CN112030159A - Ultra-high-speed laser cladding system and laser cladding method - Google Patents
Ultra-high-speed laser cladding system and laser cladding method Download PDFInfo
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- 238000004372 laser cladding Methods 0.000 title claims abstract description 82
- 238000000034 method Methods 0.000 title claims abstract description 21
- 239000000843 powder Substances 0.000 claims abstract description 220
- 238000010438 heat treatment Methods 0.000 claims abstract description 166
- 239000000919 ceramic Substances 0.000 claims abstract description 125
- 229910052751 metal Inorganic materials 0.000 claims abstract description 63
- 239000002184 metal Substances 0.000 claims abstract description 63
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 21
- 229910052802 copper Inorganic materials 0.000 claims description 21
- 239000010949 copper Substances 0.000 claims description 21
- 229910010293 ceramic material Inorganic materials 0.000 claims description 12
- 230000006698 induction Effects 0.000 claims description 10
- 239000000498 cooling water Substances 0.000 claims description 9
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 8
- 230000005484 gravity Effects 0.000 claims description 7
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 6
- 238000002844 melting Methods 0.000 claims description 6
- 230000008018 melting Effects 0.000 claims description 6
- 230000009471 action Effects 0.000 claims description 5
- 230000000712 assembly Effects 0.000 claims description 4
- 238000000429 assembly Methods 0.000 claims description 4
- -1 iron-chromium-aluminum Chemical compound 0.000 claims description 4
- 229910000838 Al alloy Inorganic materials 0.000 claims description 3
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- 239000000155 melt Substances 0.000 claims description 3
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 claims description 2
- 229910000623 nickel–chromium alloy Inorganic materials 0.000 claims description 2
- 230000003746 surface roughness Effects 0.000 claims description 2
- 238000005253 cladding Methods 0.000 abstract description 39
- 238000005516 engineering process Methods 0.000 abstract description 15
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- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 2
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
- C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/10—Pre-treatment
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Abstract
The invention provides an ultra-high speed laser cladding system and a laser cladding method, wherein the system comprises: the laser, heating power supply, powder feeder and powder heating tube assembly which produce laser beam, the powder heating tube assembly is made up of outer ceramic tube, electromagnetic heating assembly and inner ceramic tube, the inner ceramic tube is set up in the outer ceramic tube, the electromagnetic heating assembly is set up between outer ceramic tube and the inner ceramic tube; the heating power supply is connected with the electromagnetic heating assembly through a lead; the powder feeder is communicated with the inner ceramic tube through a powder feeding tube, and after normal-temperature metal powder in the powder feeder enters the inner ceramic tube through the powder feeding tube, the normal-temperature metal powder is heated into high-temperature metal powder in the inner ceramic tube by the electromagnetic heating assembly; the laser beam and the extension line of the inner ceramic tube are intersected at a molten pool on the surface of the workpiece to be cladded. The invention firstly realizes the ultra-high speed laser cladding technology based on the improvement of the initial temperature of the metal powder on the basis of the traditional powder laser cladding technology, and solves the problem of low cladding efficiency of the powder laser cladding technology.
Description
Technical Field
The invention belongs to the technical field of advanced manufacturing, and particularly relates to an ultra-high-speed laser cladding system and a laser cladding method.
Background
The powder laser cladding technology is an advanced manufacturing technology with high precision, high performance, low heat affected zone and low dilution rate, and is widely applied to the fields of preparation of modified coatings on the surfaces of metal parts, repair of surface defects, metal additive manufacturing and the like. The existing powder laser cladding technology uses metal powder and laser beam as raw materials and heat source, and melts the powder and base material by the laser beam to form a molten pool, and simultaneously makes the molten pool and the base material move relatively, thereby forming a cladding layer. Wherein the metal powder is at normal temperature, and the heat source is a pure laser heat source. In the laser cladding system, if the laser cladding efficiency is improved, the laser power can only be increased, and although the cladding efficiency is improved by the increase of the laser power, the problems of heat input, dilution rate increase, alloy element burning loss and the like in the cladding process are also caused.
Therefore, how to solve the problem of low efficiency faced by the existing powder laser cladding technology is a key problem to be solved urgently in the development of the existing powder laser cladding technology.
Disclosure of Invention
The invention aims to provide an ultrahigh-speed laser cladding system and a laser cladding method, which initially realize the ultrahigh-speed laser cladding method based on the improvement of the initial temperature of metal powder on the basis of the traditional powder laser cladding technology by innovatively arranging a powder heating laser cladding scheme, and solve the problem of low cladding efficiency of the existing powder laser cladding technology.
The technical scheme adopted by the invention for solving the technical problems is as follows:
an ultra-high speed laser cladding system comprising: the laser device comprises a laser device for generating laser beams 1, a heating power supply 6, a powder feeder 10 and a powder heating pipe assembly 12, wherein the powder heating pipe assembly 12 consists of an outer ceramic pipe 13, an electromagnetic heating component 14 and an inner ceramic pipe 15, the inner ceramic pipe 15 is arranged in the outer ceramic pipe 13, and the electromagnetic heating component 14 is arranged between the inner ceramic pipe 15 and the outer ceramic pipe 13; the heating power supply 6 is connected to the electromagnetic heating assembly 14 through a lead; the powder feeder 10 is communicated with the inner ceramic tube 15 through a powder feeding tube 11, and after the normal-temperature metal powder 9 in the powder feeder enters the inner ceramic tube 15 through the powder feeding tube 11, the normal-temperature metal powder is heated into high-temperature metal powder in the inner ceramic tube 15 by the electromagnetic heating assembly 14; the laser beam 1 and the extension line of the inner ceramic tube 15 intersect at the position of a molten pool 3 of the surface of the workpiece to be clad.
Further, the ultra-high speed laser cladding system according to the present invention, wherein the power of the laser beam 1 is 500-; the temperature of the high-temperature metal powder is 200-2000 ℃.
Further, according to the ultra-high speed laser cladding system of the present invention, the powder feeder 10 is a gravity powder feeder or an air-carrying powder feeder, the powder feeding speed is adjustable between 0g/min and 500g/min, the powder feeder 10 is connected to the inner ceramic tube through a powder feeding tube 11, and the powder feeding tube 11 is a flexible tube or a hard tube.
Further, according to the ultra-high speed laser cladding system, the included angle between the central axis of the laser beam 1 and the central axis of the powder heating pipe assembly 12 is 10-60 degrees, and the distance between the front end surface of the inner ceramic pipe and the molten pool is 5-20 mm.
Further, according to the ultra-high speed laser cladding system of the present invention, the inner ceramic tube 15 and the outer ceramic tube 13 both have a cylindrical tubular structure, the outer ceramic tube 13 is made of zirconia ceramic material or alumina ceramic material, the inner ceramic tube 15 is made of chromia ceramic material or alumina ceramic material, a powder feeding channel is formed in the center of the inner ceramic tube 15, the powder feeding channel is a circular tube channel, the inner diameter size is 0.5-2mm, the inner surface roughness is ra3.2-ra0.05, and the powder feeding channel is communicated with the powder feeding tube 11; the electromagnetic heating assembly 14 is wound on the outer wall of the inner ceramic tube 15 between the inner ceramic tube 15 and the outer ceramic tube 13, a first connecting terminal of the electromagnetic heating assembly 14 is led out along the outer wall of the inner ceramic tube 15, and a second connecting terminal of the electromagnetic heating assembly 14 is led out along the outer wall of the outer ceramic tube 13; the heating power supply 6 is connected to the first connection terminal through a first wire 7, and the heating power supply 6 is connected to the second connection terminal through a second wire 8.
Further, according to the ultra-high-speed laser cladding system of the invention, the electromagnetic heating assembly 14 adopts an induction heating coil, the induction heating coil is made of a hollow copper pipe, cooling water is filled in the hollow copper pipe, the heating power supply is a medium-frequency or high-frequency heating power supply with the output power of 1kw-200kw and the alternating-current frequency of 100khz-2000khz, and the output current is adjustable at 0-500A; the first lead 7 and the second lead 8 are both cables or copper pipes which are filled with cooling water.
Further, according to the ultra-high speed laser cladding system, the electromagnetic heating assembly 14 adopts a resistance heating wire, the resistance heating wire is a nickel-chromium alloy resistance wire or an iron-chromium-aluminum alloy resistance wire, the diameter of the resistance heating wire is 0.5-3mm, the output power of the heating power supply is 10-100 kw, and the output voltage is 0-70V; the first lead 7 and the second lead 8 are both cables or copper pipes which are filled with cooling water.
Further, the ultra-high speed laser cladding system according to the present invention, wherein the powder heating pipe assembly 12 comprises a plurality of sets of powder heating pipe assemblies 12 symmetrically arranged around the laser beam 1.
The invention discloses an ultrahigh-speed laser cladding method based on an ultrahigh-speed laser cladding system, which comprises the following steps of:
step one, placing normal-temperature metal powder 9 into a powder feeder 10, starting the powder feeder 10, and enabling the normal-temperature metal powder 9 to flow to an inner ceramic tube 15 in a powder heating tube assembly 12 through a powder feeding tube 11 due to the action of gravity or the blowing force of powder feeding air;
step two, turning on the heating power supply 6, and heating the normal-temperature metal powder flowing through the inner ceramic tube 15 into high-temperature metal powder by the electromagnetic heating assembly;
step three, converging the high-temperature metal powder 2 output from the front end face of the inner ceramic tube 15 and the laser beam 1 on the surface of the workpiece to be clad, forming a molten pool on the surface of the workpiece to be clad after the high-temperature metal powder is melted by the laser beam 1, and enabling the molten pool 3 and the workpiece to be clad to move relatively according to a preset path, so that a laser cladding layer is formed on the surface of the workpiece to be clad.
Further, according to the ultra-high speed laser cladding method, in the second step, a heating power supply is started, when an electromagnetic induction coil is selected as the electromagnetic heating component, normal temperature metal powder flowing through a powder feeding channel of the inner ceramic tube is heated into high temperature metal powder under the action of electromagnetic induction through an alternating magnetic field generated by high-frequency alternating current, when a resistance heating wire is selected as the electromagnetic heating component, the normal temperature metal powder flowing through the inner ceramic tube is heated into the high temperature metal powder through resistance heat generated by current passing through the resistance heating wire, and the temperature of the high temperature metal powder is 200-2000 ℃; in the third step, the power of the laser beam is 500-20000w, and the laser beam forms a circular light spot with the diameter of 0.5-10mm or a rectangular light spot with the width of 0.5-4mm and the length of 2-50mm at the molten pool, the included angle between the laser beam and the powder heating pipe assembly is 10-60 degrees, and the distance between the molten pool and the front end face of the ceramic pipe in the molten pool is 5-20 mm.
The technical scheme of the invention can at least achieve the following beneficial effects:
1) the metal powder is heated in advance by adopting an induction heating mode, so that the metal powder is in a high-temperature state before entering a molten pool, and can be melted only by very small laser energy and very short time, so that the molten pool is formed on the surface of the base material, and the cladding layer is formed by fast moving, therefore, the ultrahigh-speed laser cladding efficiency of the invention is very high, and the problem that the efficiency of the traditional laser cladding technology is difficult to further improve is solved. Compared with the traditional laser cladding, under the condition of adopting 4000w laser power and cladding a stainless steel cladding layer with the thickness of 1mm, the invention can improve the cladding efficiency of the traditional laser cladding of 0.15-0.4 square meter/h to 0.5-1 square meter/h, and the cladding efficiency is obviously improved. The main performance comparison between the conventional laser cladding technology and the ultra-high speed laser cladding technology is shown in the following table:
| serial number | Performance parameter | Existing coaxial powder feeding laser melting Coating technique (melting at 4kw Covering 1mm thickness as an example) | Existing high speed laser cladding The technique (at a power of 4kw, cladding 1mm thickness as an example) | The invention relates to ultra-high-speed laser melting Coating technique (melting at 4kw Covering 1mm thickness as an example) |
| 1 | Cladding efficiency (Square meter/h) | 0.15-0.2 | 0.2-0.4 | 0.4-1.0 |
| 2 | Cladding line speed (mm/s) | 10-30 | 100-300 | 100-1000 |
| 3 | Initial temperature (. degree. C.) of metal powder | At normal temperature | At normal temperature | 200-2000 |
| 4 | Minimum dilution ratio (%) | 5 | 2 | 0.5 |
2) The temperature of the powder is in direct proportion to the absorptivity of the laser, the absorptivity of the laser is increased after the powder is heated, and the reflectivity of the laser is reduced, so that the invention can further improve the energy utilization rate of the laser and reduce the problems of optical fiber burning, cladding head burning and the like caused by laser reflection light.
3) Because the powder is heated and then sent into the laser melting pool, the powder heating process can decompose impurities such as moisture, dust and the like adsorbed in the air on the surface of the powder in advance, so that air holes, slag inclusion and the like generated by the moisture and the dust in the cladding layer are greatly reduced, and the quality of the cladding layer is improved.
4) In conclusion, the powder heating pipe assembly and the heating power supply which are innovatively arranged are used for heating the metal powder to the high temperature even to be melted, so that the powder can be melted by using very low laser power in a very short time, and the cladding efficiency is greatly improved. And the heated powder can improve the utilization rate of laser energy and reduce laser reflection, thereby minimizing the adverse effect caused by the laser reflection in the laser cladding process. The powder heating process can also decompose and volatilize moisture, dust and the like adsorbed on the surface of the powder, and the quality of the laser cladding layer is improved. The invention solves the problems of low efficiency, low cladding quality, large reflected light hazard and the like of the traditional laser cladding technology, and has very wide industrial application prospect.
Drawings
The present invention will be described in further detail with reference to the accompanying drawings.
FIG. 1 is a schematic view of an ultra-high speed laser cladding system according to the present invention;
FIG. 2 is a schematic view of a powder heating tube assembly employing an induction heating coil according to the present invention;
FIG. 3 is a schematic structural view of a powder heating tube assembly using a resistance heating wire according to the present invention;
FIG. 4 is a schematic cross-sectional view of a powder heating tube assembly according to the present invention;
the meanings of the reference symbols in the figures are as follows:
1. the laser welding method comprises the following steps of laser beam, 2 high-temperature metal powder, 3 molten pool, 4 cladding layer, 5 base material, 6 heating power supply, 7 first lead, 8 second lead, 9 normal-temperature metal powder, 10 powder feeder, 11 powder feeding pipe, 12 powder heating pipe assembly, 13 outer ceramic chamber, 14 electromagnetic heating assembly and 15 inner ceramic pipe.
Detailed Description
The following detailed description of the embodiments of the present invention is provided to enable those skilled in the art to more clearly understand the present invention, but not to limit the scope of the present invention.
As shown in fig. 1, fig. 2, fig. 3 and fig. 4, the ultra-high speed laser cladding method of the present invention is implemented based on the ultra-high speed laser cladding system shown in fig. 1, and the ultra-high speed laser cladding system includes: the laser device comprises a laser device for providing a laser beam 1, a heating power supply 6, a powder feeder 10 and a powder heating pipe assembly 12, wherein the powder heating pipe assembly 12 consists of an outer ceramic pipe 13, an electromagnetic heating component 14 and an inner ceramic pipe 15; the heating power supply 6 is respectively connected with two ends of the electromagnetic heating component 14 through a first lead 7 and a second lead 8; the powder feeder 10 is filled with normal temperature metal powder 9 and is connected with the inner ceramic tube 15 through a powder feeding tube 11; the laser beam 1 intersects the extension line of the inner ceramic tube 15 at the molten pool 3. After the powder feeder 10 and the heating power supply 6 are started, the normal temperature metal powder 9 enters the inner ceramic tube 15 through the powder feeding tube 11, is heated in the inner ceramic tube 15 by the electromagnetic heating assembly 14, the heated high temperature metal powder 2 is sent out from the lower end of the inner ceramic tube 15, is converged at the position of the molten pool 3 together with the laser beam 1, and forms the cladding layer 4 on the surface of the substrate 5 along with the relative movement of the molten pool 3 and the substrate 5.
Further, the ultra-high speed laser cladding system according to the present invention, wherein the power of the laser beam 1 provided by the laser is 500-.
Further, the ultra-high speed laser cladding system according to the present invention, wherein the powder feeder 10 is a gravity powder feeder or an air-borne powder feeder, preferably an air-borne powder feeder, the powder feeding rate is 0-500g/min, preferably 0-300g/min, and the powder feeding rate is adjustable. The powder feeder 10 is connected with the inner ceramic tube through a powder feeding tube 11, and the powder feeding tube 11 is a hose or a hard tube, preferably a hose connection.
Further in accordance with the ultra high speed laser cladding system of the present invention, the angle between the central axis of the laser beam 1 and the central axis of the powder heating tube assembly 12 is between 10 ° and 60 °, preferably between 15 ° and 45 °, and a plurality of powder heating tube assemblies 12 may be symmetrically arranged around the laser beam. The extension line of the inner ceramic tube 15 and the laser beam 1 converge at the position of the molten pool 3, and the distance between the molten pool 3 and the end surface of the inner ceramic tube is 5-20mm, preferably 10-15 mm.
Further, according to the ultra-high speed laser cladding system of the present invention, the powder heating tube assembly 12 is composed of an outer ceramic tube 13, an electromagnetic heating assembly 14 and an inner ceramic tube 15, the inner ceramic tube 15 and the outer ceramic tube 13 both have cylindrical tubular structures, the inner ceramic tube 15 is disposed inside the outer ceramic tube 13, and the electromagnetic heating assembly 14 is disposed between the inner ceramic tube 15 and the outer ceramic tube 13. Wherein, the outer ceramic tube 13 is made of high temperature resistant and insulating ceramic materials such as zirconia or alumina; the inner ceramic tube 15 is made of high-temperature-resistant and insulating ceramic materials such as chromium oxide or aluminum oxide, a powder feeding channel is formed in the center of the inner ceramic tube 15, the powder feeding channel is preferably a cylindrical channel, the inner diameter of the cylindrical channel is 0.5-2mm, preferably 0.8-1.2mm, and the roughness of the inner surface of the powder feeding channel is Ra3.2-Ra0.05, preferably Ra1.6-Ra0.2. The powder feeding channel at the center of the inner ceramic tube is communicated with the powder feeding tube 11. The electromagnetic heating assembly 14 is arranged between the inner ceramic tube 15 and the outer ceramic tube 13 and wound on the outer wall of the inner ceramic tube 15, a first connecting terminal of the electromagnetic heating assembly 14 is led out from the upper end of the powder heating tube assembly 12 along the outer wall of the inner ceramic tube 15, and a second connecting terminal of the electromagnetic heating assembly 14 is led out from the lower end of the powder heating tube assembly 12 along the outer wall of the outer ceramic tube 13.
More specifically, the electromagnetic heating assembly 14 preferably adopts an induction heating coil or a resistance heating wire, when the electromagnetic heating assembly 14 adopts an induction heating coil, as shown in fig. 2, the induction heating coil is preferably made of a hollow copper pipe, cooling water is introduced into the copper pipe, the hollow copper pipe is wound on the outer wall of the inner ceramic pipe 15 between the inner ceramic pipe 15 and the outer ceramic pipe 13, a first connection terminal of the hollow copper pipe is led out from the upper end of the powder heating pipe assembly 12 along the outer wall of the inner ceramic pipe 15, and a second connection terminal of the hollow copper pipe is led out from the lower end of the powder heating pipe assembly 12 along the outer wall of the outer ceramic pipe 13. Meanwhile, a first lead wire 7 of a heating power supply 6 is connected with a first connecting terminal of the hollow copper pipe, a second lead wire 8 of the heating power supply 6 is connected with a second connecting terminal of the hollow copper pipe, the heating power supply 6 is a medium-frequency or high-frequency heating power supply with the output power of 1kw-200kw and the alternating current frequency of 100khz-2000khz, the preferred output power is 50kw, the alternating current frequency is 1000khz-1500khz, the output current of the heating power supply is adjustable from 0 to 500A, the preferred frequency is 100 plus 300A, and the first lead wire 7 and the second lead wire 8 are both made of cables or copper pipes which are communicated with cooling water, and the preferred copper pipes are made of copper pipes; the metal powder in the inner ceramic tube 15 is heated by the induction heating coil based on the electromagnetic induction effect.
When the electromagnetic heating component 14 is a resistance heating wire, as shown in fig. 3, the resistance heating wire is preferably a resistance heating wire made of nichrome or iron-chromium-aluminum alloy, and the diameter of the resistance heating wire is 0.5-3mm, and the preferred diameter is 1.5-2 mm; the resistance heating wire is wound on the outer wall of the inner ceramic tube 15 between the inner ceramic tube 15 and the outer ceramic tube 13, a first connecting terminal of the resistance heating wire is led out from the upper end of the powder heating tube assembly 12 along the outer wall of the inner ceramic tube 15, and a second connecting terminal of the resistance heating wire is led out from the lower end of the powder heating tube assembly 12 along the outer wall of the outer ceramic tube 13. Meanwhile, a first lead 7 of the heating power supply 6 is connected to a first connecting terminal of the resistance heating wire, a second lead 8 of the heating power supply 6 is connected to a second connecting terminal of the resistance heating wire, the output power of the heating power supply 6 is 10kw-100kw, the output voltage is 0-70V, the preferable output power is 10-30kw, and the output voltage is 20-50V, and the first lead 7 and the second lead 8 are both made of a cable or a copper pipe through which cooling water is introduced, and the preferable copper pipe is made of the copper pipe. The metal powder in the inner ceramic tube 15 is heated by the resistance heating wire based on the resistance heating effect.
The invention further provides a brand-new ultra-high speed laser cladding method based on the ultra-high speed laser cladding system, and the method specifically comprises the following steps:
step one, placing normal-temperature metal powder 9 into a powder feeder 10 and starting the powder feeder 10, wherein the normal-temperature metal powder 9 flows to an inner ceramic tube 15 in a powder heating tube assembly 12 through a powder feeding tube 11 due to the action of gravity or the blowing force of powder feeding air;
wherein, as mentioned above, the powder feeder 10 is a gravity powder feeder or an air-borne powder feeder, the powder feeding rate is 0-500g/min, preferably 0-300g/min, and the powder feeding rate is adjustable. The powder feeder 10 is connected with the inner ceramic tube through a powder feeding tube 11, and the powder feeding tube 11 is a hose or a hard tube, preferably a hose. The powder heating pipe assembly 12 is composed of an outer ceramic pipe 13, an electromagnetic heating component 14 and an inner ceramic pipe 15. The outer ceramic tube 13 is made of a high temperature resistant, insulating ceramic material such as zirconia or alumina. The electromagnetic heating component 14 is made of an electromagnetic induction coil or a resistance heating wire. The inner ceramic tube 15 is made of high temperature resistant and insulating ceramic materials such as chromium oxide or aluminum oxide, a powder feeding channel is formed inside, the inner diameter of the powder feeding channel is 0.5-2mm, preferably 0.8-1.2mm, and the roughness of the inner surface of the powder feeding channel is Ra3.2-Ra0.05, preferably Ra1.6-Ra0.2.
Secondly, a heating power supply 6 is started, when an electromagnetic induction coil is selected as the electromagnetic heating component 14, the normal-temperature metal powder 9 flowing through a powder feeding passage of the inner ceramic tube 15 is heated into high-temperature metal powder 2 under the action of electromagnetic induction through an alternating magnetic field generated by high-frequency alternating current, when a resistance heating wire is selected as the electromagnetic heating component 14, after current flows through the resistance heating wire 14, resistance heat is generated when the current flows, the resistance heat further heats the inner ceramic tube 15, and the heated inner ceramic tube 15 heats the passing metal powder 9, so that the high-temperature metal powder 2 is formed;
step three, the heated high-temperature metal powder 2 and the laser beam 1 are converged at a molten pool 3, the molten pool is formed on the surface of the base material 5 after the high-temperature metal powder is rapidly melted by the laser beam 1, and the molten pool 3 and the base material 5 are relatively moved according to a preset path, so that a cladding layer 4 is formed on the surface of the base material 5.
Wherein the power of the laser beam 1 is 500-20000W, preferably 3000-6000W, as described above. The laser beam 1 forms a circular spot with a diameter of 0.5-10mm or a rectangular spot with a width of 0.5-4mm and a length of 2-50mm, preferably a circular spot with a diameter of 1.5-4mm, at the melt pool 3. The angle between the laser beam 1 and the powder heating tube assembly 12 is between 10 ° and 60 °, preferably between 15 ° and 45 °, and a plurality of powder heating tube assemblies 12 may be symmetrically arranged around the laser beam. The extension line of the inner ceramic tube 15 and the laser beam 1 converge at the position of the molten pool 3, and the distance between the molten pool 3 and the end surface of the inner ceramic tube is 5-20mm, preferably 10-15 mm. The temperature of the heated high-temperature metal powder 2 is 200 ℃ to 2000 ℃, preferably 500 ℃ to 1200 ℃.
According to the method, the powder heating pipe assembly and the heating power supply are innovatively arranged, so that the metal powder is heated to a high temperature even to be melted, the powder can be melted by using very small laser power in a very short time, and the cladding efficiency is greatly improved. And the heated powder can improve the utilization rate of laser energy and reduce laser reflection, thereby minimizing the adverse effect caused by laser reflection in the laser cladding process. The powder heating process can also decompose and volatilize moisture, dust and the like adsorbed on the surface of the powder, and the quality of the laser cladding layer is improved. The invention solves the problems of low efficiency, low cladding quality, large reflected light hazard and the like of the traditional laser cladding technology, and has very wide industrial application prospect.
Example 1
Embodiment 1 is based on the embodiment that the heating of electromagnetic heating subassembly carries out laser cladding to hydraulic support hydro-cylinder piston rod.
1. The embodiment is the surface laser cladding of a hydraulic support oil cylinder piston rod (hereinafter referred to as a piston rod), the diameter of the piston rod is 260mm, the length of a cladding area is 1900mm, and the material is 27 SiMn.
2. According to the ultrahigh-speed laser cladding scheme of the piston rod in the embodiment, a 4Kw laser beam is adopted, a light spot converged at the position of a molten pool is a circular light spot with the diameter of 3mm, the included angle between the laser beam and the inner ceramic tube is adjusted to be 25 degrees, and the distance between the molten pool and the end face of the inner ceramic tube is 13 mm.
3. Selecting an air-borne disc type powder feeder, selecting 304L stainless steel powder with the powder granularity of 45-150um, loading the powder into the powder feeder, starting the powder feeder, and adjusting the powder feeding flow of the powder feeder to be 150 g/min.
4. The heating power supply with the output power of 50kw and the alternating current frequency of 1000khz is selected, the heating power supply is started, the induced current is adjusted to be 100A, the electromagnetic heating assembly starts to perform electromagnetic induction heating on the metal powder flowing through the inner ceramic tube, and the temperature of the heated high-temperature metal powder is 900 ℃ after the powder flows out of the inner ceramic tube.
5. The relative motion between the system and the piston rod is set to be spiral circular motion, the rotating speed of the piston rod is 14.7r/min, and the spiral feeding is 1.5 mm.
6. After the system runs for 1 hour and 26 minutes, the piston rod finishes laser cladding.
According to the scheme of the embodiment, the thickness of the cladding layer obtained on the piston rod is 1.1mm, the cladding efficiency is 1.08 square meters per hour, which is 2.7-7.2 times of that of the traditional laser cladding, and the dilution rate of the cladding layer is 0.8% by measuring the components of the cladding layer and sampling and observing the microstructure. The obtained cladding layer is flat and smooth, the interior of the cladding layer is compact and free of defects, the cladding layer is well combined with the base material, and the requirement of laser cladding on the surface of the piston rod of the hydraulic support oil cylinder is completely met.
Example 2
1. The embodiment is the surface laser cladding of a hydraulic support oil cylinder piston rod (hereinafter referred to as a piston rod), the diameter of the piston rod is 260mm, the length of a cladding area is 1900mm, and the material is 27 SiMn.
2. According to the ultrahigh-speed laser cladding scheme of the piston rod in the embodiment, a 4Kw laser beam is adopted, a light spot converged at the position of a molten pool is a circular light spot with the diameter of 3mm, the included angle between the laser beam and the inner ceramic tube is adjusted to be 25 degrees, and the distance between the molten pool and the end face of the inner ceramic tube is 13 mm.
3. Selecting an air-borne disc type powder feeder, selecting 304L stainless steel powder with the powder granularity of 45-150um, loading the powder into the powder feeder, starting the powder feeder, and adjusting the powder feeding flow of the powder feeder to be 150 g/min.
4. The power supply with the output power of 30kw and the output voltage of 0-70V is selected, the power supply is started, the voltage is adjusted to 36V, current passes through the resistance heating wire 14, resistance heat is generated when the current flows due to the fact that the resistance heating wire has high resistance, the inner ceramic tube 15 is further heated by the resistance heat, the metal powder 9 passing through is heated by the heated inner ceramic tube 15, and therefore the heated metal powder 2 is formed, and the detection temperature of the heated metal powder is 600 ℃.
5. The relative motion between the system and the piston rod is set to be spiral circular motion, the rotating speed of the piston rod is 12r/min, and the spiral feeding is 1.5 mm.
6. After the system runs for 1 hour and 45 minutes, the piston rod finishes laser cladding.
According to the scheme of the embodiment, the thickness of the cladding layer obtained on the piston rod is 1.1mm, the cladding efficiency is 0.89 square meter/h, which is 2.2-5.9 times of that of the traditional laser cladding, and the dilution rate of the cladding layer is 0.7% by measuring the components of the cladding layer and sampling and observing the microstructure. The obtained cladding layer is flat and smooth, the interior of the cladding layer is compact and free of defects, the cladding layer is well combined with the base material, and the requirement of laser cladding on the surface of the piston rod of the hydraulic support oil cylinder is completely met.
The above description is only for the preferred embodiment of the present invention, and the technical solution of the present invention is not limited thereto, and any known modifications made by those skilled in the art based on the main technical idea of the present invention belong to the technical scope of the present invention, and the specific protection scope of the present invention is subject to the description of the claims.
Claims (10)
1. An ultra-high speed laser cladding system, comprising: the laser device comprises a laser device for generating a laser beam (1), a heating power supply (6), a powder feeder (10) and a powder heating pipe assembly (12), wherein the powder heating pipe assembly (12) consists of an outer ceramic pipe (13), an electromagnetic heating component (14) and an inner ceramic pipe (15), the inner ceramic pipe (15) is arranged in the outer ceramic pipe (13), and the electromagnetic heating component (14) is arranged between the inner ceramic pipe (15) and the outer ceramic pipe (13); the heating power supply (6) is connected to the electromagnetic heating assembly (14) through a lead; the powder feeder (10) is communicated with the inner ceramic tube (15) through a powder feeding tube (11), and after the normal-temperature metal powder (9) in the powder feeder enters the inner ceramic tube (15) through the powder feeding tube (11), the normal-temperature metal powder is heated into high-temperature metal powder in the inner ceramic tube (15) by the electromagnetic heating assembly (14); the extension lines of the laser beam (1) and the inner ceramic tube (15) are intersected at a molten pool (3) on the surface of a workpiece to be clad.
2. Ultra high speed laser cladding system according to claim 1, wherein the power of said laser beam (1) is 500-; the temperature of the high-temperature metal powder is 200-2000 ℃.
3. The ultra-high speed laser cladding system according to claim 1 or 2, wherein the powder feeder (10) is a gravity powder feeder or an air-carrying powder feeder, the powder feeding rate is adjustable between 0g/min and 500g/min, the powder feeder (10) is connected with the inner ceramic tube through a powder feeding tube (11), and the powder feeding tube (11) is a flexible tube or a hard tube.
4. Ultra high speed laser cladding system according to any one of claims 1 to 3, wherein the angle between the central axis of the laser beam (1) and the central axis of the powder heating tube assembly (12) is between 10 ° and 60 °, and the distance between the front end face of the inner ceramic tube and the melt pool is between 5mm and 20 mm.
5. The ultra-high speed laser cladding system according to any one of claims 1 to 4, wherein the inner ceramic tube (15) and the outer ceramic tube (13) each have a cylindrical tubular structure, the outer ceramic tube (13) is made of zirconia ceramic material or alumina ceramic material, the inner ceramic tube (15) is made of chromia ceramic material or alumina ceramic material, a powder feeding channel is formed in the center of the inner ceramic tube (15), the powder feeding channel is a circular tube channel, the inner diameter size is 0.5-2mm, the inner surface roughness is Ra3.2-Ra0.05, and the powder feeding channel is communicated with the powder feeding tube (11); the electromagnetic heating assembly (14) is wound on the outer wall of the inner ceramic tube (15) between the inner ceramic tube (15) and the outer ceramic tube (13), a first wiring terminal of the electromagnetic heating assembly (14) is led out along the outer wall of the inner ceramic tube (15), and a second wiring terminal of the electromagnetic heating assembly (14) is led out along the outer wall of the outer ceramic tube (13); heating power supply (6) through first wire (7) connect in first binding post, heating power supply (6) through second wire (8) connect in second binding post.
6. The ultra-high speed laser cladding system according to claim 5, wherein the electromagnetic heating assembly (14) adopts an induction heating coil, the induction heating coil is made of a hollow copper pipe, cooling water is filled in the hollow copper pipe, the heating power supply is a medium-frequency or high-frequency heating power supply with the output power of 1kw-200kw and the alternating current frequency of 100khz-2000khz, and the output current is adjustable at 0-500A; the first lead (7) and the second lead (8) are both cables or copper pipes which are filled with cooling water.
7. The ultra-high-speed laser cladding system according to claim 5, wherein the electromagnetic heating assembly (14) adopts a resistance heating wire, the resistance heating wire is a nickel-chromium alloy resistance wire or an iron-chromium-aluminum alloy resistance wire, the diameter of the resistance heating wire is 0.5-3mm, the output power of the heating power supply is 10-100 kw, and the output voltage is 0-70V; the first lead (7) and the second lead (8) are both cables or copper pipes which are filled with cooling water.
8. Ultra high speed laser cladding system according to any one of claims 5 to 7, wherein said powder heating tube assembly (12) comprises a plurality of sets of powder heating tube assemblies (12) symmetrically arranged around the laser beam (1).
9. An ultra high speed laser cladding method based on the ultra high speed laser cladding system according to any one of claims 1 to 8, comprising the steps of:
placing normal-temperature metal powder (9) into a powder feeder (10) and starting the powder feeder (10), wherein the normal-temperature metal powder (9) flows to an inner ceramic tube (15) in a powder heating tube assembly (12) through a powder feeding tube (11) due to the action of gravity or the blowing force of powder feeding air;
step two, a heating power supply (6) is started, and the electromagnetic heating assembly heats the normal-temperature metal powder flowing through the inner ceramic tube (15) to become high-temperature metal powder;
step three, converging the high-temperature metal powder (2) output from the front end face of the inner ceramic tube (15) and the laser beam (1) on the surface of the workpiece to be clad, melting the high-temperature metal powder by the laser beam (1) to form a molten pool on the surface of the workpiece to be clad, and enabling the molten pool (3) and the workpiece to be clad to move relatively according to a preset path, so that a laser cladding layer is formed on the surface of the workpiece to be clad.
10. The ultra high speed laser cladding method according to claim 9,
when the electromagnetic heating assembly selects a resistance heating wire, the normal-temperature metal powder flowing through the inner ceramic tube is heated into high-temperature metal powder through resistance heat generated by the resistance heating wire through current, and the temperature of the high-temperature metal powder is 200-2000 ℃;
in the third step, the power of the laser beam is 500-20000w, and the laser beam forms a circular light spot with the diameter of 0.5-10mm or a rectangular light spot with the width of 0.5-4mm and the length of 2-50mm at the molten pool, the included angle between the laser beam and the powder heating pipe assembly is 10-60 degrees, and the distance between the molten pool and the front end face of the ceramic pipe in the molten pool is 5-20 mm.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112620656A (en) * | 2021-01-12 | 2021-04-09 | 无锡科技职业学院 | Novel processing mechanism and process for metal wire fused deposition |
| CN114438491A (en) * | 2022-02-17 | 2022-05-06 | 安徽铭谷激光智能装备科技有限公司 | Laser cladding high-entropy alloy special machine tool equipment |
| CN115433937A (en) * | 2022-08-26 | 2022-12-06 | 同济大学 | Device and method for magnetic field assisted ultrahigh-speed laser cladding of iron-based amorphous coating |
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| CN110747467A (en) * | 2019-11-29 | 2020-02-04 | 浙江工业大学 | Laser rapid cladding process and device based on electromagnetic induction heating |
| CN213739680U (en) * | 2020-09-25 | 2021-07-20 | 陕西天元智能再制造股份有限公司 | Superspeed laser cladding system |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN110747467A (en) * | 2019-11-29 | 2020-02-04 | 浙江工业大学 | Laser rapid cladding process and device based on electromagnetic induction heating |
| CN213739680U (en) * | 2020-09-25 | 2021-07-20 | 陕西天元智能再制造股份有限公司 | Superspeed laser cladding system |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112620656A (en) * | 2021-01-12 | 2021-04-09 | 无锡科技职业学院 | Novel processing mechanism and process for metal wire fused deposition |
| CN114438491A (en) * | 2022-02-17 | 2022-05-06 | 安徽铭谷激光智能装备科技有限公司 | Laser cladding high-entropy alloy special machine tool equipment |
| CN115433937A (en) * | 2022-08-26 | 2022-12-06 | 同济大学 | Device and method for magnetic field assisted ultrahigh-speed laser cladding of iron-based amorphous coating |
| CN115433937B (en) * | 2022-08-26 | 2024-03-26 | 同济大学 | Device and method for cladding iron-based amorphous coating by using magnetic field assisted ultra-high speed laser |
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