with high precision, high performance and no metallurgical defects on the surface of the metal member.

Description

Ultrahigh-speed laser-induction composite cladding method and device
Technical Field
The invention belongs to the technical field of surface coating processing, and particularly relates to an ultrahigh-speed laser-induction composite cladding method and device.
Background
As an advanced surface coating technology, laser cladding can prepare a high-performance coating which is metallurgically bonded with a base material, has low dilution rate and compact tissue structure on the surface of a metal material, so the laser cladding has been widely applied to the field of surface strengthening and repairing of metal members. However, the conventional laser cladding technology (LC) has several problems: (1) the deposition efficiency is low, and the preparation cost is high; (2) Although the deposition precision is higher than that of the traditional surfacing process, the deposition precision is still lower than that of physical vapor deposition, chemical vapor deposition and other processes, the subsequent processing cost is high, and the limitation is large especially for the preparation requirements of ultrathin wear-resistant and corrosion-resistant coatings on the surface and coating materials with higher hardness and poor machining performance; (3) The cladding layer is easy to generate metallurgical defects, laser cladding has the characteristics of rapid heating and rapid cooling, the temperature gradient and the cooling rate of a molten pool are large, so that the residual stress is increased, the cladding layer is easy to generate the metallurgical defects such as cracks, air holes and the like, and the cladding layer has great limitation particularly when a high-hardness and high-cracking sensitivity material coating is deposited.
To solve the above problems, some solutions have been proposed in the prior art. For example, patent document (publication No. CN101125394 a) discloses an automatic powder feeding laser-induction hybrid cladding process method and device, which combines laser and induction heat source to realize hybrid processing, not only greatly improves laser cladding efficiency, but also solves the problem that an alloy material with poor weldability and high cracking sensitivity is easy to crack in the laser cladding process. However, the deposition efficiency of the laser-induction composite cladding process method is still low, which results in high cost, and the method still cannot compete with the traditional process in many application occasions. In addition, in the process of the laser-induction composite cladding technology, laser beams act on the surface of a base material, so that part of the base material and alloy powder are melted simultaneously. Along with the induction heating, the preheating temperature of the substrate rises, the absorption rate of the substrate to laser beams is continuously increased, so that the melting depth of the laser-induction composite cladding layer is increased compared with that of a pure laser cladding layer, and the dilution rate of the cladding layer is increased. Therefore, the laser-induction hybrid cladding can sacrifice the performance of the cladding layer to a certain extent while solving the problem of cracking of the cladding layer.
For another example, patent document (publication No. CN 111041473A) discloses a method for preparing an ultra-high-speed laser cladding layer by magnetic preheating and stirring assistance, which combines an electromagnetic assistance system with an ultra-high-speed laser cladding processing system to eliminate cracks and pores of the cladding layer, improve the surface quality and performance of the cladding layer, and increase the powder utilization rate. However, the electromagnetic assistance in the method needs to be realized by the cooperation of an electromagnetic generating device arranged below the workpiece and an exciting coil arranged above the workpiece, so that the influence factors in the processing process are numerous, the process is complex, and the cladding effect and quality are difficult to ensure. In addition, the electromagnetic device in the method only acts on the local position of the surface of the shaft workpiece, so that the surface of the workpiece is heated unevenly, frequent rapid cooling and rapid heating cycles are needed in the processing process, and the forming quality of a cladding layer is unstable. Particularly, when the material coating with high cracking sensitivity and high processing difficulty on the surface of a large-shaft-diameter or large-size workpiece is subjected to high-speed cladding, the forming quality of the cladding layer is difficult to ensure.
Therefore, research and study are still needed in the field, so as to further improve the forming quality and deposition efficiency of the cladding layer and expand the range of cladding materials, thereby enabling the laser cladding technology to be applied in a wider industrial field.
Disclosure of Invention
Aiming at the defects or improvement requirements in the prior art, the invention provides an ultrahigh-speed laser-induction composite cladding method and device, which combine ultrahigh-speed laser cladding with induction heating, can realize ultrahigh-efficiency deposition of a metal cladding layer with high precision, high performance and no metallurgical defects on the surface of a metal member, and is particularly suitable for strengthening and repairing a high-hardness wear-resistant coating on the surface of a thin-walled member with small wall thickness and easy deformation.
In order to achieve the above object, according to a first aspect of the present invention, there is provided an ultra-high-speed laser-induction hybrid cladding method, in which an induction heating coil for preheating a workpiece is arranged near a workpiece to be clad as a processing object, and omni-directional uniform heating of a region of the workpiece to be clad is achieved by a shape of the induction heating coil and a spatial arrangement with respect to the workpiece to be clad, and uniformity of temperature field distribution of the region of the workpiece to be clad is improved; and performing ultrahigh-speed laser-induction hybrid cladding above a cladding area of the workpiece to be clad by adopting an ultrahigh-speed laser cladding and induction heating mode, so that a laser beam spot and a powder beam interact at a target position above the cladding area to heat the alloy powder to a molten drop or semi-molten drop state, and the alloy powder is sprayed to a micro molten pool on the preheating surface of the workpiece in a liquid or semi-solid form, thereby preparing a pore-free, crack-free and compact high-quality cladding layer which is metallurgically bonded with the workpiece.
Through the conception, on one hand, the preheating of the workpiece is realized to reduce the temperature gradient of the workpiece, the effective proceeding of the subsequent laser cladding is convenient, the problem of uneven temperature of the region of the workpiece to be clad is also considered, the omnibearing uniform heating of the region of the workpiece to be clad can be realized through the targeted design and arrangement of the induction heating coil, the uniformity of the temperature distribution of the region of the workpiece to be clad is ensured, and the stability of the quality of the subsequently prepared cladding layer is ensured; on the other hand, the high-speed laser cladding and the induction heating are organically combined through the linkage control and the synergistic effect of the ultrahigh-speed laser cladding and the induction heating, and the high-quality cladding layer which has good spreadability, high interface wettability and binding force, extremely low dilution rate, high surface precision, no air holes, no cracks and compactness can be prepared through the cooperation and the cooperation between the ultrahigh-speed laser cladding and the induction heating, the density reaches more than 99.8 percent, and the powder deposition efficiency and the utilization rate are greatly improved; furthermore, the invention organically combines the high-speed laser cladding and the induction heating through the linkage control and the synergistic effect of the ultrahigh-speed laser cladding and the induction heating, can regulate and control the cooling process of a laser heat affected zone, avoids the heat affected zone from generating tissues with poor comprehensive properties such as cracks, hard and brittle martensite and the like under the action of high-speed laser, and has great value particularly for materials with poor weldability, hardening and cracking tendency such as high-carbon steel, cast iron and the like. Through the design, the invention is not only suitable for cladding of general materials, but also suitable for high-speed cladding of material coatings with high cracking sensitivity and large processing difficulty on the surfaces of large-shaft-diameter or large-size workpieces, and greatly expands the application range.
Preferably, the shape of the induction heating coil and the arrangement mode of the induction heating coil and the workpiece to be clad are designed according to the shape characteristics of the workpiece to be clad, and the omnibearing uniform heating of the region of the workpiece to be clad is ensured through the design.
Preferably, by designing a specific cladding process of ultra-high-speed laser cladding and a specific heating process of induction heating, and performing ultra-high-speed laser-induction hybrid cladding by using the processes, the linkage control of the ultra-high-speed laser cladding and the induction heating is realized, and the synergistic effect of the ultra-high-speed laser cladding and the induction heating is further utilized to ensure that a high-quality cladding layer which is good in spreadability, high in interface wettability and bonding force, extremely low in dilution rate, high in surface precision, free of pores, free of cracks and compact is prepared.
According to the second aspect of the invention, the invention not only provides an idea of an ultra-high speed laser-induction hybrid cladding method, but also provides a specific operation scheme, and specifically comprises the following steps:
s1, fixing a workpiece to be cladded and carrying out pretreatment;
s2, designing and arranging induction heating coils for preheating the workpiece according to the characteristics of the workpiece to be clad in a targeted manner, and designing an ultra-high-speed laser cladding process and an induction heating process at the same time;
s3, the induction heating coils which are designed and arranged in a targeted manner are used for realizing all-around uniform heating of the region of the workpiece to be cladded according to the designed induction heating process, so that the uniformity of the temperature distribution of the region of the workpiece to be cladded is ensured, and the quality stability of a cladding layer prepared subsequently is ensured;
s4, after the surface of the workpiece is heated to a preset temperature, cladding is carried out by utilizing a designed ultra-high-speed laser cladding process, in the cladding process, through the linkage control and the synergistic effect of the ultra-high-speed laser cladding and induction heating, a laser beam spot and a powder beam interact at a specified position above the region to be clad of the workpiece, so that alloy powder is heated to a molten drop or semi-molten drop state and is sprayed to a micro-molten pool on the preheating surface of the workpiece in a liquid or semi-solid mode, and then a cladding layer which is metallurgically combined with the workpiece is prepared;
and S5, after finishing cladding of one cladding layer, judging whether the thickness of the cladding layer meets the requirement, if so, finishing the cladding process, otherwise, repeating the steps S2-S4 until the required thickness is reached, thereby obtaining the high-quality cladding layer which is free of air holes, cracks and compactness.
As a further optimization, the specific shape and arrangement of the induction heating coil are designed according to the shape characteristics of the workpiece to be clad, specifically, for the pipe fitting, the induction heating coil is designed to be annular, and is arranged outside or inside the pipe fitting and is coaxially arranged with the pipe fitting, so that the all-around surrounding type uniform heating of the area to be clad of the pipe fitting is realized.
Preferably, for the shaft-type solid part, the induction heating coil is designed to be annular and is arranged outside the part and coaxial with the part, so that the all-around surrounding uniform heating of the region to be clad of the part is realized.
As a further preference, for the plate-like and block-like pieces, the induction heating coil is designed in a linear form and arranged above the workpiece, so that an omnidirectional uniform heating of the region of the part to be clad is achieved.
Preferably, the design of the ultra-high-speed laser cladding process is as follows: the diameter of the laser beam spot is designed to be 0.5 mm-5 mm, preferably 1 mm-3 mm; the position where the laser beam spot and the powder beam are converged above the surface of the workpiece is designed to be 0.5-5 mm; the laser power is designed to be 1kW to 15kW, preferably 6kW to 10kW; the laser processing speed is designed to be 20m/min-300m/min, preferably 210 m/min-250 m/min; the flow rate of the protective gas is designed to be 10L/min to 25L/min, preferably 15L/min to 25L/min; the powder feeding amount is designed to be 10 g/min-500 g/min, preferably 160 g/min-400 g/min; the flow rate of the powder feeding air is designed to be 2L/min-15L/min, preferably 3L/min-12L/min; the lap joint rate is designed to be 40-90%, and preferably 60-90%.
As a further preferred, the induction heating process is designed as follows: the distance between the induction heating coil and the surface of the workpiece is designed to be 1-10 mm; the heating temperature of the workpiece is designed to be 350-800 ℃.
Preferably, the focusing position of the laser beam spot on the surface of the workpiece is located in front of, in the middle of or behind the induction heating position during the cladding process.
As a further preference, the method further comprises the steps of: and S6, detecting the surface of the cladding layer by adopting penetration or ultrasonic flaw detection after cladding.
As a further preference, the method further comprises the steps of: and S7, polishing the surface of the cladding layer of the workpiece.
According to the third aspect of the present invention, the present invention not only provides a specific operation scheme of the ultra-high speed laser-induction hybrid cladding method, but also provides a set of targeted operation scheme for specific application objects, that is, further provides an ultra-high speed laser-induction hybrid cladding method specially used for pipe fittings, which comprises the following steps:
s1, fixing a pipe fitting to be clad and carrying out pretreatment;
s2, designing an annular induction heating coil, arranging the annular induction heating coil outside or inside the pipe fitting and coaxially arranging the annular induction heating coil and the pipe fitting so as to realize all-around surrounding type uniform heating of a to-be-clad area of the pipe fitting; simultaneously designing an ultra-high speed laser cladding process and an induction heating process for ultra-high speed laser-induction composite cladding of the pipe fitting;
s3, utilizing the induction heating coils which are designed and arranged in a targeted manner to realize all-around surrounding type uniform heating of the to-be-clad area of the pipe fitting according to the designed induction heating process, ensuring the uniformity of the temperature distribution of the to-be-clad area of the pipe fitting and ensuring the quality stability of a subsequently prepared cladding layer;
s4, after the surface of the pipe to be clad is heated to a preset temperature, cladding is carried out by utilizing a designed ultra-high-speed laser cladding process, in the cladding process, through the linkage control and the synergistic effect of the ultra-high-speed laser cladding and induction heating, a laser beam spot and a powder beam interact at a specified position above the area of the pipe to be clad, so that alloy powder is heated to a molten drop or semi-molten drop state and is sprayed to a micro-molten pool on the preheating surface of the pipe in a liquid or semi-solid mode, and then the cladding layer which is in metallurgical combination with the pipe is prepared;
and S5, after finishing cladding of a cladding layer, judging whether the thickness of the cladding layer meets the requirement, if so, finishing the cladding process, otherwise, repeating the steps S2-S4 until the required thickness is reached, thereby obtaining a pore-free, crack-free and compact high-quality cladding layer on the surface of the pipe fitting to be clad.
As a further preference, the laser cladding is performed on the outer surface of the tube, the induction heating coil being arranged outside the tube and coaxially with the tube.
As a further preference, the laser cladding is performed on the inner surface of the tube, and the induction heating coil is arranged inside or outside the tube and is arranged coaxially with the tube.
As a further preferred aspect, the invention also designs a cladding process suitable for ultra-high speed laser cladding of the special object of the pipe fitting, specifically, the cladding process comprises the following steps: the diameter of the laser beam spot is designed to be 0.5 mm-5 mm, preferably 1 mm-3 mm; the position of the laser beam spot and the powder beam converged above the surface of the workpiece is designed to be 0.5-5 mm; the laser power is designed to be 1kW to 15kW, preferably 6kW to 10kW; the laser processing speed is designed to be 20m/min-300m/min, preferably 210 m/min-250 m/min; the protective gas flow is designed to be 10L/min-20L/min; the powder feeding amount is designed to be 10 g/min-500 g/min, preferably 160 g/min-400 g/min; the flow rate of the powder feeding air is designed to be 5L/min-12L/min; the lap joint rate is designed to be 70% -90%.
As a further preference, the present invention also specifically designs an induction heating process adapted to this particular object, the object being a pipe: the distance between the induction heating coil and the surface of the workpiece is designed to be 5-10 mm; the heating temperature of the workpiece is designed to be 400-700 ℃.
According to a fourth aspect of the present invention, the present invention not only provides a specific operation scheme of the ultra-high speed laser-induction hybrid cladding method, but also provides a dedicated device matched with the operation scheme, that is, also provides an ultra-high speed laser-induction hybrid cladding apparatus, which includes a laser scanning unit, an induction heating unit, a powder conveying unit and a three-dimensional moving unit, wherein:
the laser scanning unit is used for outputting laser beam spots with energy in Gaussian distribution or uniform distribution;
the induction heating unit comprises an induction heating power supply, an induction heating coil, an infrared thermometer and a temperature controller, wherein the induction heating coil is connected with the induction heating power supply, and the induction heating coil is designed and arranged in a targeted manner according to the characteristics of a workpiece to be clad so as to realize the all-around uniform heating of the region of the workpiece to be clad, ensure the uniformity of the temperature distribution of the region of the workpiece to be clad and ensure the quality stability of a subsequent cladding layer; the infrared thermometer is used for measuring the temperature of the induction heating area on the surface of the workpiece and feeding the temperature back to the temperature controller, and the temperature controller controls the output power of the induction heating power supply based on the temperature fed back by the infrared thermometer so that the induction heating coil reaches the preset temperature;
the powder conveying unit is used for conveying powder and forming a powder beam flow at the nozzle, meanwhile, the powder beam flow and the laser beam flow are converged at a preset position above the surface of a workpiece, so that the alloy powder is heated to a molten drop or semi-molten drop state through the interaction of the laser beam flow and the powder beam flow above the workpiece, finally, the alloy powder is sprayed on the surface of the workpiece in a liquid or semi-solid mode to form a micro-molten pool through laser direct irradiation, and the micro-molten pool is rapidly cooled and solidified to obtain a cladding layer which is metallurgically combined with the workpiece;
the three-dimensional moving unit is used for driving the workpiece to be clad to perform three-dimensional motion so as to ensure that the ultra-high-speed laser-induction hybrid cladding is performed at the position required by the workpiece.
Generally, compared with the prior art, the above technical solution conceived by the present invention mainly has the following technical advantages:
1. by combining induction heating with ultrahigh-speed laser cladding, the invention fully utilizes the characteristics of high deposition precision and deposition efficiency of the ultrahigh-speed laser cladding and low heat input of the substrate, and the high-efficiency and high-stability preheating and postheating effects of the induction heating on the substrate, can increase the wettability between different phases of the cladding layer and between the molten or semi-molten cladding metal and the substrate on the premise of ensuring that the melting depth of the substrate is not changed obviously (namely the dilution rate of the cladding layer is not increased obviously), and further improves the binding force between different phase interfaces of the cladding layer and the cladding layer/substrate interface and the spreadability of the cladding layer; secondly, the effective utilization rate of laser can be increased, and the powder deposition amount and the utilization rate in unit time are further increased; moreover, the temperature gradient and the cooling rate of a laser melting pool and a heat affected zone can be reduced, metallurgical defects such as cracks, air holes and the like of a cladding layer can be avoided, and tissues with poor comprehensive properties such as cracks, hard and brittle martensite and the like in a heat affected zone of a base material with poor weldability and high cracking tendency such as high-carbon steel, cast iron and the like can be avoided. The comprehensive effect of the technical effects of the ultra-high-speed laser-induction hybrid cladding can realize high-precision, high-quality and high-efficiency cladding of the workpiece. In addition, the invention only uses the independent technology of induction heating to be fused with the ultra-high-speed laser cladding, avoids the cooperation of a plurality of technologies such as an electromagnetic generating device, an exciting coil and the like in the prior art, effectively reduces cladding influence factors and process complexity, and ensures cladding effect and quality.
2. For shaft solid parts, the induction heating coil is arranged outside the workpiece, and for pipe fittings, the induction heating coil is arranged outside the workpiece or inside the workpiece, so that the circumferential heating of the workpiece can be ensured to be uniform, and the problems that in the prior art, the surface of the workpiece is heated unevenly, frequent rapid cooling and rapid heating circulation is needed in the machining process, and the forming quality of a cladding layer is unstable due to the fact that the shaft workpiece is heated only at the local position of the surface are effectively solved. Through the design, the invention is not only suitable for cladding of common coatings, but also suitable for high-speed cladding of material coatings (such as Ni60, metal ceramic composite layers and metal silicide composite layers) with high cracking sensitivity and large processing difficulty on the surfaces of large-shaft-diameter or large-size workpieces, and effectively ensures the forming quality of the cladding layers.
3. The invention combines induction heating and ultrahigh-speed laser cladding, can regulate and control the heat and mass transfer and flow processes of a molten pool through the synergistic action of a laser heat source and an induction heating temperature field, increases the wettability between different phases of a cladding layer and between molten or semi-molten cladding metal and a substrate, and further improves the binding force between different phase interfaces of the cladding layer and the cladding layer/substrate interface and the spreadability of the cladding layer.
4. The invention combines induction heating and ultrahigh-speed laser cladding, can realize accurate control of laser energy distribution by regulating and controlling the relative positions of the laser spot diameter, the laser power, the induction heating temperature, the laser processing speed, the powder feeding amount, the powder feeding air flow, the laser beam spot and the powder beam converging point and the surface of a workpiece in the cladding process, increases the utilization rate of laser energy, and further increases the powder deposition efficiency and the powder utilization rate on the premise of not obviously increasing the dilution rate of a cladding layer.
5. The invention combines induction heating with ultrahigh-speed laser cladding, can realize the regulation and control of the temperature gradient and the cooling rate of a laser melting pool by controlling the distribution of an induction heating temperature field on the surface of a workpiece (particularly by controlling the temperature), so that the non-equilibrium of solidification and crystallization of a cladding layer is reduced, the residual stress of the cladding layer is further reduced, the metallurgical defects of air holes, cracks and the like generated in the cladding layers with different hardness and different cracking tendency are avoided, and the regulation and control of the performance of the cladding layer are realized; meanwhile, the cooling process of the matrix heat affected zone can be regulated and controlled, and particularly for matrix materials with poor weldability and high cracking tendency, such as high-carbon steel, cast iron and the like, the structure with poor comprehensive properties, such as cracks, hard and brittle martensite and the like, generated in the matrix heat affected zone can be avoided.
6. The invention can eliminate cracks and air holes in the cladding layer, regulate and control the structure and crystal grains in the cladding layer, increase the utilization rate of powder, and prepare the cladding layer with good spreadability, high interface wettability and bonding force, high surface precision, compact structure and good comprehensive performance by the mutual synergistic action of the induction heating technology and the ultrahigh-speed laser cladding technology without electromagnetic stirring.
7. The invention also researches and designs the specific ultra-high speed laser cladding process in the ultra-high speed laser-induction composite cladding process to obtain the optimal process, specifically designs the diameter of a laser spot to be 0.5-5 mm, preferably 1-3 mm, designs the relative positions of the laser spot and a powder beam convergence point to the surface of a workpiece to be 0.5-5 mm, designs the laser power to be 1-15 kW, designs the laser processing speed to be 20-300 m/min, designs the protective gas flow to be 10-25L/min, designs the powder delivery amount to be 10-500 g/min, designs the powder delivery gas flow to be 2-15L/min and designs the lap joint rate to be 40-90 percent, thereby realizing the optimal matching of the laser-powder-substrate interaction, and further obtaining a high-flatness (Ra is less than 10 mu m), a low dilution rate (less than 4 percent) and a metallurgically combined high-quality cladding layer on the surface of the substrate.
8. The invention also researches and designs the specific induction heating process in the ultra-high-speed laser-induction composite cladding to obtain the optimal process, specifically designs the distance between an induction heating coil and the surface of the workpiece to be 1-10 mm, designs the heating temperature of the surface of the workpiece to be 350-800 ℃, so as to realize the heating of materials with certain depth on the surface and the sub-surface of the workpiece, increase the temperature of a molten pool and the high-temperature retention time, enhance the fluidity of molten or semi-molten cladding metal, further increase the wettability between different phases of a cladding layer and between the molten or semi-molten cladding metal and a substrate, and improve the binding force between different phase interfaces of the cladding layer and the cladding layer/substrate interface and the spreadability of the cladding layer; secondly, the laser energy required for forming a micro-molten pool with the same size on the surface of the substrate can be reduced, the laser energy for the interaction of the laser and the powder above the substrate is increased, and the powder deposition rate and the powder utilization rate are increased; meanwhile, the temperature gradient and the cooling rate of a laser melting pool and a heat affected zone can be reduced, the non-equilibrium of different alloy materials during solidification and crystallization and the residual stress of a cladding layer are reduced, metallurgical defects such as air holes and cracks generated in the cladding layer are avoided, and tissues with poor comprehensive properties such as cracks and hard and brittle martensite generated in a heat affected zone of base materials with poor weldability and high cracking tendency such as high-carbon steel and cast iron are avoided.
9. By the designed linkage control and synergistic effect of the ultrahigh-speed laser-induction composite cladding process and the induction heating process, the invention can ensure that the finally prepared cladding layer has high interface bonding force, no cracks, high density (more than 99.8%), low dilution rate (less than 4%, even as low as 2%), high flatness (Ra less than 10 mu m), high powder utilization rate (more than 90%), fine structure and good comprehensive service performance.
10. The invention also provides a device suitable for the method, and the device can realize ultrahigh-speed laser-induction composite cladding of various workpieces such as shaft solid parts, pipe fittings, plate-shaped parts or block-shaped parts, and has the advantages of low cladding layer dilution rate, high deposition precision, high cladding layer deposition efficiency and the like.
Drawings
Fig. 1 is a flowchart of an ultra-high speed laser-induction hybrid cladding method according to an embodiment of the present invention;
fig. 2 is a schematic view of an apparatus for processing an outer surface of a shaft-like solid component by ultra-high-speed laser-induction hybrid cladding according to an embodiment of the present invention;
FIG. 3 is a schematic view of an apparatus for ultra-high speed laser-induction hybrid cladding processing of the outer surface of a tubular member according to an embodiment of the present invention;
FIG. 4 is a schematic view of an apparatus for ultra-high speed laser-induction hybrid cladding machining of the inner surface of a tubular member with an induction coil mounted inside the workpiece according to an embodiment of the present invention;
FIG. 5 is a schematic view of an apparatus for ultra-high speed laser-induction hybrid cladding machining of the inner surface of a tubular member with an induction coil mounted on the outside of the workpiece according to an embodiment of the present invention;
FIG. 6 is a schematic view of an apparatus for processing the outer surface of a plate-shaped or block-shaped component by ultra-high speed laser-induction hybrid cladding according to an embodiment of the present invention;
fig. 7 is a macroscopic morphology view of a section of a Ni60 coating obtained by ultrahigh-speed laser cladding and ultrahigh-speed laser-induction hybrid cladding, in which (a) is a Ni60 coating obtained by simple ultrahigh-speed laser cladding, and (b) is a Ni60 coating obtained by ultrahigh-speed laser-induction hybrid cladding.
The same reference numbers will be used throughout the drawings to refer to the same elements or structures, wherein:
1-laser, 2-laser focusing or shaping device, 3-automatic powder feeder, 4-high deposition rate coaxial powder feeding nozzle, 5-induction heating power supply, 6-temperature controller, 7-induction heating coil, 8-infrared thermometer, 9-workpiece, 10-cladding layer, 11-numerical control machine tool, 11 a-rotating workbench, 11 b-three-jaw chuck, 12-mechanical arm or three-dimensional moving shaft, and 12 a-clamp.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. 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 provides an ultrahigh-speed laser-induction composite cladding method which can increase the binding force of different phase interfaces of a cladding layer and a cladding layer/substrate interface on the premise of ensuring high deposition precision and low dilution rate of the cladding layer, improve the powder deposition efficiency and utilization rate, avoid metallurgical defects such as air holes and cracks of the cladding layer and greatly improve the performance of the cladding layer. The ultrahigh-speed laser cladding technology is a novel technology at present, and the energy density and the laser scanning rate of the ultrahigh-speed laser cladding technology are greatly increased compared with the traditional laser cladding technology, so that the cooling rate and the solidification crystallization speed of a molten pool are increased, the cracking tendency of a cladding layer is further increased, and the limitation of the ultrahigh-speed laser cladding technology in depositing a high-hardness coating is larger. Therefore, there are disadvantages in directly utilizing the ultra-high speed laser cladding technology to realize cladding of a high-hardness cladding layer, so those skilled in the art need further research to start from other angles to realize effective utilization of the ultra-high speed laser cladding technology.
The invention can effectively utilize the advantages of the ultra-high speed laser cladding technology by combining the induction heating and the ultra-high speed laser cladding technology, and can overcome the defects of high cooling rate and solidification crystallization speed of a molten pool, high cracking tendency of a cladding layer and limitation in depositing a high-hardness cladding layer in the ultra-high speed laser cladding technology. Through the specific design and arrangement of the induction heating units, the problems that the surface of a workpiece is heated unevenly, and the forming quality of a cladding layer is unstable due to frequent rapid cooling and rapid heating cycles in the machining process can be effectively solved, so that the induction heating unit is particularly suitable for high-speed cladding of a material coating with high surface cracking sensitivity and high machining difficulty of a large-diameter or large-size workpiece, and the forming quality of the cladding layer is effectively ensured.
As shown in fig. 1, the ultra-high speed laser-induction hybrid cladding method provided by the embodiment of the invention specifically includes the following steps:
s1, workpiece pretreatment:
firstly, fixing a workpiece to be cladded and preprocessing the workpiece, specifically, fixing the workpiece on a working platform, and polishing the region to be cladded on the surface of the workpiece by using a polisher or abrasive paper to remove surface rust and pollutants, and also removing the surface rust and pollutants by using a laser cleaning technology.
S2, designing process parameters and adjusting the parameters:
the design process parameters mainly comprise the design of an induction heating coil and the design of an ultra-high speed laser cladding process and an induction heating process. The ultrahigh-speed laser cladding process and the induction heating process specifically comprise the diameter of a laser beam spot, the position of the laser beam spot and a powder beam converged above the surface of a workpiece, laser power, laser processing speed, protective gas flow, powder feeding amount, powder feeding gas flow, lap joint rate, the distance between an induction heating coil and the surface of the workpiece, workpiece heating temperature and the like.
The design of the induction heating coil is specifically designed and arranged according to the characteristics of the workpiece to be clad, and the specific shape and arrangement mode of the induction heating coil are designed according to the shape characteristics of the workpiece to be clad. The induction heating coil is suitable for shaft solid parts, pipe fittings, plates and blocks, and for the shaft solid parts, the induction heating coil is designed to be annular, is arranged outside a workpiece and is coaxial with the workpiece to heat the outer surface of the shaft solid part, so that the uniformity of the heating temperature of a region to be clad on the surface of the workpiece is ensured, and the technical defect that the forming quality of a cladding layer is unstable under high cladding efficiency due to uneven heating of the surface of the workpiece in the prior art can be effectively overcome. For the pipe fitting, the induction heating coil is designed to be annular, is arranged outside or inside the pipe fitting and is coaxial with the pipe fitting, so that all-around surrounding type heating of a to-be-clad area of the pipe fitting is realized. Specifically, when cladding the outer surface, the induction heating coil is annular, is arranged outside the workpiece and is coaxial with the workpiece, so as to heat the outer surface of the pipe fitting and facilitate deposition of the cladding layer on the outer surface of the pipe fitting; when cladding the inner surface, induction heating coil is annular, arranges in the inside of work piece and also sets up with the work piece is coaxial to heat the pipe fitting inner surface and be convenient for deposit the cladding layer on the pipe fitting inner surface. When the inner surface of a pipe fitting with a smaller inner diameter is clad, the induction heating coil is arranged outside the workpiece and is coaxial with the workpiece in order to improve the stability of the ultra-high-speed laser-induction composite cladding process and ensure the deposition quality of a cladding layer, and the induction heating coil is arranged on the outer side of the workpiece to heat the inner surface and the subsurface layer of the workpiece from the outer surface inwards so as to facilitate the deposition of the cladding layer on the inner surface of the pipe fitting in consideration of the difficulty in installation and accurate positioning of the induction heating coil. By designing the annular coil and arranging the annular coil and the workpiece coaxially, the uniformity of the heating temperature of the region to be clad on the surface of the workpiece is ensured, and the technical defect that the forming quality of a cladding layer is unstable under the high cladding efficiency due to uneven heating of the surface of the workpiece in the prior art can be effectively overcome. For the plate and block members, the induction heating coil is linear and is located above the workpiece, thereby ensuring that the substrate can be rapidly heated to a set temperature with high cladding efficiency.
During adjustment, parameters and action positions of laser, the induction heating coil and the powder beam used for cladding are adjusted, so that the laser spot reaches a preset diameter, the distance between the induction heating coil and the surface of the workpiece reaches a preset distance, and the laser beam spot and the powder beam are converged at a preset position above the surface of the workpiece. Specifically, the laser spot is made to reach a preset diameter by adjusting the defocusing amount of the laser beam. Wherein the preset diameter is 0.5 mm-5 mm, preferably 1 mm-3 mm, thereby ensuring that the laser energy density reaches 10 in the cladding process 3 W/cm 2 -10 4 W/cm 2 . The relative position of the induction heating coil and the workpiece to be clad is adjusted to enable the distance between the induction heating coil and the surface of the workpiece to reach a preset distance, and the preset distance is preferably 1 mm-10 mm, so that the materials with certain depth on the surface and the sub-surface of the substrate can be heated to a preset temperature. By adjusting the relative positions of the laser beam spot, the powder beam and the workpiece to be clad, the laser beam spot and the powder beam are converged at a preset position above the surface of the workpiece, and the preset position is preferably 0.5-5 mm, so that the laser beam and the alloy powder are ensured to be fully interacted above the substrate, the alloy powder is heated to a molten or semi-molten state, is sprayed on the surface of the substrate in a fluid or semi-solid mode and is combined with a micro-molten pool formed by directly irradiating the laser on a base material, and the high deposition precision (namely the surface flatness) of the surface of the clad layer is ensured.
S3, induction heating:
the induction heating coils which are designed and arranged in a targeted manner are utilized to realize the all-round uniform heating of the region of the workpiece to be cladded according to the designed induction heating process, so that the uniformity of the temperature distribution of the region of the workpiece to be cladded is ensured, and the quality stability of a cladding layer prepared subsequently is ensured. Specifically, the surface of the workpiece is heated to a preset temperature by using an induction heating coil, so that a temperature field with gradient distribution between the preset temperature and room temperature is formed in the depth range of 0.5-5 mm from the surface of the workpiece. The preset temperature is 350-800 ℃, and the temperature is designed in the range, so that the cooling condition of different alloy materials during solidification and crystallization can be met, the residual stress of the cladding layer is reduced, and the metallurgical defects of cracks, air holes and the like of the cladding layer are avoided. The induction heating coil is installed outside the workpiece or located inside the workpiece above the workpiece.
S4, ultra-high-speed laser-induction hybrid cladding:
after the surface of a workpiece is heated to a preset temperature, cladding is carried out by utilizing a designed ultra-high-speed laser cladding process, in the cladding process, through the linkage control and the synergistic effect of the ultra-high-speed laser cladding and induction heating, a laser beam spot and a powder beam are enabled to interact at a specified position above a region to be clad of the workpiece, so that alloy powder is heated to a molten drop or semi-molten drop state and is sprayed to a micro-molten pool on the preheating surface of the workpiece in a liquid or semi-solid mode, and a cladding layer which is metallurgically combined with the workpiece is prepared. Specifically, after the surface of a workpiece is heated to a preset temperature, a powder feeder is started to convey alloy powder, the workpiece and an induction heating coil move relatively, a laser is started and outputs a laser beam, a laser beam spot and a powder beam flow fully act above the workpiece to heat the alloy powder to a molten drop or semi-molten drop state, a small amount of laser beam energy acts on the preheated surface of the workpiece to form a micro molten pool, and the alloy powder is sprayed on the micro molten pool on the surface of the workpiece in a liquid form and then is rapidly carried out (10) 2 ℃/s～10 3 Cooling and solidifying at the temperature of/s) to obtain a cladding layer which is in metallurgical bonding with the workpiece. In the cladding process, the focusing position of the laser beam spot on the surface of the workpiece is positioned in front of, in the middle of or behind the induction heating position.
In particular, ultra-high-speed laser-induction hybrid claddingThe coating process comprises the following steps: the laser power is 1 kW-15 kW, the laser processing speed (relative movement speed of a workpiece and a laser beam) is 20m/min-300m/min, the flow of laser processing protective gas (particularly inert gas such as argon) is designed to be 10L/min-25L/min, and the protective gas can effectively protect a molten pool through the flow design, so that the molten pool is not oxidized in the cladding process, and the stability of the molten pool and the forming quality of a cladding layer are improved; the powder feeding amount is 10-400 g/min, the powder feeding flow is 2-15L/min, the gas for powder feeding is specifically inert gas, and the powder feeding gas can stably and uniformly spray powder under different powder feeding amounts through the flow design, so that the spraying speed and the spraying form of the powder flow can meet the requirements of high-speed composite cladding, and meanwhile, a molten pool can be further protected, and the oxidation of the molten pool can be prevented; the lapping rate is 40-90%. Through the matching effect of the parameters, the better matching of the laser-powder-substrate interaction can be realized, so that a high-quality cladding layer with high flatness (Ra < 10 mu m), low dilution rate (less than 4 percent) and metallurgical bonding can be obtained on the surface of the substrate. In order to maximize the powder deposition efficiency and the utilization rate, the cladding process is further optimized, specifically, the laser power is 6 kW-10 kW, the laser processing speed is 210 m/min-250 m/min, the powder delivery amount is 160 g/min-400 g/min, and the protective gas flow is 15L/min-25L/min; the flow rate of the powder conveying gas is 3L/min to 12L/min, and the lap joint rate is 60 percent to 90 percent. Through the cooperation of the parameters, the optimal matching of the laser-powder-substrate interaction can be realized, so that a high-quality cladding layer with high flatness (Ra < 8 mu m), low dilution rate (less than 4 percent) and metallurgical bonding can be obtained on the surface of the substrate, the powder utilization rate can reach more than 90 percent, and the deposition efficiency can reach 300cm 2 /min～800cm 2 /min。
S5, finishing cladding:
after a cladding layer is cladded, whether the thickness of the cladding layer meets the requirement is judged, and the specific thickness requirement is determined according to the actual processing requirement. For example, a surface corrosion resistant layer typically requires 0.02 to 0.1mm, and a surface repair or surface enhancement coating thickness typically > 0.8mm. If the thickness meets the requirement, the cladding process is ended, and if not, the steps S2-S4 are repeated until the required thickness is reached. The specific thickness can be measured by a high-precision thickness meter, the thickness of a single-pass cladding layer can be adjusted in a large range of 0.02-2 mm, and the preparation requirements of cladding layers with various thicknesses are met.
Preferably, in order to avoid metallurgical defects in the cladding layer, the method may further comprise the steps of: and S6, after cladding, detecting the surface of the cladding layer by adopting penetration or ultrasonic flaw detection to ensure that the cladding layer has no metallurgical defects. If the surface layer is detected to have small pores, the surface layer is removed through post-treatment, and if the surface layer has obvious defects such as large cracks, the surface layer is treated on the spot.
Further, in order to make the roughness of the cladding surface of the workpiece meet the application requirement, the method further comprises the following steps: and S7, polishing the surface of the cladding layer of the workpiece.
The invention also provides a super-high-speed laser-induction composite cladding method suitable for the specific object, which comprises the following steps:
s1, fixing a pipe fitting to be clad and carrying out pretreatment;
s2, designing an annular induction heating coil, arranging the annular induction heating coil outside or inside the pipe fitting and coaxially arranging the annular induction heating coil and the pipe fitting so as to realize all-around surrounding type heating of a to-be-clad area of the pipe fitting, wherein the distance between the induction heating coil and the surface of a workpiece is designed to be 5-10 mm; simultaneously designing an ultra-high speed laser cladding process and an induction heating process for ultra-high speed laser-induction composite cladding of the pipe fitting, wherein the diameter of a laser beam spot is designed to be 0.5-5 mm, preferably 1-3 mm; the position of the laser beam spot and the powder beam converged above the surface of the workpiece is designed to be 0.5-5 mm; the laser power is designed to be 1kW to 15kW, preferably 6kW to 10kW; the laser processing speed is designed to be 20m/min-300m/min, preferably 210 m/min-250 m/min; the protective gas flow is designed to be 10L/min-20L/min; the powder feeding amount is designed to be 10 g/min-500 g/min, preferably 160 g/min-400 g/min; the flow rate of the powder feeding air is designed to be 5L/min-12L/min; the lap joint rate is designed to be 70% -90%;
s3, utilizing the induction heating coils which are designed and arranged in a targeted manner to realize all-around surrounding type heating of the to-be-clad area of the pipe fitting according to a designed induction heating process, ensuring the uniformity of the temperature distribution of the to-be-clad area of the pipe fitting, and ensuring the quality stability of a subsequently prepared cladding layer;
s4, after the surface of the pipe to be clad is heated to 400-700 ℃, cladding is carried out by utilizing a designed ultra-high-speed laser cladding process, in the cladding process, through the linkage control and the synergistic effect of the ultra-high-speed laser cladding and induction heating, a laser beam spot and a powder beam interact at a specified position above the area of the pipe to be clad, so that alloy powder is heated to a molten drop or semi-molten drop state and is sprayed to a micro-molten pool on the preheating surface of the pipe in a liquid or semi-solid mode, and then a cladding layer which is metallurgically combined with the pipe is prepared;
and S5, after finishing cladding of a cladding layer, judging whether the thickness of the cladding layer meets the requirement, if so, finishing the cladding process, otherwise, repeating the steps S2-S4 until the required thickness is reached, thereby obtaining a pore-free, crack-free and compact high-quality cladding layer on the surface of the pipe fitting to be clad.
As shown in fig. 2 to 5, the invention also provides an ultrahigh-speed laser-induction hybrid cladding device for implementing the method, which can perform laser cladding strengthening and repairing on the outer surfaces of solid parts with different sizes, the inner and outer surfaces of hollow parts with different wall thicknesses and plate-shaped/block-shaped parts with different sizes.
The ultrahigh-speed laser-induction composite cladding device comprises a laser scanning unit, an induction heating unit, a powder conveying unit and a three-dimensional moving unit, wherein the laser scanning unit is used for outputting laser beam spots with energy in Gaussian distribution or uniform distribution; the induction heating unit comprises an induction heating power supply 5, an induction heating coil 7, an infrared thermometer 8 and a temperature controller 6, wherein the induction heating coil 7 is connected with the induction heating power supply 5, is arranged outside a workpiece 9 to be clad or inside the workpiece 9 or above the workpiece 9, and keeps a preset distance (preferably 1-10 mm) with the surface of the workpiece, the infrared thermometer 8 is used for measuring the temperature of an induction heating area on the surface of the workpiece and feeding the temperature back to the temperature controller 6, and the temperature controller 6 controls the temperature of the induction heating coil 7 to reach the preset temperature based on the temperature fed back by the infrared thermometer 8; the powder conveying unit is used for conveying alloy powder to form a powder beam, converging the powder beam and a laser beam spot at a preset position above the surface of a workpiece, heating the alloy powder to a molten drop or semi-molten drop state under the heating action of the laser beam spot, spraying the heated alloy powder to a micro-molten pool on the surface of the workpiece in a liquid or semi-solid mode, and rapidly cooling and solidifying to obtain a cladding layer 10 which is metallurgically combined with the workpiece; the three-dimensional moving unit is used for driving the workpiece to be cladded to perform three-dimensional movement so as to ensure that the ultrahigh-speed laser-induction composite cladding is performed at the cladding position required by the workpiece.
Specifically, the laser scanning unit comprises a laser 1 and a laser focusing or shaping device 2, wherein the laser 1 is used for emitting laser, and the laser focusing or shaping device 2 is used for focusing or shaping the laser emitted by the laser 1 so as to output a laser beam spot with energy in a gaussian distribution or uniform distribution.
Further, the powder conveying unit comprises an automatic powder feeder 3 and a high-deposition-rate coaxial powder feeding nozzle 4, the automatic powder feeder 1 is used for feeding alloy powder to the high-deposition-rate coaxial powder feeding nozzle 4, the alloy powder is sent out through the high-deposition-rate coaxial powder feeding nozzle 4 to form a powder beam, and the powder beam and the laser beam are converged at a preset position above the surface of the workpiece, and the preset position is preferably 0.5 mm-5 mm.
More specifically, the three-dimensional moving unit may be a numerical control machine tool 11, a robot arm, or a three-dimensional movement axis 12.
The following are examples of the present invention:
example 1
In the present embodiment, ultra-high-speed laser-induction hybrid cladding is performed on the surface of a shaft-like solid component, specifically, a roll with a roll diameter of 245mm is taken as an example, and the method is also applicable to shaft-like solid components with other roll diameters.
In this embodiment, the apparatus shown in fig. 2 is used for implementation, the motion control unit is a four-axis numerical control machine, and the specific implementation steps include:
(1) Selecting Ni60 alloy powder with the particle size of 25-60 microns as a cladding material, taking high-carbon alloy steel as a base material, fixing a workpiece on a rotary worktable 11a of a numerical control machine tool by adopting a three-jaw chuck 11b, and polishing the to-be-cladded area on the surface of the workpiece by adopting a polisher or abrasive paper to remove surface rust and pollutants, or removing the surface rust and pollutants by adopting laser cleaning equipment;
(2) Adopting a multi-turn annular induction heating coil, wherein the distance between the coil and the surface of the roller is 5mm; the infrared thermometer aims at the induction heating area on the surface of the workpiece, is connected with the temperature controller and the induction power supply, detects and controls the induction heating temperature, and sets the induction heating temperature to be 500 ℃;
(3) Adjusting the defocusing amount of the laser beam and the relative position of the laser beam and the induction heating coil to focus a laser beam spot in the middle of the induction heating coil on the surface of the workpiece, wherein the size of the laser beam spot is phi 5mm; adjusting the position of the powder feeder from the surface of the workpiece and the flow of powder feeding gas to ensure that the laser beam spot and the powder beam are converged at the position 3mm above the surface of the workpiece; setting laser power at 10kw, protective gas flow at 25L/min, powder feeding amount at 500g/min, powder feeding gas flow at 15L/min, laser scanning rate at 300m/min, and lap joint rate at 80%;
(4) Starting an induction heating power supply and a numerical control machine tool to enable a workpiece and an induction heating coil to move relatively, starting a laser and a powder feeder after the temperature of a heating area reaches a preset temperature of 500 ℃, enabling a focused laser beam and a powder beam to fully act above the workpiece to heat the powder beam to a molten drop or semi-molten drop state, enabling a small amount of laser beam energy to act on the preheated workpiece surface to form a micro molten pool, and rapidly cooling and solidifying Ni60 alloy powder after being sprayed on the micro molten pool on the workpiece surface in a liquid form to obtain a cladding layer metallurgically combined with a matrix;
(5) After a metal cladding layer is cladded on the outer surface of the roller, 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) to (4) until the required thickness is reached.
Example 2
In this embodiment, ultra-high speed laser-induction hybrid cladding is performed on the outer surface of a tubular hollow component, specifically, a pipe with a diameter of 100mm and a wall thickness of 8mm is taken as an example for explanation, and the method is also applicable to tubular components with other diameters and wall thicknesses.
The embodiment is implemented by using the device shown in fig. 3, the motion control unit is a four-axis numerical control machine, and the specific implementation steps include:
(1) Selecting Ni-based alloy-WC metal ceramic composite powder as a cladding material, wherein the Ni alloy is Ni60 alloy powder with the grain size of 25-60 mu m, the WC is cast WC with the grain size of 20-50 mu m, the Ni alloy powder and the cast WC are mixed in a mechanical mixing mode, and the base material is common low-carbon steel; fixing a workpiece on a rotary worktable 11a of a numerical control machine tool by using a three-jaw chuck 11b, and polishing the region to be clad on the surface of the workpiece by using a polisher or abrasive paper to remove surface rust and pollutants, or removing the surface rust and pollutants by using laser cleaning equipment;
(2) Adopting a single-turn annular induction heating coil, wherein the distance between the coil and the surface of the pipe is 10mm, an infrared thermometer aims at an induction heating area on the surface of a workpiece, the infrared thermometer is connected with a temperature controller and an induction power supply, the induction heating temperature is detected and controlled, and the induction heating temperature is set to be 800 ℃;
(3) Adjusting the defocusing amount of the laser beam and the relative position of the laser beam and the induction heating coil to ensure that the focusing position of the laser beam spot on the surface of the workpiece is slightly lagged behind the heating position of the induction heating coil, wherein the size of the laser beam spot is phi 3mm; adjusting the position of the powder feeder from the surface of the workpiece and the flow of powder feeding gas to ensure that the laser beam spot and the powder beam are converged at the position 0.5mm above the surface of the workpiece; setting the laser power to be 8kw, the protective gas flow to be 22L/min, the powder feeding amount to be 280g/min, the powder feeding gas flow to be 12L/min, the laser processing speed to be 210m/min, and the lap joint rate to be 60%;
(4) Starting an induction heating power supply and a numerical control machine tool to enable a workpiece and an induction heating coil to move relatively, after the temperature of a heating area reaches a preset temperature of 800 ℃, starting a laser and a powder feeder to enable a focused laser beam and a powder beam to act sufficiently above the workpiece, heating the powder beam to a molten drop or semi-molten drop state, enabling a small amount of laser beam energy to act on the surface of the preheated workpiece to form a micro molten pool, spraying Ni60-WC composite powder to the micro molten pool on the surface of the workpiece in a Ni60 melt and WC particle form, and then rapidly cooling and solidifying to obtain a cladding layer which is metallurgically combined with a matrix;
(5) After a metal cladding layer is cladded on the outer surface of the pipe, 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) to (4) until the required thickness is reached;
(6) And after cladding, detecting the surface of the cladding layer by adopting penetration flaw detection to ensure that the cladding layer has no metallurgical defects.
Example 3
In this embodiment, ultra-high-speed laser-induction hybrid cladding is performed on the inner surface of a tubular hollow member, and an induction coil is installed inside a workpiece. Specifically, a pipe material having a diameter of 200mm and a wall thickness of 10mm is exemplified, and the same is applied to a tubular member having a different diameter and wall thickness.
In this embodiment, the apparatus shown in fig. 4 is used for implementation, the motion control unit is a four-axis numerical control machine, and the specific implementation steps include:
(1) Selecting Co-based alloy-WC metal ceramic composite powder as a cladding material, wherein the Co-based alloy is Stellite12 alloy powder with the particle size of 25-60 mu m, the WC is cast WC with the particle size of 20-50 mu m, the Co-based alloy and the cast WC are mixed in a mechanical mixing mode, and the base material is common low-carbon steel; fixing the workpiece on a numerical control machine tool by adopting a three-jaw chuck, and polishing the region to be clad on the inner surface of the workpiece by adopting a polisher to remove surface rust and pollutants, or removing the surface rust and the pollutants by adopting laser cleaning equipment;
(2) A single-turn annular induction heating coil is arranged inside a workpiece, and the distance between the coil and the surface of the pipe is 1mm; the infrared thermometer aims at the induction heating area on the surface of the workpiece, is connected with the temperature controller and the induction power supply, detects and controls the induction heating temperature, and sets the induction heating temperature to 350 ℃;
(3) Adjusting the defocusing amount of the laser beam and the relative position of the laser beam and the induction heating coil to ensure that the focusing position of the laser beam spot on the surface of the workpiece slightly lags behind the heating position of the induction heating coil, wherein the size of the laser beam spot is phi 0.5mm; adjusting the distance between the powder feeder and the surface of the workpiece and the flow of the powder feeding gas to ensure that the laser beam spot and the powder beam are converged at a position 2mm above the surface of the workpiece; setting the laser power to be 1kw, the protective gas flow to be 10L/min, the powder feeding amount to be 10g/min, the powder feeding gas flow to be 2L/min, the laser processing speed to be 20m/min, and the lap joint rate to be 90%;
(4) Starting an induction heating power supply and a numerical control machine tool to enable the workpiece and an induction heating coil to move relatively, after the temperature of a heating area reaches a preset temperature of 350 ℃, starting a laser and a powder feeder to enable a focused laser beam and a powder beam to fully act above the workpiece to heat the powder beam to a molten drop or semi-molten drop state, and enabling a small amount of energy of the laser beam to act on the surface of the preheated workpiece to form a micro molten pool; spraying the Stellite12-WC composite powder to a micro-molten pool on the surface of a workpiece in the form of Stellite12 melt and WC particles, and then quickly cooling and solidifying to obtain a cladding layer which is metallurgically bonded with a substrate;
(5) After cladding a metal cladding layer on the inner surface of the pipe, judging whether the thickness of the cladding layer meets the requirement of a working condition, if so, finishing the cladding process; if not, repeating the steps (2) to (4) until the required thickness is achieved;
(6) After cladding, detecting the surface of the cladding layer by adopting ultrasonic flaw detection to ensure that the cladding layer has no metallurgical defects;
(7) And polishing the surface of the workpiece to ensure that the surface roughness meets the application requirement.
Example 4
In this embodiment, ultra-high-speed laser-induction hybrid cladding is performed on the inner surface of a tubular hollow member, and an induction coil is installed outside a workpiece. Specifically, a pipe material having a diameter of 80mm and a wall thickness of 5mm is exemplified, and the same is true for a tubular member having another diameter and wall thickness.
In this embodiment, the apparatus shown in fig. 5 is used for implementation, the motion control unit is a four-axis numerical control machine, and the specific implementation steps include:
(1) Selecting Fe-based alloy powder with the particle size of 25-60 microns as a cladding material, using a base material of cast iron, fixing a workpiece on a rotary worktable 11a of a numerical control machine tool by using a three-jaw chuck 11b, and polishing a region to be clad on the inner surface of the workpiece by using a polisher or abrasive paper to remove surface rust and pollutants, or removing the surface rust and pollutants by using laser cleaning equipment;
(2) A multi-turn annular induction heating coil is arranged outside a workpiece, and the distance between the coil and the surface of the pipe is 5mm; the infrared thermometer aims at the induction heating area on the surface of the workpiece, is connected with the temperature controller and the induction power supply, detects and controls the induction heating temperature, and sets the induction heating temperature to be 400 ℃;
(3) Adjusting the defocusing amount of the laser beam and the relative position of the laser beam and the induction heating coil to enable the focusing position of the laser beam spot on the surface of the workpiece to be positioned in the middle of the heating position of the induction heating coil, wherein the size of the laser beam spot is phi 1mm; adjusting the position of the powder feeder from the surface of the workpiece and the flow of powder feeding gas to ensure that the laser beam spot and the powder beam are converged at the position 1mm above the surface of the workpiece; setting the laser power to be 5kw, the protective gas flow to be 15L/min, the powder feeding amount to be 100g/min, the powder feeding gas flow to be 5L/min, the laser processing speed to be 80m/min, and the lap joint rate to be 40%;
(4) Starting an induction heating power supply and a numerical control machine tool to enable the workpiece and an induction heating coil to move relatively, after the temperature of a heating area reaches a preset temperature of 400 ℃, starting a laser and a powder feeder to enable a focused laser beam and a powder beam to fully act above the workpiece to heat the powder beam to a molten drop or semi-molten drop state, and enabling a small amount of energy of the laser beam to act on the surface of the preheated workpiece to form a micro molten pool; the Fe-based alloy powder is sprayed on a micro-molten pool on the surface of a workpiece in a melt form and then is rapidly cooled and solidified to obtain a cladding layer which is metallurgically bonded with a substrate;
(5) After a metal cladding layer is cladded on the inner surface of the pipe, 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) to (4) until the required thickness is reached;
(6) After cladding, detecting the surface of the cladding layer by adopting ultrasonic flaw detection to ensure that the cladding layer has no metallurgical defects;
(7) And polishing the surface of the workpiece to ensure that the surface roughness meets the application requirement.
Example 5
In this example, the description will be made of a block-shaped solid member having a length × width × height of 300mm × 200mm × 100mm, the surface of which is subjected to ultra-high-speed laser-induction hybrid cladding, and the present invention is also applicable to other solid members having various shapes and various sizes.
In this embodiment, the apparatus shown in fig. 6 is used for implementation, the motion control unit uses a robot arm, and the specific implementation steps include:
(1) Selecting Ni-Cr-Si alloy powder with the grain diameter of 25-60 mu m as a cladding material, and taking high-carbon alloy steel as a base material; fixing the workpiece on a working platform by using a clamp 12a, polishing the region to be clad on the surface of the workpiece by using sand paper to remove surface rust and pollutants, or removing the surface rust and pollutants by using laser cleaning equipment;
(2) A linear induction heating coil is adopted, the lower surface of the coil is parallel to the surface of the workpiece to be cladded, and the gap is 2mm; the infrared thermometer aims at the induction heating area on the surface of the workpiece, is connected with the temperature controller and the induction power supply, detects and controls the induction heating temperature, and sets the induction heating temperature to 700 ℃;
(3) Adjusting the defocusing amount of the laser beam and the relative position of the laser beam and the induction heating coil to ensure that the focusing position of the laser beam spot on the surface of the workpiece slightly lags behind the heating position of the induction heating coil, wherein the size of the laser beam spot is phi 2mm; adjusting the distance between the powder feeder and the surface of the workpiece and the flow of the powder feeding gas to ensure that the laser beam spot and the powder beam are converged at a position 5mm above the surface of the workpiece; setting the laser power to be 6kw, the protective gas flow to be 18L/min, the powder feeding amount to be 160g/min, the powder feeding gas flow to be 8L/min, the laser processing speed to be 80m/min, and the lap joint rate to be 85%;
(4) Starting an induction heating power supply and a numerical control machine tool to enable a workpiece and an induction heating coil to move relatively, after the temperature of a heating area reaches a preset temperature of 700 ℃, starting a laser and a powder feeder to enable a focused laser beam and a powder beam to fully act above the workpiece to heat the powder beam to a molten drop or semi-molten drop state, enabling a small amount of laser beam energy to act on the surface of the preheated workpiece to form a micro molten pool, and spraying Ni-Cr-Si alloy powder in the form of a melt to the micro molten pool on the surface of the workpiece and then rapidly cooling and solidifying to obtain a cladding layer which is metallurgically combined with a matrix;
(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) to (4) until the required thickness is reached;
(6) After cladding, detecting the surface of the cladding layer by adopting ultrasonic flaw detection to ensure that the cladding layer has no metallurgical defects;
(7) And polishing the surface of the workpiece to make the surface roughness meet the application requirement.
In order to further illustrate the technical effects of the invention, the invention further analyzes the macro-morphology, the micro-morphology and the mechanical properties of the ultra-high-speed laser-induction composite cladding Ni60 coating (namely, tests are carried out on the cladding layer prepared by adopting the relevant parameters and the implementation steps in the embodiment 1), and carries out comparative analysis on the Ni60 cladding layer obtained under the conditions of the same laser processing parameters and without introducing induction heating (namely, pure ultra-high-speed laser cladding). The result shows that a large number of through cracks exist in the Ni60 coating obtained by the single ultrahigh-speed laser cladding, but no cracks are found in the Ni60 coating obtained by the ultrahigh-speed laser-induction composite cladding, and the density reaches over 99.8 percent, as shown in FIG. 6. Under the condition of the same laser processing parameters and powder feeding amount, the dilution rate of the single-layer ultrahigh-speed laser-induction cladding Ni60 coating is about 2.2 +/-0.2%, the thickness is about 355 +/-10 mu m, the distance between secondary dendrite arms is about 1.15 +/-0.40 mu m, the hardness is about HV775 +/-52, and the powder utilization rate is about 92%; the dilution rate of the single-layer ultrahigh-speed laser cladding Ni60 coating is about 1.9% + -0.3%, the thickness is about 198 + -15 mu m, the hardness is about HV786 + -75, and the powder utilization rate is about 51%. Compared with a pure ultrahigh-speed laser-induction composite cladding process, the ultrahigh-speed laser-induction composite cladding process provided by the invention can effectively avoid metallurgical defects such as cracks and air holes in a coating material with high hardness and difficult processing on the premise of ensuring the fine structure of a cladding layer, so that the forming quality and the mechanical property of the cladding layer are improved, the deposition efficiency and the utilization rate of alloy powder can be greatly increased, and the increase amplitude is up to 79%.
The ultrahigh-speed laser-induction composite cladding technology provided by the invention can increase the binding force of different phase interfaces of the cladding layer and the cladding layer/substrate interface on the premise of ensuring low dilution rate and high deposition precision of the cladding layer, and improve the deposition efficiency and the powder utilization rate of the cladding layer; the temperature gradient and the cooling rate of a laser melting pool can be regulated and controlled by controlling the distribution of the induction heating temperature field on the surface of the workpiece, the residual stress of the cladding layer is reduced, the cracking tendency of the cladding layer is reduced, and further the generation of metallurgical defects such as air holes, cracks and the like in the cladding layer is avoided. Compared with the traditional laser-induction hybrid cladding technology, the ultrahigh-speed laser-induction hybrid cladding technology provided by the invention changes the interaction process of laser beam-induction heating temperature field-powder beam-matrix, so that the thermal deformation and heat affected zone of the base material is smaller, the cladding layer dilution rate is lower, the surface smoothness of the cladding layer is increased, the performance of the cladding layer is improved, and the later processing cost is reduced.
The method and the device have the advantages of simple implementation process, good flexibility, high processing stability and wide range of applicable cladding materials, and comprise various wear-resistant, corrosion-resistant, fatigue-resistant and heat-resistant materials, in particular various single alloy powder and composite powder such as Fe-based, ni-based, co-based and the like, and especially have great advantages in the aspects of metal silicide and metal ceramic composite coating materials which have higher hardness, larger cracking tendency and difficult processing. For high-carbon steel, cast iron and other base materials with poor weldability and high cracking tendency, the invention not only can obtain a hard surface coating without metallurgical defects such as pores, cracks and the like on the surface, but also can regulate and control the structure and the performance of a heat affected zone of the base body, and avoids generating cracks and hard and brittle martensite structures with poor comprehensive performance.
Overall, the invention has the following advantages: on the premise of ensuring high deposition precision and low dilution rate of a cladding layer, the bonding force of different phase interfaces of the cladding layer and a cladding layer/substrate interface is increased, and the deposition efficiency of the cladding layer and the powder utilization rate are further improved; secondly, the technical problems of high hardness, high cracking tendency, easy generation of pores, cracks and other metallurgical defects of a cladding layer of a difficult-to-machine material under the ultra-high-speed laser cladding process can be solved; thirdly, the structure with poor comprehensive performance such as cracks, hard and brittle martensite and the like in a heat affected zone of a base material with poor weldability and high cracking tendency of high-carbon steel, cast iron and the like under the ultra-high-speed laser cladding technology is avoided. The invention is suitable for strengthening and repairing the inner and outer surfaces of solid and hollow parts with various shapes, especially for strengthening and repairing the high-hardness wear-resistant coating on the surface of a thin-walled part with smaller wall thickness and easy deformation, and other cladding technologies have certain limitations.
It will be understood by those skilled in the art that the foregoing is only an exemplary embodiment of the present invention, and is not intended to limit the invention to the particular forms disclosed, since various modifications, substitutions and improvements within the spirit and scope of the invention are possible and within the scope of the appended claims.

Claims (6)

1. The ultrahigh-speed laser induction hybrid cladding method for the pipe fitting with poor weldability and high cracking tendency is characterized by comprising the following steps of:
s1, fixing a pipe fitting to be clad and carrying out pretreatment;
s2, designing a closed circular induction heating coil, arranging the closed circular induction heating coil outside or inside the pipe fitting and coaxially arranging the closed circular induction heating coil and the pipe fitting so as to realize 360-degree all-around surrounding type heating of a to-be-clad area of the pipe fitting; simultaneously designing an ultra-high speed laser cladding process and an induction heating process for ultra-high speed laser-induction composite cladding of the pipe fitting, wherein the ultra-high speed laser cladding process comprises the following steps: the diameter of the laser beam spot is designed to be 1 mm-3 mm, and the position of the laser beam spot and the powder beam converged above the surface of the workpiece is designed to be 0.5 mm-5 mm; the laser power is designed to be 6 kW-10 kW, the laser processing speed is designed to be 210 m/min-250 m/min, and the protective gas flow is designed to be 10L/min-20L/min; the powder feeding amount is designed to be 160-400 g/min, and the powder feeding air flow is designed to be 5-12L/min; the lap joint rate is designed to be 70% -90%; the induction heating process comprises the following steps: the distance between the induction heating coil and the surface of the workpiece is designed to be 5-10 mm; the heating temperature of the workpiece is designed to be 400-700 ℃;
s3, the 360-degree all-around surrounding type heating of the to-be-clad area of the pipe fitting is achieved by utilizing the induction heating coils which are designed and arranged in a targeted mode according to a designed induction heating process, the uniformity of the temperature distribution of the to-be-clad area of a circle of the circumference of the pipe fitting is guaranteed, and the quality stability of a subsequently prepared cladding layer is guaranteed;
s4, after the surface of the pipe to be clad is heated to a preset temperature, cladding is carried out by utilizing a designed ultra-high-speed laser cladding process, a laser beam spot is positioned in front of, in the middle of or behind an induction heating position along a cladding direction at the focusing position of the surface of a workpiece in the cladding process, the cladding direction is parallel to the axis of the pipe, and the laser beam spot and a powder beam interact at a specified position above the area of the pipe to be clad through the linkage control and the synergistic action of the ultra-high-speed laser cladding and the induction heating in the cladding process, so that alloy powder is heated to a molten drop or semi-molten drop state and is sprayed to a micro-molten pool on the preheating surface of the pipe in a liquid or semi-solid form, and then a cladding layer which is metallurgically combined with the pipe is prepared;
s5, after a cladding layer is clad, judging whether the thickness of the cladding layer meets the requirement, if so, finishing the cladding process, otherwise, repeating the steps S2-S4 until the required thickness is reached, so as to obtain a high-quality cladding layer with the density of more than 99.8%, the dilution rate of less than 4%, the flatness Ra of less than 10 mu m and the powder utilization rate of more than 90% on the surface of the pipe to be clad, and simultaneously, the heat affected zone of the pipe base material has no cracks and hard and brittle martensite structures.
2. The ultra high speed laser induction hybrid cladding method according to claim 1, wherein laser cladding is performed on an outer surface of the pipe, and the induction heating coil is disposed outside the pipe and coaxially disposed with the pipe.
3. The ultra high speed laser induction hybrid cladding method according to claim 1, wherein laser cladding is performed on an inner surface of the tube, and the induction heating coil is disposed inside or outside the tube and is disposed coaxially with the tube.
4. The ultra high speed laser induction hybrid cladding method according to claim 1, further comprising the steps of: and S6, detecting the surface of the cladding layer by adopting penetration or ultrasonic flaw detection after cladding.
5. The ultra high speed laser induction hybrid cladding method as set forth in any one of claims 1 to 4, further comprising the steps of: s7, polishing the surface of the cladding layer of the workpiece.
6. An ultra-high-speed laser induction hybrid cladding apparatus for implementing the cladding method according to any one of claims 1 to 5, comprising a laser scanning unit, an induction heating unit, a powder conveying unit, and a three-dimensional moving unit, wherein:
the laser scanning unit is used for outputting laser beam spots with energy in Gaussian distribution or uniform distribution;
the induction heating unit comprises an induction heating power supply, an induction heating coil, an infrared thermometer and a temperature controller, wherein the induction heating coil is connected with the induction heating power supply, and the induction heating coil is designed and arranged in a targeted manner according to the characteristics of a workpiece to be clad so as to realize 360-degree all-around heating of the region of the workpiece to be clad and ensure the uniformity of the temperature distribution of the region of the workpiece to be clad; the infrared thermometer is used for measuring the temperature of the induction heating area on the surface of the workpiece and feeding the temperature back to the temperature controller, and the temperature controller controls the output power of the induction heating power supply based on the temperature fed back by the infrared thermometer so that the induction heating coil reaches the preset temperature;
the powder conveying unit is used for conveying powder and forming a powder beam flow at the nozzle, meanwhile, the powder beam flow and the laser beam flow are converged at a preset position above the surface of a workpiece, so that the alloy powder is heated to a molten drop or semi-molten drop state through the interaction of the laser beam flow and the powder beam flow above the workpiece, finally, the alloy powder is sprayed on the surface of the workpiece in a liquid or semi-solid mode to form a micro-molten pool through laser direct irradiation, and the micro-molten pool is rapidly cooled and solidified to obtain a cladding layer which is metallurgically combined with the workpiece;
the three-dimensional moving unit is used for driving the workpiece to be cladded to perform three-dimensional movement so as to ensure that the ultrahigh-speed laser-induction composite cladding is performed at the position required by the workpiece.
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