CN112045186A - Method and tool for repairing tip of cast isometric crystal high-temperature alloy turbine rotor blade - Google Patents
Method and tool for repairing tip of cast isometric crystal high-temperature alloy turbine rotor blade Download PDFInfo
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- CN112045186A CN112045186A CN202010912911.7A CN202010912911A CN112045186A CN 112045186 A CN112045186 A CN 112045186A CN 202010912911 A CN202010912911 A CN 202010912911A CN 112045186 A CN112045186 A CN 112045186A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
- B22F2007/068—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts repairing articles
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Abstract
The invention belongs to the technical field of maintenance of aero-engines, and relates to a method and a tool for repairing a cast isometric crystal high-temperature alloy turbine rotor blade tip, wherein the method adopts a selective laser melting or selective electron beam melting process to complete repair, the blade can be placed in a selective laser melting or selective electron beam melting equipment forming area by means of the tool and is formed at the blade tip, data are obtained through three-dimensional scanning to perform reverse modeling to obtain a model needing to be repaired and formed and relevant position information, and the corresponding tool and the blade clamp are designed, the structure and the form of the tool are not limited, and the tool can be used for completing the blade clamp, assisting positioning and position calibration; printing, repairing and forming are carried out after positioning and calibration, and finally post-processing and detection are completed; the positioning precision of blade repair is well controlled, and the method has the advantages of small heat input, fine crystal grains, good mechanical property, small deformation, good surface roughness, high dimensional precision, no need of machining in near-net forming, high forming speed and high forming efficiency and the like.
Description
Technical Field
The invention belongs to the technical field of maintenance of aero-engines, relates to repair of parts at the hot end of an engine, and particularly relates to a method and a tool for repairing a cast isometric crystal high-temperature alloy turbine rotor blade tip.
Background
The tip part of the cast isometric crystal superalloy turbine rotor blade is extremely easy to damage under high temperature and high pressure of the working environment, and a large amount of tip repairing work is needed. The traditional repairing method is to adopt welding processes such as laser welding and the like to build up welding on the top of the blade, then machine and polish the blade to remove redundant materials, and then the repairing is finished. The method has the problems of large welding deformation, large influence of heat input on the structure performance of the blade, poor surface roughness, poor size precision, large machining difficulty, low efficiency, high cost and the like. Therefore, a new blade tip repairing method is urgently needed to solve the problems. Selective Laser Melting (SLM) and selective Electron Beam Melting (EBM) are novel additive manufacturing processes, have the advantages of small heat input, fine crystal grains, good mechanical properties, small deformation, good surface roughness, high dimensional accuracy, no need of machining in near-net forming, high forming speed and high forming efficiency and the like, and the selective laser melting and selective electron beam melting are applied to blade tip repair to solve various problems of the traditional repair method. However, selective laser melting and selective electron beam melting are processes for directly manufacturing parts, and no method for repairing parts exists before, and a plurality of problems need to be overcome when the method is used for repairing blade tips: the part is difficult to clamp and position, the part interferes with the equipment process, a repaired part does not have a three-dimensional digital model, laser and electron beams are difficult to accurately position in a repaired area during part printing, a printing material is combined with a base material, and the like.
Disclosure of Invention
The purpose of the invention is: the repair method and the repair tool for the blade tips of the cast isometric crystal high-temperature alloy turbine rotor blades realize the technical breakthrough of applying selective laser melting and selective electron beam melting to part repair, exert the advantages of high selective melting size precision, small deformation, good surface roughness, high speed and the like, well control the positioning precision of blade repair, and improve the efficiency and the quality of repair work.
In order to solve the technical problem, the technical scheme of the invention is as follows:
on one hand, the repair method for the cast isometric crystal superalloy turbine rotor blade tip is provided, and the repair method utilizes selective laser melting or selective electron beam melting to repair the cast isometric crystal superalloy turbine rotor blade tip; powder is spread on the surface of the blade tip of the blade layer by layer through laser selective melting equipment or electron beam selective melting equipment, and laser or electron beam scanning forming is utilized; comprises the following steps:
step one, tool design and blade clamping: the tool is arranged on a mounting substrate of selective laser melting equipment or selective electron beam melting equipment, clamps and assists in positioning the blade, and calibrates the position of the blade; and assisting selective laser melting or selective electron beam melting to repair the blade tips;
step two, surface grinding: fixing the blade on a tool, and grinding the blade to be flush with the top of the tool;
step three, three-dimensional scanning: the blade and the tool which are kept in a clamping state are integrally scanned in three dimensions to obtain complete point cloud data, and the relative positions of the blade and the tool are measured and determined;
step four, reverse modeling: performing geometric reconstruction by using the point cloud data, performing reverse modeling to obtain a three-dimensional digital model of the blade and the tool, and establishing a three-dimensional model of a part to be repaired at the blade tip to be repaired at the top of the blade;
fifthly, printing space positioning: completing printing space positioning of the three-dimensional digital models of the blade and the tool in model processing software of a laser selective melting or electron beam selective melting process, and setting the three-dimensional model of the part to be repaired of the blade tip as a printing part;
step six, repair material selection and process parameter setting:
materials: high-temperature alloy powder with the granularity range of 10-80um is melted in a laser selection area; the electron beam selective area melts the high-temperature alloy powder with the granularity range of 40-150 um;
the technological parameters are as follows: the thickness of the laser selective melting powder layer is 20-90um, the thickness of the electron beam selective melting powder layer is 60-200um, and the parameters adopted by the main body part of the blade tip repairing printing are as follows: the laser power is 80-180W, the laser scanning speed is 400-1200mm/s, and the scanning line interval is 0.08-0.16 mm; and (3) melting and repairing the printed main body part in the selected area of the blade tip electron beam by adopting the following parameters: the preheating temperature of the electron beam is 900-;
step seven, position calibration: measuring the position deviation between the actual position of the position calibration graph and the position in the software printing space, compensating the deviation back to the software printing space, and adjusting the position of the three-dimensional model of the blade tip repairing part;
step eight, printing, repairing and forming: guiding data into selective laser melting or selective electron beam melting equipment, installing the blade together with a tool, operating the equipment to finish leveling, powder laying and printing, printing a part to be repaired of the blade tip on the top of the blade, and repairing the blade tip;
step nine, post-processing: and milling, grinding, polishing or sand blasting the repair area to ensure that the surface quality of the repair area meets the blade repair requirement.
The repairing method also comprises the following steps of detecting the repaired part of the blade tip: and detecting whether the repaired part of the blade tip of the blade has defects by using nondestructive detection methods such as industrial CT, X-ray photography, penetration detection, forming process monitoring, ultrasonic detection and the like.
3. And step two, surface grinding adopts any one of the following modes:
a. clamping the blade and the tool and then grinding;
b. the blade and the tool are ground respectively and then clamped, so that the tops of the ground blade and the tool are located on the same plane.
And in the third step, the relative positions of the blade and the tool are determined by measuring the distance and angle data between the blade and the tool and between the blade and each part of the tool.
And step three, carrying out three-dimensional scanning when the blade is clamped by the tool and is not installed in the selective laser melting equipment or selective electron beam melting equipment, or carrying out three-dimensional scanning when the blade is clamped by the tool and is installed in the equipment.
And fifthly, adjusting the coordinates of the blade and the tool in a printing space coordinate system of the software by using the relative positions of the blade and the tool obtained in the third step, keeping the relative positions, aligning the tool with the substrate plane of the printing space in the direction X, Y, and aligning the top surface of the blade tip of the blade with the substrate plane of the printing space in the Z direction.
On the other hand, provide a brilliant superalloy turbine rotor blade apex of casting equiaxial and restore frock, it contains to restore the frock: comprises a base block 1, a base plate base 2, a bolt 3 and a locking block 4;
the height of the base block 1 is equal to the height of the blade tip after the clamping, the base block is welded and fixed on the surface of the base plate base, and the included angle of the two base blocks is a 90-degree right angle;
the length and the width of the substrate base 2 are equal to the length and the width of the cross section of a forming cabin of selective laser melting or selective electron beam melting equipment, sink grooves matched with the locking blocks 4 are uniformly distributed in the substrate base 2, and meanwhile, threaded holes fixedly matched with the bolts 3 and the locking blocks 4 are formed in the substrate base 2;
the bolt 3 is used for clamping and fixing the blade by matching the substrate base 2 and the locking block 4;
the height of the locking block 4 is equal to the thickness of the base plate, and a bolt hole matched with the bolt 3 is formed in the middle of the locking block and used for clamping and fixing a clamping tool of the blade.
Preferably, the thickness of the substrate base 2 is more than or equal to 35 mm.
Preferably, the tool and the components thereof are made of metal materials such as 304 and 316L stainless steel or GH3536 high-temperature alloy.
The invention has the beneficial effects that:
the present invention is applicable to all types of aircraft engine turbine rotor blades, including but not limited to: turbofan engines, turbo-propeller engines, turboshaft engines, turbojet engines, and the like.
The method is suitable for repairing all grades of aeroengine turbine rotor blades of cast isometric crystal high-temperature alloy.
The repair material of the invention is selected to be suitable for all grades of cast isometric crystal high-temperature alloy.
Both Selective Laser Melting (SLM) and selective Electron Beam Melting (EBM) are suitable for use in the present invention.
The turbine blade is clamped by the special tool designed, the outstanding problems of difficult repair area positioning, easy unfused repair interface and air hole defects and the like existing when the blade tip is repaired by the selective laser melting and selective electron beam melting technology are solved, and the problem that the repair part has no three-dimensional digifax is solved by the three-dimensional scanning and reverse modeling technology of the part, so that the selective laser melting and selective electron beam melting technology is successfully applied to the repair of the blade tip of the cast isometric crystal high-temperature alloy turbine blade, and the limitation that the selective melting technology can only be used for part manufacturing and cannot be used for part repair is broken through.
Compared with the existing turbine blade tip damage repair technology (such as laser direct deposition, argon arc welding, micro-beam plasma arc welding and the like), the Selective Laser Melting (SLM) and selective Electron Beam Melting (EBM) repair method has the advantages of small heat input, small near-net-shape machining allowance, capability of repairing a plurality of blades (20-40 pieces) at one time and the like, so that the repair joint has the advantages of fine grains, no deformation, good mechanical property, high size precision and the like, and the repair efficiency and quality of the turbine blade tip damage can be greatly improved.
Drawings
In order to more clearly illustrate the technical solution of the present invention, the drawings used in the embodiment of the present invention will be briefly explained. It is obvious that the drawings described below are only some embodiments of the invention, and that for a person skilled in the art, other drawings can be obtained from these drawings without inventive effort.
FIG. 1 is a schematic view of a tooling structure;
FIG. 2 is a schematic view of a fixture clamping a blade;
FIG. 3 is a schematic structural view of a three-dimensional model of a tip repair portion;
FIG. 4 is a schematic view of a print location block;
wherein, the device comprises a base block 1, a base plate 2, a bolt 3, a locking block 4, a blade 5 and a positioning block 6.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention. It is to be understood that the embodiments described are only a few embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Features of various aspects of embodiments of the invention will be described in detail below. In the following detailed description, numerous specific details are set forth in order to provide a 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 these specific details. The following description of the embodiments is merely intended to better understand the present invention by illustrating examples thereof. The present invention is not limited to any particular arrangement or method provided below, but rather covers all product structures, any modifications, alterations, etc. of the method covered without departing from the spirit of the invention.
In the drawings and the following description, well-known structures and techniques are not shown to avoid unnecessarily obscuring the present invention.
Detailed description of the preferred embodiment
Repairing tip abrasion damage of isometric crystal high-temperature alloy turbine blades cast by a certain type of engine K4002 by adopting EOS M290 laser selective melting (SLM) equipment, and specifically comprising the following steps:
s1, tool design and blade clamping: a tool is designed to assist in blade positioning, clamping and Selective Laser Melting (SLM) repair. The designed tool appearance and clamping mode are shown in figures 1 and 2.
Referring to fig. 1 to 4, the tooling of the present invention includes a base block 1, a base plate 2, a bolt 3 and a locking block 4.
The base blocks 1 are 150mm (length) x 50mm (width) x 120mm (height), are welded on the surface of the base plate base, and are placed at a right angle of 90 degrees in an included angle;
the size of the base plate base 2 is 252mm (length) multiplied by 252mm (width) multiplied by 45mm (thickness), the base plate base is provided with M5 threaded holes which can be matched with bolts 3 and locking blocks 4 to fix the blade, and meanwhile, four corners of the base plate base are provided with M8 threaded holes which can be connected with an equipment forming cabin lifting platform by bolts;
the bolt 3 is an M5 standard bolt and is used for clamping and fixing the blade by matching with the substrate base 2 and the locking block 4;
the height of the locking block 4 is 40mm, the width of the locking block is consistent with the width of the blade edge plate, and an M5 bolt hole is formed in the middle of the locking block and used for clamping and fixing the blade by matching the substrate base 2 and the bolt 3;
the tool and the components thereof are made of 316L stainless steel.
S2, surface grinding: after the blade is fixed on a tool, the blade and the top of the base block are ground and leveled by a grinding machine, the surface roughness reaches Ra1.6um after grinding, the flatness reaches 0.1mm, the blade and the tool can be respectively ground and then clamped, and the top of the blade and the top of the base block after grinding are required to be positioned on the same plane.
S3, three-dimensional scanning: and (3) carrying out three-dimensional scanning on the blade and the tool which are kept in a clamping state integrally to obtain complete point cloud data, measuring data such as distances and angles between the blade and each side surface of the base block, measuring data such as distances and angles between each side surface of the base block and each side surface of the base plate base, and determining relative positions of the blade, the base block and the base plate base. The measured data may be a variety of different kinds of data including, but not limited to, distance, angle data.
S4, reverse modeling: and (3) carrying out noise point removal, surface smoothing and geometric reconstruction on point cloud data obtained by three-dimensional scanning, completing reverse modeling, obtaining a three-dimensional digital model of the blade and the tool, and designing a three-dimensional model of a repaired part at the blade tip needing to be repaired on the top of the blade by using three-dimensional modeling software.
S5, printing space positioning: and (3) introducing the three-dimensional digital models of the blade and the tool into model processing software of a laser selective melting (SLM) process, adjusting the coordinates of the blade, the base block and the base plate in a printing space coordinate system of the software by using the relative positions among the blade, the base block and the base plate base obtained in S3, keeping the relative positions of the blade, the base block and the base plate base, aligning the base plate base with a base plate plane of a printing space in the direction X, Y, aligning the top surface of the base block with the base plate plane of the printing space in the direction Z, positioning the printing space of the three-dimensional digital models of the blade and the tool in the model processing software, and setting the three-dimensional model of the blade tip repairing part as a printing part.
S6, repair material selection and process parameter setting:
materials: selective Laser Melting (SLM) of isometric crystal superalloy powder cast by K4002 with a grain size range of 10-80 um;
the technological parameters are as follows: different parameters are selected according to different grades of materials, the thickness of a Selective Laser Melting (SLM) powder layer is 45um, and the parameters adopted by a main body part of the blade tip repairing printing are as follows: the laser power is 100W, the laser scanning speed is 1200mm/s, and the scanning line spacing is 0.10 mm.
S7, position calibration: the method comprises the steps of installing a blade and a tool in a laser selective melting (SLM), enabling the installation position to be consistent with the installation position of a substrate required by equipment, using model processing software and equipment of the laser selective melting (SLM) process, printing a position calibration graph, namely a positioning block, on the surface of a base block, enabling the shape, the size and the number of the positioning block to be unlimited, facilitating measurement, measuring the position of the positioning block in a software printing space and the actual position of the positioning block on the base block after printing, calculating position deviation, compensating the deviation back to the software printing space, and correspondingly adjusting the position of a three-dimensional model of a blade tip repairing part.
S8, printing, repairing and forming: and finishing the slicing processing and the process parameter setting of the three-dimensional model of the blade tip repairing part, importing the data into laser selective melting (SLM) equipment, and installing the blade and the tool in the laser selective melting (SLM) equipment, wherein the installation position is consistent with the installation position of the substrate required by the equipment. And the operation equipment finishes leveling, powder spreading and printing, and prints the repaired part of the blade tip on the top of the blade to realize the repair of the blade tip.
S9, post-processing: and taking the repaired blade down from the tool, and milling, grinding, polishing or sandblasting the repaired area to ensure that the surface quality of the repaired blade meets the blade repairing requirement.
S10, detection: and detecting whether the repaired part of the blade tip of the blade has defects by using nondestructive detection methods such as industrial CT, X-ray photography, penetration detection, forming process monitoring, ultrasonic detection and the like.
Specific example II
The method adopts Arcam A2X electron beam selective melting (EBM) equipment to repair tip abrasion damage of isometric crystal high-temperature alloy turbine blades cast by K4002 of certain engines, and comprises the following specific steps:
s1, tool design and blade clamping: a tool is designed to assist in blade positioning, clamping and electron beam selective melting (EBM) repair. The designed tool appearance and clamping mode are shown in figures 1 and 2.
Referring to fig. 1 to 4, the tooling of the present invention includes a base block 1, a base plate 2, a bolt 3 and a locking block 4.
The base blocks 1 are 150mm (length) x 50mm (width) x 120mm (height), are welded on the surface of the base plate base, and are placed at a right angle of 90 degrees in an included angle;
the size of the base plate base 2 is 252mm (length) multiplied by 252mm (width) multiplied by 45mm (thickness), and the base plate base is provided with an M5 threaded hole which can be matched with the bolt 3 and the locking block 4 to fix the blade;
the bolt 3 is an M5 standard bolt and is used for clamping and fixing the blade by matching with a locking block;
the height of the locking block 4 is 40mm, the width of the locking block is consistent with the width of the blade edge plate, and an M5 bolt hole is formed in the middle of the locking block and used for clamping and fixing the blade by matching the substrate base 2 and the bolt 3;
the tool and the components thereof are made of GH3536 high-temperature alloy.
S2, surface grinding: after the blade is fixed on a tool, the blade and the top of the base block are ground and leveled by a grinding machine, the surface roughness reaches Ra1.6um after grinding, the flatness reaches 0.1mm, the blade and the tool can be respectively ground and then clamped, and the top of the blade and the top of the base block after grinding are required to be positioned on the same plane.
S3, three-dimensional scanning: and (3) carrying out three-dimensional scanning on the blade and the tool which are kept in a clamping state integrally to obtain complete point cloud data, measuring data such as distances and angles between the blade and each side surface of the base block, measuring data such as distances and angles between each side surface of the base block and each side surface of the base plate base, and determining relative positions of the blade, the base block and the base plate base. The measured data may be a variety of different kinds of data including, but not limited to, distance, angle data.
S4, reverse modeling: and (3) carrying out noise point removal, surface smoothing and geometric reconstruction on point cloud data obtained by three-dimensional scanning, completing reverse modeling, obtaining a three-dimensional digital model of the blade and the tool, and designing a three-dimensional model of a repaired part at the blade tip needing to be repaired on the top of the blade by using three-dimensional modeling software.
S5, printing space positioning: and (3) introducing the three-dimensional digital models of the blade and the tool into model processing software of an electron beam selective melting (EBM) process, adjusting the coordinates of the blade, the base block and the base plate in a printing space coordinate system of the software by utilizing the relative positions among the blade, the base block and the base plate obtained in S3, keeping the relative positions of the three, aligning the base plate base with a base plate plane of a printing space in the direction X, Y, aligning the top surface of the base block with the base plate plane of the printing space in the direction Z, positioning the printing space of the three-dimensional digital models of the blade and the tool in the model processing software, and setting the three-dimensional model of the blade repairing part as a printing part.
S6, repair material selection and process parameter setting:
materials: electron beam selective melting (EBM) uses K4002 equiaxed high-temperature alloy powder with the granularity range of 40-150 um;
the technological parameters are as follows: different parameters are selected according to different grades of materials, the thickness of an electron beam selective melting (EBM) powder layer is 100um, and the parameters adopted by a main body part of the blade tip repairing printing are as follows: the preheating temperature of the electron beam is 1000 ℃, the beam current of the electron beam is 35mA, the focusing current is 100mA, the scanning speed is 20m/s, and the filling space is 0.50 mm.
S7, position calibration: the method comprises the steps of installing a blade and a tool in electron beam selective melting (EBM) equipment, wherein the installation position is consistent with the installation position of a substrate required by the equipment, using model processing software and equipment of an electron beam selective melting (EBM) process, printing a position calibration graph, namely a positioning block on the surface of a base block, wherein the shape, the size and the number of the positioning block are not limited, and the measurement is convenient.
S8, printing, repairing and forming: and finishing the slicing treatment and the process parameter setting of the three-dimensional model of the blade tip repairing part, introducing the data into electron beam selective area melting (EBM) equipment, and installing the blade and the tool in the electron beam selective area melting (EBM) equipment, wherein the installation position is consistent with the installation position of a substrate required by the equipment. And the operation equipment finishes leveling, powder spreading and printing, and prints the repaired part of the blade tip on the top of the blade to realize the repair of the blade tip.
S9, post-processing: and taking the repaired blade down from the tool, and milling, grinding, polishing or sandblasting the repaired area to ensure that the surface quality of the repaired blade meets the blade repairing requirement.
S10, detection: and detecting whether the repaired part of the blade tip of the blade has defects by using nondestructive detection methods such as industrial CT, X-ray photography, penetration detection, forming process monitoring, ultrasonic detection and the like.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solutions of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily conceive various equivalent modifications or substitutions within the technical scope of the present invention, and these modifications or substitutions should be covered within the scope of the present invention.
Claims (9)
1. A method for repairing the tip of a cast isometric crystal superalloy turbine rotor blade comprises the steps of repairing the tip of the cast isometric crystal superalloy turbine rotor blade by selective laser melting or selective electron beam melting; powder is spread on the surface of the blade tip of the blade layer by layer through laser selective melting equipment or electron beam selective melting equipment, and laser or electron beam scanning forming is utilized; comprises the following steps:
step one, tool design and blade clamping: the tool is arranged on a mounting substrate of selective laser melting equipment or selective electron beam melting equipment, clamps and assists in positioning the blade, and calibrates the position of the blade; and assisting selective laser melting or selective electron beam melting to repair the blade tips;
step two, surface grinding: fixing the blade on a tool, and grinding the blade to be flush with the top of the tool;
step three, three-dimensional scanning: the blade and the tool which are kept in a clamping state are integrally scanned in three dimensions to obtain complete point cloud data, and the relative positions of the blade and the tool are measured and determined;
step four, reverse modeling: performing geometric reconstruction by using the point cloud data, performing reverse modeling to obtain a three-dimensional digital model of the blade and the tool, and establishing a three-dimensional model of a part to be repaired at the blade tip to be repaired at the top of the blade;
fifthly, printing space positioning: completing printing space positioning of the three-dimensional digital models of the blade and the tool in model processing software of a laser selective melting or electron beam selective melting process, and setting the three-dimensional model of the part to be repaired of the blade tip as a printing part;
step six, repair material selection and process parameter setting:
materials: high-temperature alloy powder with the granularity range of 10-80um is melted in a laser selection area; the electron beam selective area melts the high-temperature alloy powder with the granularity range of 40-150 um;
the technological parameters are as follows: selecting different parameters according to different grades of cast high-temperature alloys, wherein the thickness of the melting powder layer in a laser selective area is 20-90um, the thickness of the melting powder layer in an electron beam selective area is 60-200um, and the parameters adopted in the main body part of the blade tip repairing printing are as follows: the laser power is 80-180W, the laser scanning speed is 400-1200mm/s, and the scanning line interval is 0.08-0.16 mm; and (3) melting and repairing the printed main body part in the selected area of the blade tip electron beam by adopting the following parameters: the preheating temperature of the electron beam is 900-;
step seven, position calibration: measuring the position deviation between the actual position of the position calibration graph and the position in the software printing space, compensating the deviation back to the software printing space, and adjusting the position of the three-dimensional model of the blade tip repairing part;
step eight, printing, repairing and forming: guiding data into selective laser melting or selective electron beam melting equipment, installing the blade together with a tool, operating the equipment to finish leveling, powder laying and printing, printing a part to be repaired of the blade tip on the top of the blade, and repairing the blade tip;
step nine, post-processing: and milling, grinding, polishing or sand blasting the repair area to ensure that the surface quality of the repair area meets the blade repair requirement.
2. The method for repairing the tip of the cast isometric crystal superalloy turbine rotor blade according to claim 1, wherein: the repairing method also comprises the following steps of detecting the repaired part of the blade tip: and detecting whether the repaired part of the blade tip of the blade has defects by using nondestructive detection methods such as industrial CT, X-ray photography, penetration detection, forming process monitoring, ultrasonic detection and the like.
3. The method for repairing the tip of the cast isometric crystal superalloy turbine rotor blade according to claim 1, wherein: and step two, surface grinding adopts any one of the following modes:
a. clamping the blade and the tool and then grinding;
b. the blade and the tool are ground respectively and then clamped, so that the tops of the ground blade and the tool are located on the same plane.
4. The method for repairing the tip of the cast isometric crystal superalloy turbine rotor blade according to claim 1, wherein: and in the third step, the relative positions of the blade and the tool are determined by measuring the distance and angle data between the blade and the tool and between the blade and each part of the tool.
5. The method for repairing the tip of the cast isometric crystal superalloy turbine rotor blade according to claim 1, wherein: and step three, carrying out three-dimensional scanning when the blade is clamped by the tool and is not installed in the selective laser melting equipment or selective electron beam melting equipment, or carrying out three-dimensional scanning when the blade is clamped by the tool and is installed in the equipment.
6. The method for repairing the tip of the cast isometric crystal superalloy turbine rotor blade according to claim 1, wherein: and fifthly, adjusting the coordinates of the blade and the tool in a printing space coordinate system of the software by using the relative positions of the blade and the tool obtained in the third step, keeping the relative positions, aligning the tool with the substrate plane of the printing space in the direction X, Y, and aligning the top surface of the blade tip of the blade with the substrate plane of the printing space in the Z direction.
7. The tool for repairing the blade tip of the cast isometric crystal superalloy turbine rotor blade realizes the method for repairing the blade tip of the cast isometric crystal superalloy turbine rotor blade, which is characterized in that: the repair tool comprises: comprises a base block (1), a base plate base (2), a bolt (3) and a locking block (4);
the height of the base block (1) is equal to the height of the blade tip after the clamping, the base block is fixed on the surface of the base plate, and the included angle of the two base blocks is a 90-degree right angle;
the length and the width of the substrate base (2) are equal to the length and the width of the cross section of a forming cabin of laser selective melting or electron beam selective melting equipment, sinking grooves matched with the locking blocks (4) are uniformly distributed in the substrate base (2), and meanwhile, threaded holes fixedly matched with the bolts (3) and the locking blocks (4) are formed in the substrate base (2);
the bolt (3) is used for clamping and fixing the blade by matching the substrate base (2) and the locking block (4);
the height of the locking block (4) is equal to the thickness of the base plate, and a bolt hole matched with the bolt (3) is formed in the middle of the locking block and used for clamping and fixing a clamping tool of the blade.
8. The tool for repairing the blade tip of the cast isometric crystal superalloy turbine rotor blade according to claim 7, wherein the tool comprises: the thickness of the substrate base (2) is more than or equal to 35 mm.
9. The tool for repairing the blade tip of the cast isometric crystal superalloy turbine rotor blade according to claim 7, wherein the tool comprises: the tool and the components thereof are made of 304 and 316L stainless steel or GH3536 high-temperature alloy gold.
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