CN111910182A - Repair powder for laser cladding of axle and repair method thereof - Google Patents
Repair powder for laser cladding of axle and repair method thereof Download PDFInfo
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- CN111910182A CN111910182A CN202010633745.7A CN202010633745A CN111910182A CN 111910182 A CN111910182 A CN 111910182A CN 202010633745 A CN202010633745 A CN 202010633745A CN 111910182 A CN111910182 A CN 111910182A
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- 239000000843 powder Substances 0.000 title claims abstract description 119
- 238000004372 laser cladding Methods 0.000 title claims abstract description 71
- 238000000034 method Methods 0.000 title claims abstract description 62
- 230000008439 repair process Effects 0.000 title claims abstract description 33
- 230000008569 process Effects 0.000 claims abstract description 30
- 239000007789 gas Substances 0.000 claims description 55
- 230000007547 defect Effects 0.000 claims description 47
- 239000000203 mixture Substances 0.000 claims description 31
- 238000005253 cladding Methods 0.000 claims description 29
- 230000001681 protective effect Effects 0.000 claims description 26
- 238000004140 cleaning Methods 0.000 claims description 25
- 238000001035 drying Methods 0.000 claims description 24
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 22
- 239000010410 layer Substances 0.000 claims description 19
- 239000000047 product Substances 0.000 claims description 18
- 238000010438 heat treatment Methods 0.000 claims description 17
- 238000002156 mixing Methods 0.000 claims description 16
- 239000011265 semifinished product Substances 0.000 claims description 15
- 238000003754 machining Methods 0.000 claims description 14
- 238000005498 polishing Methods 0.000 claims description 13
- 238000001816 cooling Methods 0.000 claims description 12
- 238000000227 grinding Methods 0.000 claims description 12
- 229910052786 argon Inorganic materials 0.000 claims description 11
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 10
- 238000011049 filling Methods 0.000 claims description 10
- 229910000831 Steel Inorganic materials 0.000 claims description 6
- 239000011247 coating layer Substances 0.000 claims description 6
- 238000000576 coating method Methods 0.000 claims description 6
- 238000007254 oxidation reaction Methods 0.000 claims description 6
- 238000005507 spraying Methods 0.000 claims description 6
- 239000010959 steel Substances 0.000 claims description 6
- 229910001339 C alloy Inorganic materials 0.000 claims description 5
- 229920000742 Cotton Polymers 0.000 claims description 5
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 5
- 239000012459 cleaning agent Substances 0.000 claims description 5
- 238000007599 discharging Methods 0.000 claims description 5
- 239000004744 fabric Substances 0.000 claims description 5
- 230000003647 oxidation Effects 0.000 claims description 5
- 238000007781 pre-processing Methods 0.000 claims description 5
- 238000005303 weighing Methods 0.000 claims description 5
- 229910052759 nickel Inorganic materials 0.000 abstract description 19
- 229910052748 manganese Inorganic materials 0.000 abstract description 16
- 229910052804 chromium Inorganic materials 0.000 abstract description 15
- 230000004888 barrier function Effects 0.000 abstract description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 21
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 18
- 229910052742 iron Inorganic materials 0.000 description 15
- 229910052802 copper Inorganic materials 0.000 description 14
- 229910052750 molybdenum Inorganic materials 0.000 description 14
- 229910052758 niobium Inorganic materials 0.000 description 14
- 238000003466 welding Methods 0.000 description 12
- 238000005260 corrosion Methods 0.000 description 6
- 230000007797 corrosion Effects 0.000 description 6
- 239000007921 spray Substances 0.000 description 6
- 238000005516 engineering process Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 238000005299 abrasion Methods 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229910019589 Cr—Fe Inorganic materials 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 229910000905 alloy phase Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000003137 locomotive effect Effects 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 238000002604 ultrasonography Methods 0.000 description 1
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Classifications
-
- 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
-
- 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
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/055—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 20% but less than 30%
-
- 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
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/058—Alloys based on nickel or cobalt based on nickel with chromium without Mo and W
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Laser Beam Processing (AREA)
Abstract
The invention discloses repair powder for laser cladding of an axle and a repair method thereof, belonging to the technical field of axle repair. The method comprises the following steps: c: 0.08
0.12%、Mn：0.4
0.6%、Cr：20.0
23.0%、Nb3.15
4.15%、Ti：0.25
0.55% Ni: and (4) the balance. The invention aims to break through the technical barrier, provide repair powder for laser cladding of axles for railway vehicles in China and a repair method thereof by using the advantages of laser cladding, and perform repairable treatment on damaged axles by adopting the process.
Description
Technical Field
The invention belongs to the technical field of axle repair, and particularly relates to repair powder for laser cladding of an axle and a repair method thereof.
Background
At present, axles of railway locomotives such as high-speed rails, motor trains and the like are imported from foreign countries, and the axles are scratched when trains run or wheels are replaced. The axles carry the weight of the car and are also subject to vibrations of different frequencies, particularly in high-speed running high-speed trains. For this reason, the quality and performance requirements for the axle are particularly high when the axle wear is less than a certain range, such as: 1mm, and scratches can be removed by mechanical grinding. But beyond that depth they must be discarded. Therefore, thousands of axles are imported from foreign countries to maintain normal operation every year, and the cost is huge.
For a scrapped axle, there is currently no repair technology and capability, and a new axle must be replaced for the normal operation of the operating vehicle.
Disclosure of Invention
The invention provides a repair powder for laser cladding of an axle and a repair method thereof, aiming at solving the technical problems in the background technology.
The invention adopts the following technical scheme: a repair powder for laser cladding of an axle comprises the following components in percentage by weight: c: 0.08-0.12%;
Nb：3.15～4.15％；
Ti：0.25～0.55％；
Cr：20.0～23.0％；
Mn：0.4～0.6％；
ni: and (4) the balance.
In a further embodiment, the composition further comprises the following components in percentage by weight:
Si：0.4～0.6％；
P：0.014～0.016％；
S:0.014～0.016％；
Mo：8.0～10.0％；
Co：0.8～1.2％；
Al：0.25～0.55％；
Fe：4～6％；
Cu：0.06～0.08％。
the method for repairing the axle by using the repair powder for laser cladding of the axle specifically comprises the following steps:
step 1, preprocessing an axle to be repaired
Removing a fatigue layer of the axle to be repaired through mechanical processing to obtain a semi-finished product;
Cleaning a region to be cladded on the axle; when cleaning, spraying alcohol or acetone cleaning solution on the surface of the axle and the surface defects by using a spraying pot, and wiping the surface defects by using cotton cloth;
step 3, drying the powder
Uniformly mixing the powder, placing the mixture in a high-temperature environment of 150-170 ℃ for 2-3 hours, and drying; and naturally cooling to room temperature;
step 4, laser cladding
Setting technological parameters of laser cladding according to the thickness requirement of a defect cladding layer, performing laser cladding on the defect position of the axle correspondingly according to the stepping parameters, and filling and covering the defect position;
step 5, machining
Processing the fused and coated product and the original size of the axle into the final size by utilizing a lathe and a grinding machine, and then polishing the surface of the product by utilizing polishing equipment according to the surface requirement of the product to ensure that the axle is processed into the original size after the defects are fused and coated by laser;
and 6, delivering the axle to be put into use.
In a further embodiment, the method specifically comprises the following steps: the axle is made of low-carbon alloy steel.
In a further embodiment, before the powder drying process in step 3, the first cleaned semi-finished product is subjected to a preheating treatment, and the preheating environment is as follows: 200 ℃ and 300 ℃, and the preheating time is 1 hour.
In a further embodiment, before the laser cladding process in step 4, the cladding powder is pretreated, and the axle to be processed is subjected to secondary treatment, which includes the following steps:
step 401, filling cladding powder into a powder feeder, and detecting the stability of the powder feeding speed of the feeder through multiple times of powder feeding, weighing and calibration;
step 402, clamping and fixing the axle, positioning and fixedly installing the axle to be processed in an area to be processed, and cleaning the surface to be processed and the surface nearby the defect by using a volatile cleaning agent.
In a further embodiment, before the machining process in step 5, the stress caused by laser cladding is removed or reduced for the axle subjected to laser cladding by a mechanical means, which specifically includes the following means: heat treatment, ultrasonic or mechanical vibration;
before the mechanical processing technology, the stress caused by laser cladding is removed or reduced by a mechanical means on the axle subjected to laser cladding through heat treatment, and the heat treatment process comprises the following steps: heating to 900 ℃ and 950 ℃, keeping for 30-45 minutes, and then cooling for 1.5-2 hours; and removing the stresses of different types and different degrees in the x, y and z directions of the laser welding by heat treatment.
In a further embodiment, the laser cladding process parameters include: the laser cladding process parameters comprise: the laser power is 1000-3000W, the spot diameter is 2-5mm, the scanning speed is 5-30mm/s, the powder feeding speed is 10-25g/min, the powder feeding gas is argon, the flow rate of the powder feeding gas is 10-15L/min, the protective gas is argon, the flow rate of the protective gas is 20L/min, and the step diameter is 0.3-0.7.
In a further embodiment, the powder feeding gas is used for conveying powder, the protective gas is used for protecting the surface of the defect from oxidation during cladding, and the laser emission time is after the protective gas and the powder feeding gas are emitted, and the protective gas and the powder discharging gas are not in sequence.
In a further embodiment, during the laser coating process, when the powder feeding speed is constant, the coating thickness d is in accordance with the following empirical formula:
wherein d is the average thickness of the coating layer; f is a proportionality coefficient and is related to the powder feeding speed; p is laser power; v is the walking speed, i.e. the scanning speed of the laser; and D is the diameter of the light spot.
The invention has the beneficial effects that: the invention aims to break through the technical barrier, provide repair powder for laser cladding of axles for railway vehicles in China and a repair method thereof by using the advantages of laser cladding, and perform repairable treatment on damaged axles by adopting the process.
The mechanical properties and the like of the repaired axle can meet the use standards: so that the surface of the steel plate has stronger hardness, wear resistance and corrosion resistance; and through adjusting the jet time between the powder gas, the protective gas and the laser, the protective gas is ensured to reach the surface of the defect in advance of the laser, and the effect of preventing the surface from being oxidized is achieved.
Drawings
FIG. 1 is a process flow diagram of the present invention.
Fig. 2 is a schematic structural view of the axle of the present invention.
Each of the labels in fig. 2 is: axle seat 1, shaft shoulder 2.
Detailed Description
In the following description, numerous specific details are set forth in order to provide a more thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without one or more of these specific details. In other instances, well-known features have not been described in order to avoid obscuring the invention.
In order to facilitate understanding of the technical scheme of the repair powder for laser cladding of the axle and the repair method thereof, the invention firstly briefly introduces the structure of the axle and the current situation of the current axle: as shown in fig. 2, the axle includes an axle seat 1 and a shoulder 2. The axle seat position may allow for installation of the wheel or brake system, and the axle seat and shoulder are often scratched when the wheel and brake system are disassembled. The tiny scratches form crack sources in high-speed running high-speed iron, and can be continuously enlarged along with the increase of vibration and service, and even lead to the breakage of an axle. The scratches in the prior art are described herein as defects, the radius of the axle is normally 190 mm, and when the depth of the defect does not exceed 1mm, the scratches can be removed by mechanical grinding; however, when the depth of the defect exceeds 1mm, the defect is discarded, and the cost is huge. Therefore, the inventor realizes effective repair of the axle with the defect depth of 1-4 mm through the scheme, and the axle can finally normally run, so that the reuse rate of the axle is increased, and the scrappage is reduced. When the depth of the defect exceeds 4 mm, the axle can be directly replaced without repair.
Firstly, in order to ensure that the fatigue strength of the repaired axle is not affected and the service life and safety of the axle are ensured, the scheme adopts nickel-based alloy powder as the repairing filler. The repair powder comprises the following components in percentage by weight: c: 0.08-0.12%, Mn: 0.4-0.6%, Cr: 20.0-23.0%, Nb: 3.15-4.15%, Ti: 0.25 to 0.55%, Si: 0.4-0.6%, P: 0.014 to 0.016%, S0.014 to 0.016%, Mo: 8.0-10.0%, Co: 0.8-1.2%, Al: 0.25 to 0.55%, Fe: 4-6%, Cu: 0.06-0.08%, Ni: and (4) the balance.
In the formula, the hardness, the wear resistance and the corrosion resistance of the surface of the cladding layer are enhanced. Because the axle is made of alloy steel material, usually EA4T low-carbon alloy steel, the axle has the advantages of stronger fatigue resistance, high hardness, strong tensile strength, good toughness, wear resistance and corrosion resistance. In order to increase the bonding strength between the axle matrix and the cladding powder and strengthen the hardness, the wear resistance and the corrosion resistance of the surface. Among them, the element C contributes to increase the hardness of the cladding layer. On one hand, because the C element has super-strong hardness and is plated with chrome on the surface of the C element so as to improve the corrosion resistance of the cladding surface, on the other hand, in the laser cladding process, a small amount of Fe solution can be formed on the surface of the axle base material, and a Cr-Fe alloy phase is easily formed with the Cr element, so that the hardness and the wear resistance of the cladding layer are improved. The Ni and Mn elements contribute to the improvement of the corrosion resistance of the cladding layer.
In a further embodiment, the method for repairing the repair powder for laser cladding of the axle specifically includes the following steps:
step 1, preprocessing an axle to be repaired
Removing a fatigue layer of the axle to be repaired through mechanical processing to obtain a semi-finished product; the thickness of the fatigue layer is selected according to the service time of the axle, and the removable thickness is controlled within the range of 0.5-4 mm.
Cleaning a region to be cladded on the axle; when cleaning, spraying alcohol or acetone cleaning solution on the surface of the axle and the surface defects by using a spraying pot, and wiping the surface defects by using cotton cloth;
step 3, drying the powder
Uniformly mixing the powder, placing the mixture in a high-temperature environment of 150-170 ℃ for 2-3 hours, and drying; and naturally cooling to room temperature;
step 4, laser cladding
Setting technological parameters of laser cladding according to the thickness requirement of a defect cladding layer, performing laser cladding on the defect position of the axle correspondingly according to the stepping parameters, and filling and covering the defect position;
step 5, machining
Processing the fused and coated product and the original size of the axle into the final size by utilizing a lathe and a grinding machine, and then polishing the surface of the product by utilizing polishing equipment according to the surface requirement of the product to ensure that the axle is processed into the original size after the defects are fused and coated by laser;
and 6, delivering the axle to be put into use.
In a further embodiment, before the powder drying process in step 3, the first cleaned semi-finished product is subjected to a preheating treatment, and the preheating environment is as follows: 200 ℃ and 300 ℃, and the preheating time is 1 hour.
The process comprises the following steps: the method reduces the cooling speed of the laser cladding surface, avoids the generation of hardened structures and reduces the welding stress and deformation, and is an effective method for preventing the generation of welding cracks.
In a further embodiment, before the laser cladding process in step 4, the cladding powder is pretreated, and the axle to be processed is subjected to secondary treatment, which includes the following steps:
step 401, filling cladding powder into a powder feeder, and detecting the stability of the powder feeding speed of the feeder through multiple times of powder feeding, weighing and calibration;
step 402, clamping and fixing the axle, positioning and fixedly installing the axle to be processed in an area to be processed, and cleaning the surface to be processed and the surface nearby the defect by using a volatile cleaning agent.
The process comprises the following steps: because the basis of the cladding process is the constant powder feeding speed in the laser coating process, the powder feeder needs to be calibrated when the powder feeder is used every time so as to detect the stability of the powder feeding speed of the feeder and further improve the coating accuracy.
In a further embodiment of the method of the invention,
before the mechanical processing technology, removing or reducing stress caused by laser cladding on the axle subjected to laser cladding through heat treatment or through mechanical means, wherein the heat treatment process comprises the following steps: heating to 900 ℃ and 950 ℃, keeping for 30-45 minutes, and then cooling for 1.5-2 hours; and removing the stresses of different types and different degrees in the x, y and z directions of the laser welding by heat treatment. In the laser welding process, the stress is divided into tensile stress and compressive stress, and the magnitude and the type of the stress are different in different directions. Meanwhile, the stress variation trend in each direction is different under the influence of various factors such as material properties and the like. Therefore, it is very important how to remove the anisotropic stress, and the heat treatment process is improved for this purpose.
For example, in one embodiment, the x direction is tensile stress and the z direction is compressive stress, and the stress accumulation amounts are different with different trends. How to adopt a process to remove the stress with different properties is a difficult point in the process.
The process comprises the following steps: the stress caused by laser cladding is removed or reduced by means of heat treatment, ultrasound, machinery and the like.
In a further embodiment, the laser cladding process parameters include: the laser power is 1000-3000W, the spot diameter is 2-5mm, the scanning speed is 5-30mm/s, the powder feeding speed is 10-25g/min, the powder feeding gas is argon, the flow rate of the powder feeding gas is 10-15L/min, the protective gas is argon, the flow rate of the protective gas is 20L/min, and the step diameter is 0.3-0.7.
By adopting the process, the stability of the coating layer can be improved, and the later polishing thickness can be reduced. In the laser coating process, when the powder feeding speed is constant, the coating layer thickness d accords with the following empirical formula:
wherein d is the average thickness of the coating layer; f is a proportionality coefficient and is related to the powder feeding speed; p is laser power; v is the walking speed, i.e. the scanning speed of the laser; and D is the diameter of the light spot. Therefore, the process parameters are obtained by combining the formula and carrying out a plurality of tests, and the whole sealing surface is fully paved in a sealing way to the maximum extent under the condition of meeting the requirement of thickness, so that the overlapping degree is reduced.
In a further embodiment, the powder feeding gas is used for conveying powder, the protective gas is used for protecting the surface of the defect from oxidation during cladding, and the laser emission time is after the protective gas and the powder feeding gas are emitted, and the protective gas and the powder discharging gas are not in sequence.
By adopting the process, the stability of the alloy components in the axle can be ensured in the cladding process of the nickel-based powder. Firstly, argon is used as protective gas, and is matched with the protective gas in the laser cladding process to form a temporary atmosphere layer around the powder, so that the condition that the base material and the powder are contacted with air in a molten state to generate oxidation reaction and nitridation reaction, other components are introduced, and then laser reaches the surface of a defect.
The invention will now be further described with reference to the following examples, which are intended to be illustrative of the invention and are not to be construed as limiting the invention.
Example 1
The embodiment provides repair powder for laser cladding of an axle and a repair method thereof, and the repair powder comprises the following steps:
step 1, preprocessing an axle to be repaired
Removing a fatigue layer of the axle to be repaired through mechanical processing to obtain a semi-finished product; the axle is made of low-carbon alloy steel, and the thickness of the removed fatigue layer is controlled to be 0.5-1 mm.
By using cotton woven cloth and a spray can, during cleaning, the spray can sprays alcohol or acetone cleaning solution on the surface and surface defects of the axle, namely, the area to be clad on the axle is cleaned for the first time; carrying out preheating treatment on the semi-finished product after the first cleaning, wherein the preheating environment is as follows: preheating time was 1 hour at 250 ℃. Reducing the cooling speed of the laser cladding surface, avoiding the generation of hardened structures and reducing the welding stress and deformation, which is an effective method for preventing the generation of welding cracks
Step 3, drying the powder
And C: 0.10%, Mn: 0.5%, Cr: 21.5%, Nb: 3.85%, Ti: 0.30%, Si: 0.5%, P: 0.015%, S0.015%, Mo: 9.0%, Co: 1.0%, Al: 0.40%, Fe: 5%, Cu: 0.07%, Ni: after uniformly mixing the rest powder, placing the mixture in a high-temperature environment of 160 ℃ for 2.5 hours, and drying the mixture; and naturally cooling to room temperature;
step 4, laser cladding
The method comprises the following steps of pretreating cladding powder and carrying out secondary treatment on an axle to be processed: step 401, filling cladding powder into a powder feeder, and detecting the stability of the powder feeding speed of the feeder through multiple times of powder feeding, weighing and calibration; step 402, clamping and fixing the axle, positioning and fixedly installing the axle to be processed in an area to be processed, and cleaning the surface to be processed and the surface nearby the defect by using a volatile cleaning agent;
setting technological parameters of laser cladding according to the thickness requirement of a defect cladding layer, performing laser cladding on the defect position of the axle correspondingly according to the stepping parameters, and filling and covering the defect position;
step 5, machining
The stress caused by laser cladding is removed or reduced for the axle subjected to laser cladding by a mechanical means,
before the machining process, stress caused by laser cladding is removed or reduced for the axle subjected to laser cladding through heat treatment, wherein the heat treatment process comprises the following steps: heating to 900 ℃ and 950 ℃, keeping for 30-45 minutes, and then cooling for 1.5-2 hours;
machining the part into the final size by a grinding machine according to the original size of the axle of the cladded product, and then polishing the surface of the product by polishing equipment according to the surface requirement of the product, wherein the roughness of the coarse grinding reaches 0.2mm, the roughness of the fine grinding reaches 0.1mm, and the axle is machined into the original size after the defects are subjected to laser cladding;
and 6, delivering the axle to be put into use.
Wherein the laser cladding process parameters comprise: the laser power is 2000W, the diameter of a light spot is 5mm, the scanning speed is 11mm/s, the powder feeding speed is 20g/min, the powder feeding gas is argon, the flow rate of the powder feeding gas is 12.5L/min, the protective gas is argon, the flow rate of the protective gas is 20L/min, and the stepping is 0.5 mm.
Further, the powder feeding gas is used for conveying powder, the protective gas is used for protecting the surface of the defect during cladding to prevent oxidation, the laser emission time is located after the protective gas and the powder feeding gas are emitted, and the protective gas and the powder discharging gas are not in sequence.
The formulation of the nickel-based powder was adjusted on the basis of example 1 as in examples 2 to 12.
Example 2
The present embodiment is different from embodiment 1 in that: and C: 0.12%, Mn: 0.4%, Cr: 22.1%, Nb: 4.10%, Ti: 0.41%, Si: 0.48%, P: 0.014%, S: 0.014%, Mo: 8.2%, Co: 1.1%, Al: 0.36%, Fe: 4.2%, Cu: 0.06%, Ni: after uniformly mixing the rest powder, placing the mixture in a high-temperature environment of 160 ℃ for 2.5 hours, and drying the mixture; and naturally cooled to room temperature. The other steps are the same.
Example 3
The present embodiment is different from embodiment 1 in that: and C: 0.12%, Mn: 0.4%, Cr: 18.9%, Nb: 3.85%, Ti: 0.30%, Si: 0.5%, P: 0.015%, S0.015%, Mo: 9.0%, Co: 1.0%, Al: 0.40%, Fe: 5%, Cu: 0.07%, Ni: after uniformly mixing the rest powder, placing the mixture in a high-temperature environment of 160 ℃ for 2.5 hours, and drying the mixture; and naturally cooled to room temperature. The other steps are the same.
Example 4
The present embodiment is different from embodiment 1 in that: and C: 0.12%, Mn: 0.4%, Cr: 21.5%, Nb: 3.85%, Ti: 0.30%, Si: 0.5%, P: 0.015%, S0.015%, Mo: 9.0%, Co: 1.0%, Al: 0.40%, Fe: 5%, Cu: 0.07%, Ni: after uniformly mixing the rest powder, placing the mixture in a high-temperature environment of 160 ℃ for 2.5 hours, and drying the mixture; and naturally cooled to room temperature. The other steps are the same.
Example 5
The present embodiment is different from embodiment 1 in that: and C: 0.05%, Mn: 0.4%, Cr: 25.6%, Nb: 3.85%, Ti: 0.30%, Si: 0.5%, P: 0.015%, S0.015%, Mo: 9.0%, Co: 1.0%, Al: 0.40%, Fe: 5%, Cu: 0.07%, Ni: after uniformly mixing the rest powder, placing the mixture in a high-temperature environment of 160 ℃ for 2.5 hours, and drying the mixture; and naturally cooled to room temperature. The other steps are the same.
Example 6
The present embodiment is different from embodiment 1 in that: and C: 0.15%, Mn: 0.4%, Cr: 25.6%, Nb: 3.85%, Ti: 0.30%, Si: 0.5%, P: 0.015%, S0.015%, Mo: 9.0%, Co: 1.0%, Al: 0.40%, Fe: 5%, Cu: 0.07%, Ni: after uniformly mixing the rest powder, placing the mixture in a high-temperature environment of 160 ℃ for 2.5 hours, and drying the mixture; and naturally cooled to room temperature. The other steps are the same.
Example 7
The present embodiment is different from embodiment 1 in that: and C: 0.10%, Mn: 0.2%, Cr: 25.6%, Nb: 3.85%, Ti: 0.30%, Si: 0.5%, P: 0.015%, S0.015%, Mo: 9.0%, Co: 1.0%, Al: 0.40%, Fe: 5%, Cu: 0.07%, Ni: after uniformly mixing the rest powder, placing the mixture in a high-temperature environment of 160 ℃ for 2.5 hours, and drying the mixture; and naturally cooled to room temperature. The other steps are the same.
Example 8
The present embodiment is different from embodiment 1 in that: and C: 0.10%, Mn: 1.0%, Cr: 25.6%, Nb: 3.85%, Ti: 0.30%, Si: 0.5%, P: 0.015%, S0.015%, Mo: 9.0%, Co: 1.0%, Al: 0.40%, Fe: 5%, Cu: 0.07%, Ni: after uniformly mixing the rest powder, placing the mixture in a high-temperature environment of 160 ℃ for 2.5 hours, and drying the mixture; and naturally cooled to room temperature. The other steps are the same.
Example 9
The present embodiment is different from embodiment 1 in that: and C: 0.10%, Mn: 0.5%, Cr: 25.6%, Nb: 2.57%, Ti: 0.30%, Si: 0.5%, P: 0.015%, S0.015%, Mo: 9.0%, Co: 1.0%, Al: 0.40%, Fe: 5%, Cu: 0.07%, Ni: after uniformly mixing the rest powder, placing the mixture in a high-temperature environment of 160 ℃ for 2.5 hours, and drying the mixture; and naturally cooled to room temperature. The other steps are the same.
Example 10
The present embodiment is different from embodiment 1 in that: and C: 0.10%, Mn: 0.5%, Cr: 25.6%, Nb: 4.96%, Ti: 0.30%, Si: 0.5%, P: 0.015%, S0.015%, Mo: 9.0%, Co: 1.0%, Al: 0.40%, Fe: 5%, Cu: 0.07%, Ni: after uniformly mixing the rest powder, placing the mixture in a high-temperature environment of 160 ℃ for 2.5 hours, and drying the mixture; and naturally cooled to room temperature. The other steps are the same.
Example 11
The present embodiment is different from embodiment 1 in that: and C: 0.10%, Mn: 0.5%, Cr: 25.6%, Nb: 3.85%, Ti: 0.13%, Si: 0.5%, P: 0.015%, S0.015%, Mo: 9.0%, Co: 1.0%, Al: 0.40%, Fe: 5%, Cu: 0.07%, Ni: after uniformly mixing the rest powder, placing the mixture in a high-temperature environment of 160 ℃ for 2.5 hours, and drying the mixture; and naturally cooled to room temperature. The other steps are the same.
Example 12
The present embodiment is different from embodiment 1 in that: and C: 0.10%, Mn: 0.5%, Cr: 25.6%, Nb: 3.85%, Ti: 0.16%, Si: 0.5%, P: 0.015%, S0.015%, Mo: 9.0%, Co: 1.0%, Al: 0.40%, Fe: 5%, Cu: 0.07%, Ni: after uniformly mixing the rest powder, placing the mixture in a high-temperature environment of 160 ℃ for 2.5 hours, and drying the mixture; and naturally cooled to room temperature. The other steps are the same.
The specific proportion and the related mechanical property test data are shown in the following table (abrasion resistance: the abrasion loss of the cladding layer is detected under the test pressure of 240N/reciprocating frequency of 2Hz and the test time of 2 h).
Example 13
A repair powder for laser cladding of an axle and a repair method thereof comprise the following steps:
step 1, preprocessing an axle to be repaired
Removing a fatigue layer of the axle to be repaired through mechanical processing to obtain a semi-finished product; the axle is made of low-carbon alloy steel, and the thickness of the removed fatigue layer is controlled to be 0.5-4 mm.
By using cotton woven cloth and a spray can, during cleaning, the spray can sprays alcohol or acetone cleaning solution on the surface and surface defects of the axle, namely, the area to be clad on the axle is cleaned for the first time; carrying out preheating treatment on the semi-finished product after the first cleaning, wherein the preheating environment is as follows: preheating time was 1 hour at 250 ℃. Reducing the cooling speed of the laser cladding surface, avoiding the generation of hardened structures and reducing the welding stress and deformation, which is an effective method for preventing the generation of welding cracks
Step 3, drying the powder
And C: 0.10%, Mn: 0.5%, Cr: 21.5%, Nb: 3.85%, Ti: 0.30%, Si: 0.5%, P: 0.015%, S0.015%, Mo: 9.0%, Co: 1.0%, Al: 0.40%, Fe: 5%, Cu: 0.07%, Ni: after uniformly mixing the rest powder, placing the mixture in a high-temperature environment of 160 ℃ for 2.5 hours, and drying the mixture; and naturally cooling to room temperature;
step 4, laser cladding
The method comprises the following steps of pretreating cladding powder and carrying out secondary treatment on an axle to be processed: step 401, filling cladding powder into a powder feeder, and detecting the stability of the powder feeding speed of the feeder through multiple times of powder feeding, weighing and calibration; step 402, clamping and fixing the axle, positioning and fixedly installing the axle to be processed in an area to be processed, and cleaning the surface to be processed and the surface nearby the defect by using a volatile cleaning agent;
setting technological parameters of laser cladding according to the thickness requirement of a defect cladding layer, performing laser cladding on the defect position of the axle correspondingly according to the stepping parameters, and filling and covering the defect position;
step 5, machining
Machining the part into the final size by using a grinding machine and a machining means according to the original size of the axle of the cladded product, and then polishing the surface of the product by using polishing equipment according to the surface requirement of the product to ensure that the axle is machined into the original size after the defect is subjected to laser cladding;
and 6, delivering the axle to be put into use.
Wherein the laser cladding process parameters comprise: the laser power is 2000W, the diameter of a light spot is 5mm, the scanning speed is 11mm/s, the powder feeding speed is 20g/min, the powder feeding gas is argon, the flow rate of the powder feeding gas is 12.5L/min, the protective gas is argon, the flow rate of the protective gas is 20L/min, and the stepping is 0.5 mm.
Further, the powder feeding gas is used for conveying powder, the protective gas is used for protecting the surface of the defect during cladding to prevent oxidation, the laser emission time is located after the protective gas and the powder feeding gas are emitted, and the protective gas and the powder discharging gas are not in sequence.
Example 14
The present embodiment is different from embodiment 1 in that: step 5, machining
The stress caused by laser cladding is removed or reduced for the axle subjected to laser cladding by a mechanical means,
before the machining process, vibration is carried out on a welding seam area. So that the vibration source and the structure generate stable resonance. And (3) utilizing the variable load stress generated by stable resonance to enable the welding seam area to generate plastic deformation. The purpose of eliminating welding stress is achieved. The stainless steel metal structure has better stress relieving effect by using a vibration method.
Machining the part into the final size by a grinding machine according to the original size of the axle of the cladded product, and then polishing the surface of the product by polishing equipment according to the surface requirement of the product, wherein the roughness of the coarse grinding reaches 0.2mm, the roughness of the fine grinding reaches 0.1mm, and the axle is machined into the original size after the defects are subjected to laser cladding;
that is, in examples 13 and 14, the mechanical stress removal treatment for the machined axle was omitted compared to example 1, and the surface residual stress was measured for the cost of example 1, example 13, and example 14, and the measurement results are shown in the following table.
It should be noted that the various features described in the above embodiments may be combined in any suitable manner without departing from the scope of the invention. The invention is not described in detail in order to avoid unnecessary repetition.
Claims (10)
1. The repair powder for laser cladding of the axle is characterized by comprising the following components in percentage by weight:
C：0.08
0.12%；
Nb：3.15
4.15%；
Ti：0.25
0.55%；
Cr：20.0
23.0%；
Mn：0.4
0.6%；
ni: and (4) the balance.
2. The repair powder for laser cladding of vehicle axles according to claim 1, further comprising the following components in weight percent:
Si：0.4
0.6%；
P：0.014
0.016%；
S: 0.014
0.016%；
Mo：8.0
10.0%；
Co：0.8
1.2%；
Al：0.25
0.55%；
Fe：4
6%；
Cu：0.06
0.08%。
3. the method for repairing an axle by laser cladding using the laser-clad repair powder for an axle according to any one of claims 1 or 2, comprising the steps of:
step 1, preprocessing an axle to be repaired
Removing a fatigue layer of the axle to be repaired through mechanical processing to obtain a semi-finished product;
step 2, cleaning the semi-finished product
Cleaning a region to be cladded on the axle; when cleaning, spraying alcohol or acetone cleaning solution on the surface of the axle and the surface defects by using a spraying pot, and wiping the surface defects by using cotton cloth;
step 3, drying the powder
Uniformly mixing the powder, placing the mixture in a high-temperature environment of 150-170 ℃ for 2-3 hours, and drying; and naturally cooling to room temperature;
step 4, laser cladding
Setting technological parameters of laser cladding according to the thickness requirement of a defect cladding layer, performing laser cladding on the defect position of the axle correspondingly according to the stepping parameters, and filling and covering the defect position;
step 5, machining
Processing the fused and coated product and the original size of the axle into the final size by utilizing a lathe and a grinding machine, and then polishing the surface of the product by utilizing polishing equipment according to the surface requirement of the product to ensure that the axle is processed into the original size after the defects are fused and coated by laser;
and 6, delivering the axle to be put into use.
4. The laser cladding method for the axle according to claim 3, wherein the axle is low carbon alloy steel.
5. The laser cladding method for the axle according to claim 3, wherein before the laser cladding process in the step 4, the cladding powder is subjected to pretreatment and the axle to be processed is subjected to secondary treatment, and the method comprises the following steps:
step 401, filling cladding powder into a powder feeder, and detecting the stability of the powder feeding speed of the feeder through multiple times of powder feeding, weighing and calibration;
step 402, clamping and fixing the axle, positioning and fixedly installing the axle to be processed in an area to be processed, and cleaning the surface to be processed and the surface nearby the defect by using a volatile cleaning agent.
6. The laser cladding method for the axle according to claim 3, wherein before the powder drying process in the step 3, the first cleaned semi-finished product is subjected to a preheating treatment, and the preheating environment is as follows: 200 ℃ and 300 ℃, and the preheating time is 1 hour.
7. The laser cladding method for the axle according to claim 3, wherein before the machining process in the step 5, the stress caused by laser cladding is removed or reduced by heat treatment or mechanical means on the axle which is already laser clad;
the heat treatment process comprises the following steps: heating to 900 ℃ and 950 ℃, keeping for 30-45 minutes, and then cooling for 1.5-2 hours;
the mechanical means is a vibration method.
8. The laser cladding method for the axle according to claim 3, wherein the laser cladding process parameters comprise: the laser power is 1000-3000W, the spot diameter is 2-5mm, the scanning speed is 5-30mm/s, the powder feeding speed is 10-25g/min, the powder feeding gas is argon, the flow rate of the powder feeding gas is 10-15L/min, the protective gas is argon, the flow rate of the protective gas is 20L/min, and the step diameter is 0.3-0.7.
9. The laser cladding method for the axle according to claim 8, wherein the powder feeding gas is used for feeding powder, the shielding gas is used for protecting the surface of the defect from oxidation during cladding, and the laser emission time is after the shielding gas and the powder feeding gas, and the shielding gas and the powder discharging gas are not in sequence.
10. The laser cladding method for the vehicle axle according to claim 8, wherein in the laser coating process, when the powder feeding speed is constant, the thickness of the coating layer is constantdThe following empirical formula is met:
(ii) a Wherein,dthe average thickness of the coating layer;fis a proportionality coefficient related to the powder feeding speed; p is laser power;vthe walking speed is the scanning speed of the laser; and D is the diameter of the light spot.
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| CN112899678A (en) * | 2021-01-20 | 2021-06-04 | 中车青岛四方机车车辆股份有限公司 | Axle remanufacturing method, remanufactured axle and system |
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| CN112458458A (en) * | 2020-12-03 | 2021-03-09 | 四川国鑫机械制造有限公司 | Laser cladding repair method for shaft neck of transmission shaft |
| CN112853346A (en) * | 2021-01-08 | 2021-05-28 | 中车青岛四方机车车辆股份有限公司 | Laser cladding remanufacturing device and remanufacturing method for railway vehicle axle |
| CN112899678A (en) * | 2021-01-20 | 2021-06-04 | 中车青岛四方机车车辆股份有限公司 | Axle remanufacturing method, remanufactured axle and system |
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| CN113463094A (en) * | 2021-07-20 | 2021-10-01 | 天津市汇利通金属表面技术有限公司 | Laser cladding surface treatment method for distribution disc of two-stage material pushing centrifugal machine and special equipment |
| CN115341137A (en) * | 2022-04-19 | 2022-11-15 | 泽高新智造(广东)科技有限公司 | Material and method for on-line laser cladding repair of steel rail defects |
| CN115341137B (en) * | 2022-04-19 | 2023-08-25 | 泽高新智造(广东)科技有限公司 | Material and method for repairing steel rail defects through online laser cladding |
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