CN111690928A - Preparation method of high-efficiency low-dilution-rate coating for boiler water wall tube bank - Google Patents
Preparation method of high-efficiency low-dilution-rate coating for boiler water wall tube bank Download PDFInfo
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- CN111690928A CN111690928A CN202010596115.7A CN202010596115A CN111690928A CN 111690928 A CN111690928 A CN 111690928A CN 202010596115 A CN202010596115 A CN 202010596115A CN 111690928 A CN111690928 A CN 111690928A
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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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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
- C22C32/0005—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with at least one oxide and at least one of carbides, nitrides, borides or silicides as the main non-metallic constituents
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23M—CASINGS, LININGS, WALLS OR DOORS SPECIALLY ADAPTED FOR COMBUSTION CHAMBERS, e.g. FIREBRIDGES; DEVICES FOR DEFLECTING AIR, FLAMES OR COMBUSTION PRODUCTS IN COMBUSTION CHAMBERS; SAFETY ARRANGEMENTS SPECIALLY ADAPTED FOR COMBUSTION APPARATUS; DETAILS OF COMBUSTION CHAMBERS, NOT OTHERWISE PROVIDED FOR
- F23M5/00—Casings; Linings; Walls
- F23M5/08—Cooling thereof; Tube walls
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- General Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Laser Beam Processing (AREA)
Abstract
The invention provides a preparation method of a high-efficiency low-dilution-rate coating of a boiler water-cooled wall tube bank, which comprises the steps of preparing a coating alloy material and realizing cladding processing of the coating by utilizing three lasers in a synergistic manner, wherein three laser beams are adopted to act on the surface of the boiler water-cooled wall tube bank in a synergistic manner, and cleaning, low-dilution-rate cladding layer preparation and medium-thickness cladding layer preparation are carried out through light spots formed by the laser beams according to a set mode so as to prepare a low-dilution-rate nickel-based coating on the surface of the water-cooled wall tube bank. The invention provides improved coating components and a preparation process, adopts the synergistic effect of three laser beams and combines the synergistic effect of coating materials in a molten bath to form a coating with improved appearance and low dilution rate on the surface of a tube bank, and greatly ensures the purity of the coating.
Description
Technical Field
The invention relates to the technical field of laser cladding additive manufacturing, in particular to a preparation method of a high-efficiency low-dilution-rate coating for a boiler water wall tube bank.
Background
The boiler pipe is at the high temperature of 500-. Boiler tube burst leakage is one of the important causes of unplanned shutdown, and the failure modes include poor material, over-temperature, abrasion, corrosion, welding defects and the like. The traditional protection such as adding protective tiles and alloying on the surface of the pipe wall cannot be widely applied due to high price or difficult implementation.
The laser cladding technology has the characteristics of controllable and rapid solidification of a heat source, high bonding strength, tissue refinement and the like, and is widely applied to the industries of aerospace, chemical engineering, molds, machinery, steel and the like. However, the single laser beam still has certain difficulties in the aspects of cladding efficiency, coating quality, interface metallurgical defect control and the like in the single preparation of the medium-thickness coating.
Disclosure of Invention
Aiming at the problems of the high-efficiency low-dilution-rate coating of the boiler water wall tube bank in the prior art, the invention provides a coating alloy powder material for reducing cracks and improving the defects of a cladding interface and a laser cladding preparation process of the low-dilution-rate coating, so that the coating quality is improved and the service life of the tube bank is prolonged.
According to the first aspect of the invention, the coating alloy powder material for the high-efficiency low-dilution-rate coating of the boiler water wall tube bank is prepared according to the following molar mass percent:
more preferably, the powder in the coating alloy powder is spherical powder, and the particle size of the powder is 53-150 μm.
Further preferably, the titanium alloy powder is TC4 titanium alloy powder.
According to a second aspect of the object of the present invention, a method for preparing a high-efficiency low-dilution-rate coating for a boiler water wall tube bank is further provided, which comprises the following steps:
step 1, preparing a coating alloy powder material according to the following mol mass percent:
the laser beam 1 is a rectangular strip-shaped laser beam and is used for cleaning and removing oxide skin on the surface of the water-cooled wall tube bank;
the laser beam 2 is a circular laser beam and is used for preparing a bottom layer on the surface of the water wall tube bank, namely a low-dilution-rate cladding layer;
the laser beam 3 is a circular laser beam and is used for preparing the surface layer of the surface of the water wall tube bank, namely preparing the medium-thickness cladding layer;
wherein the three laser beams have consistent front, middle and back positional relationship in a first cladding direction (V1) and a second cladding direction (V2) which is perpendicular to the first cladding direction, wherein:
along the first cladding direction, a laser beam 1 is arranged at the forefront, a laser beam 2 is arranged in the middle, and a laser beam 3 is arranged at the rearmost;
along the second cladding direction, the laser beam 1 is placed at the forefront, the laser beam 2 is placed in the middle, and the spot center of the laser beam 2 lags behind the spot center L1 distance of the laser beam 1, the laser beam 3 is placed at the rearmost, and the spot center of the laser beam 3 lags behind the spot center L2 distance of the laser beam 2;
in the first cladding direction, light spots formed by the three laser beams are distributed at intervals;
in the second cladding direction, the length D1 of the spot of the laser beam 1 is 2 times the spot diameter D2 of the laser beam 2 and 2 times the spot diameter D3 of the laser beam 3.
According to a third aspect of the object of the invention, a high-efficiency low-dilution-rate coating for a boiler water wall tube bank prepared according to the method is further provided.
Compared with the prior art, the high-efficiency low-dilution-rate coating powder material for the boiler water wall tube bank has the advantages that the good physical and chemical compatibility of a nickel-based material and titanium is utilized, the integral wear-resisting property of the coating alloy powder is improved by adding the wear-resisting reinforcing phase, the optimization of the microstructure of a cladding layer, the crack control and the bonding force formation cooperation are promoted by controlling the cladding process, and the cladding appearance and the coating quality of a coating interface are improved.
It should be understood that all combinations of the foregoing concepts and additional concepts described in greater detail below can be considered as part of the inventive subject matter of this disclosure unless such concepts are mutually inconsistent. In addition, all combinations of claimed subject matter are considered a part of the presently disclosed subject matter.
The foregoing and other aspects, embodiments and features of the present teachings can be more fully understood from the following description taken in conjunction with the accompanying drawings. Additional aspects of the present invention, such as features and/or advantages of exemplary embodiments, will be apparent from the description which follows, or may be learned by practice of specific embodiments in accordance with the teachings of the present invention.
Drawings
The drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. Embodiments of various aspects of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a schematic diagram of the positional relationship of three laser beams in the cladding process of the present invention, wherein V1In the cladding direction, V2Perpendicular to the cladding direction.
FIG. 2 is a graph comparing the coating prepared by the present invention with other methods, (a) is the interface defect morphology of the coating prepared by the present invention in single cladding, and (b) is the cladding interface morphology of the coating prepared by the present invention.
Detailed Description
In order to better understand the technical content of the present invention, specific embodiments are described below with reference to the accompanying drawings.
In this disclosure, aspects of the present invention are described with reference to the accompanying drawings, in which a number of illustrative embodiments are shown. Embodiments of the present disclosure are not necessarily intended to include all aspects of the invention. It should be appreciated that the various concepts and embodiments described above, as well as those described in greater detail below, may be implemented in any of numerous ways, as the disclosed concepts and embodiments are not limited to any one implementation. In addition, some aspects of the present disclosure may be used alone, or in any suitable combination with other aspects of the present disclosure.
Referring to fig. 1, according to the preparation method of the high-efficiency low-dilution-rate coating for the boiler water wall tube bank, provided by the exemplary embodiment of the invention, aiming at the problems of the preparation efficiency of the surface coating and the quality defect of the cladding layer of the traditional boiler water wall tube bank, an improved coating composition and preparation process are provided, so that a good low-dilution-rate coating is formed on the surface of the tube bank by adopting the synergistic effect of three laser beams and combining the synergistic effect of the coating material in the molten bath.
With reference to the figures, the preparation of the coating mainly comprises the steps of preparing a coating alloy material and realizing cladding processing of the coating by utilizing three lasers in cooperation. The implementation of the above process is described in more detail below with reference to specific examples.
[ disposition of coating alloy Material ]
In the preferred embodiment of the invention, the coating alloy powder material is prepared according to the following mol mass percent:
more preferably, the powder in the coating alloy powder is spherical powder, and the particle size of the powder is 53-150 μm.
Further preferably, the titanium alloy powder is TC4 titanium alloy powder, and the TC4 alloy is a high-performance alloy material in the field of laser additive manufacturing, and is easily available in the market.
Preferably, after the alloy powder material is prepared, before use, an electromagnetic powder mixing device is used for powder mixing for 1 hour, and the powder is dried for 1.5 hours in a vacuum environment at 100 ℃ and then used again.
[ preparation of coating ]
In the embodiment of the invention, as shown in fig. 1, three laser beams are preferably adopted to cooperatively act on the surface of the boiler water wall tube bank, and cleaning, low-dilution-rate cladding layer preparation and medium-thickness cladding layer preparation are carried out according to the light spots formed by the laser beams in a set mode so as to prepare the low-dilution-rate nickel-based coating on the surface of the water wall tube bank.
The laser beam 1 is a rectangular strip-shaped laser beam and is used for cleaning and removing oxide scales on the surfaces of the water-cooled wall tube banks.
The laser beam 2 is a circular laser beam and is used for preparing a bottom layer of the surface of the water wall tube bank, namely a low-dilution-rate cladding layer.
The laser beam 3 is a circular laser beam and is used for preparing the surface layer of the surface of the water wall tube bank, namely preparing the medium-thickness cladding layer.
Referring to fig. 1, the three laser beams have a consistent front, middle and rear positional relationship in both a first cladding direction (V1) and a second cladding direction (V2) perpendicular to the first cladding direction, wherein:
along the first cladding direction, a laser beam 1 is arranged at the forefront, a laser beam 2 is arranged in the middle, and a laser beam 3 is arranged at the rearmost;
in the second cladding direction, the laser beam 1 was placed at the forefront, the laser beam 2 was placed in the middle, and the spot center of the laser beam 2 lags behind the spot center L1 distance of the laser beam 1, and the laser beam 3 was placed at the rearmost, and the spot center of the laser beam 3 lags behind the spot center L2 distance of the laser beam 2.
In the first cladding direction, light spots formed by the three laser beams are distributed at intervals. Preferably, the distances of separation are the same.
In the second cladding direction, the length D1 of the spot of the laser beam 1 is 2 times the spot diameter D2 of the laser beam 2 and 2 times the spot diameter D3 of the laser beam 3.
Preferably, before the tube bank is subjected to coating preparation, the tube bank can be fixed and clamped on a clamp in advance, and tap water is introduced into the cavity of the tube bank according to actual needs.
In an alternative embodiment, a gantry-type cladding machine tool can be used to carry a group of three laser cladding processing heads (a laser cleaning head, a low-dilution-rate coating preparation processing head and a medium-thickness coating preparation processing head are in a group), the laser cleaning function is a linear light spot, the two laser cladding processing heads are circular light spots, and the spatial installation positions of the three laser cladding processing heads can be adjusted according to the structural form of a tube bank under the position configuration shown in fig. 1. In another embodiment, the planer-type cladding lathe portability multiunit processing head carries out multizone and melts and covers simultaneously, melts and covers simultaneously at present multizone multistation, further improves industrial production efficiency.
Preferably, the three laser cladding processing heads are taken as a whole, the three laser cladding processing heads can rotate for a certain angle relative to a mounting cross beam of the gantry type cladding machine tool, and the adjustment of the angle is controlled by a servo motor so as to adapt to the cladding of the arc surface of the tube bank.
The total thickness of the cladding coating is 2.2mm, the cladding thickness of the bottom layer is 0.6mm, and the cladding thickness of the surface layer is 1.6 mm.
Referring to fig. 1, in the three laser beams, the length D1 of the spot of the laser beam 1 is 10mm, the diameter D2 of the spot of the laser beam 2 is 5mm, and the diameter D3 of the spot of the laser beam 3 is 5 mm;
L1＝2.5mm-3.5mm，L2＝2.0mm-4.5mm。
in step 2, after the relative position of the three laser beams is adjusted according to the position relation of the figure 1 by guiding the red light, cladding processing is controlled by inputting cladding processing parameters.
The technological parameters used for cladding are as follows:
laser cleaning: the laser power is 500W, and the spot length is 10 mm;
preparing a low-dilution-rate coating: the laser power is 1400W, the spot size is 5mm, and the lap joint rate is 50%;
preparing a medium-thickness coating: the laser power is 2000W, the spot size is 5mm, and the lap joint rate is 50%.
The powder feeding mode is coaxial powder feeding.
And opening the powder feeder, adjusting the powder feeding speed to 0.8r/min and 2.3r/min respectively, and adjusting the powder feeding gas carrying capacity to 2.5L/min and 6.5L/min respectively. And starting a machine tool control program, and carrying out laser cladding along a preset path.
Preferably, the laser cladding processing heads corresponding to the three laser beams are fixed on a moving beam of the machine tool according to a spatial position relationship, the scanning speeds v of the three laser beams are the same, and v is 18mm/s until the set cladding processing program is finished, so that two cladding layers are obtained.
For comparison, we also performed a single cladding of medium thickness coating, resulting in a 2.6mm coating, as shown in connection with fig. 2.
As shown in fig. 2, the bottom layer and the surface layer are respectively formed by cladding through secondary processing, three light beams are adopted for cooperation, linear long rectangular light beams are used for cleaning and preheating, and the bottom layer and the surface layer are respectively clad through circular light beams, so that the efficiency is improved, the bonding quality of the cladding section is improved, and the coating quality is improved. Compared with the process of cladding the coating (with the thickness of 2.6mm) at one time under the condition of low dilution rate, the process greatly reduces the unfused defect of the coating and the substrate interface, and has few defects of the interface and the coating inside; compared with a twice cladding mode, the efficiency is greatly improved. Meanwhile, in other aspects, the combination mode of the three beams of laser used by the invention can be copied to a plurality of positions of the cross beam of the plane cladding machine tool as a whole, so that multi-region simultaneous cladding is realized, and the industrial production efficiency can be further improved.
By combining the embodiment, the mixed powder of the Herganas 625 nickel-based powder and the spherical nickel-coated tungsten carbide is added with the molybdenum disulfide and the zirconium oxide, so that on one hand, the high-efficiency wear-resisting performance is realized by mixing the tungsten carbide and the nickel-based powder, and meanwhile, the mixed powder and the molybdenum disulfide form a synergy, the friction-reducing synergy is further realized, and the wear-resisting level is improved; on the other hand, in the process of forming a molten pool by the tungsten carbide, the molybdenum disulfide and the nickel base, the zirconium oxide is used as an accelerant, the structure of the cladding layer is refined, the generation of fine cracks in the cladding layer is reduced, the binding force of the nickel base in the cladding layer to the wear-resistant tungsten carbide and the molybdenum disulfide is improved, and the quality and the wear resistance of the coating are further improved.
In addition, in the process of forming a molten pool, boron carbide and titanium alloy powder act synergistically to generate TiC and TiB through in-situ reaction2Finely dispersed TiC and TiB particles2As a reinforcing phase, the titanium carbide and the large particles of the tungsten carbide form a gap supplement effect in a molten pool, so that TiC and TiB2The tungsten carbide and the tungsten carbide are distributed in a Herganas 625 wear-resistant nickel-based molten pool more uniformly and compactly, and the effect of refining microscopic grains is achieved, so that the microstructure of the coating is enhanced, the generation of plastic deformation and fine cracks is reduced, and the quality of a cladding interface is improved. Meanwhile, TiC and TiB2Under the synergistic effect with tungsten carbide, through the mismatching effect of granularity, the stress dispersion of microstructures in the cladding layer is realized, the stress concentration problem caused by agglomeration is reduced and eliminated, the optimization of internal tissues is promoted, and the quality of the cladding interface is further improved, as shown in fig. 2.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to be limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the invention. Therefore, the protection scope of the present invention should be determined by the appended claims.
Claims (9)
1. The preparation method of the high-efficiency low-dilution-rate coating for the tube bank of the boiler water wall is characterized by comprising the following steps of:
step 1, preparing a coating alloy powder material according to the following mol mass percent:
step 2, three laser beams are adopted to act on the surface of the boiler water wall tube bank in a synergistic manner, and cleaning, low-dilution-rate cladding layer preparation and medium-thickness cladding layer preparation are carried out through light spots formed by the laser beams according to a set mode so as to prepare the low-dilution-rate nickel-based coating on the surface of the water wall tube bank, wherein:
the laser beam 1 is a rectangular strip-shaped laser beam and is used for cleaning and removing oxide skin on the surface of the water-cooled wall tube bank;
the laser beam 2 is a circular laser beam and is used for preparing a bottom layer on the surface of the water wall tube bank, namely a low-dilution-rate cladding layer;
the laser beam 3 is a circular laser beam and is used for preparing the surface layer of the surface of the water wall tube bank, namely preparing the medium-thickness cladding layer;
wherein the three laser beams have consistent front, middle and back positional relationship in a first cladding direction (V1) and a second cladding direction (V2) which is perpendicular to the first cladding direction, wherein:
along the first cladding direction, a laser beam 1 is arranged at the forefront, a laser beam 2 is arranged in the middle, and a laser beam 3 is arranged at the rearmost;
along the second cladding direction, the laser beam 1 is placed at the forefront, the laser beam 2 is placed in the middle, and the spot center of the laser beam 2 lags behind the spot center L1 distance of the laser beam 1, the laser beam 3 is placed at the rearmost, and the spot center of the laser beam 3 lags behind the spot center L2 distance of the laser beam 2;
in the first cladding direction, light spots formed by the three laser beams are distributed at intervals;
in the second cladding direction, the length D1 of the spot of the laser beam 1 is 2 times the spot diameter D2 of the laser beam 2 and 2 times the spot diameter D3 of the laser beam 3.
2. The preparation method of the high-efficiency low-dilution-rate coating for the boiler water wall tube bank according to claim 1, wherein the powder in the coating alloy powder is spherical powder, and the particle size of the powder is 53-150 μm.
3. The method for preparing the high-efficiency low-dilution-rate coating of the boiler water wall tube bank according to claim 1, wherein the titanium alloy powder is TC4 titanium alloy powder.
4. The preparation method of the high-efficiency low-dilution-rate coating for the boiler water wall tube bank according to claim 1, wherein in the step 1, after the powder material is prepared by the molar mass percent, an electromagnetic powder mixing device is adopted for powder mixing for 1 hour, and vacuum drying is carried out for 1.5 hours at 100 ℃ before use.
5. The preparation method of the high-efficiency low-dilution-rate coating for the boiler water wall tube bank according to claim 1, wherein the cladding total thickness is 2.2mm, the cladding thickness of a bottom layer is 0.6mm, and the cladding thickness of a surface layer is 1.6 mm.
6. The preparation method of the high-efficiency low-dilution-rate coating for the boiler water wall tube bank according to claim 1, wherein in the three laser beams, the length D1 of a light spot of a laser beam 1 is 10mm, the diameter D2 of a light spot of a laser beam 2 is 5mm, and the diameter D3 of a light spot of a laser beam 3 is 5 mm;
L1＝2.5mm-3.5mm，L2＝2.0mm-4.5mm。
7. the preparation method of the high-efficiency low-dilution-rate coating for the boiler water wall tube bank according to claim 1, wherein in the step 2, the cladding uses the following process parameters:
laser cleaning: the laser power is 500W, and the spot length is 10 mm;
preparing a low-dilution-rate coating: the laser power is 1400W, the spot size is 5mm, and the lap joint rate is 50%;
preparing a medium-thickness coating: the laser power is 2000W, the spot size is 5mm, and the lap joint rate is 50%;
the powder feeding mode is coaxial powder feeding.
8. The preparation method of the high-efficiency low-dilution-rate coating for the boiler water wall tube bank as claimed in claim 7, wherein laser cladding processing heads corresponding to three laser beams are fixed on a moving cross beam of a machine tool according to a spatial position relationship, and the scanning speeds v of the three laser cladding processing heads are the same, and v is 18 mm/s.
9. A boiler waterwall tube bank high efficiency low dilution coating prepared according to the method of any one of claims 1-8.
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