CN112045186B - Method and tool for repairing blade tip of cast equiaxial-crystal superalloy turbine rotor blade - Google Patents
Method and tool for repairing blade tip of cast equiaxial-crystal superalloy turbine rotor blade Download PDFInfo
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- CN112045186B CN112045186B CN202010912911.7A CN202010912911A CN112045186B CN 112045186 B CN112045186 B CN 112045186B CN 202010912911 A CN202010912911 A CN 202010912911A CN 112045186 B CN112045186 B CN 112045186B
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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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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Turbine Rotor Nozzle Sealing (AREA)
Abstract
The invention belongs to the technical field of aeroengine maintenance, and relates to a repair method and a tool for casting an equiaxed crystal superalloy turbine rotor blade tip, wherein the repair is completed by adopting a laser selective melting or electron beam selective melting process, the blade can be placed in a laser selective melting or electron beam selective melting equipment forming area by means of the tool and formed at the blade tip, a model and relevant position information which need to be repaired and formed are obtained by reversely modeling through three-dimensional scanning acquired data, and corresponding tools and blade clamping are designed, the structure and the form of the tool are not limited, and the tool can be used for completing blade clamping, auxiliary positioning and position calibration; printing, repairing and forming after positioning and calibration, and finally finishing post-treatment and detection; the method has the advantages of good control of the positioning precision of blade repair, small heat input, fine mechanical property of crystal grains, small deformation, good surface roughness, high dimensional precision, no machining in near net forming, quick and efficient forming and the like.
Description
Technical Field
The invention belongs to the technical field of maintenance of aeroengines, relates to repair of engine hot end parts, and particularly relates to a method and a tool for repairing blade tips of cast equiaxed crystal superalloy turbine rotor blades.
Background
The working environment of the cast equiaxed crystal superalloy turbine rotor blade is high temperature and high pressure, the blade tip part is extremely easy to damage, and a large amount of blade tip repair work is required. The traditional repairing method is to build up welding on the top of the blade by adopting welding processes such as laser welding and the like, and then machining and polishing are carried out to remove redundant materials, so that the repairing is completed. The method has the problems of large welding deformation, large heat input, influence on the structural performance of the blade, poor surface roughness, poor dimensional accuracy, large machining difficulty, low efficiency, high cost and the like. There is therefore a great need for a new method of blade tip repair that addresses these problems. The laser selective melting (SLM) and the electron beam selective melting (EBM) are novel additive manufacturing processes, and have the advantages of small heat input, fine crystal grains, good mechanical properties, small deformation, good surface roughness, high dimensional precision, quick and efficient near-net forming without machining, and the like, and various problems of the traditional repairing method can be solved by applying the laser selective melting and the electron beam selective melting to blade tip repairing. However, laser selective melting and electron beam selective melting are processes for directly manufacturing parts, and there is no method for repairing parts before, and many problems need to be overcome for repairing blade tips by using the processes: the clamping and positioning of the parts are difficult, the parts interfere the equipment process, the repairing parts have no three-dimensional die, the laser and the electron beam are difficult to accurately position in the repairing area when the parts are printed, the printing material is combined with the base metal, and the like.
Disclosure of Invention
The purpose of the invention is that: the method and the tool for repairing the blade tip of the cast equiaxed crystal superalloy turbine rotor blade realize the technical breakthrough of using the selective laser melting and the selective electron beam melting for repairing the part, exert the advantages of high selective melting dimensional precision, small deformation, good surface roughness, high speed and the like, well control the positioning precision of blade repair, and improve the efficiency and quality of repair work.
In order to solve the technical problem, the technical scheme of the invention is as follows:
in one aspect, a method for repairing a cast equiaxed grain superalloy turbine rotor blade tip is provided, wherein the method uses laser selective melting or electron beam selective melting to repair the cast equiaxed grain superalloy turbine rotor blade tip; spreading powder layer by layer on the surface of the blade tip of the blade by using laser selective melting equipment or electron beam selective melting equipment, and scanning and forming by using laser or electron beam; comprises the following steps:
step one, designing a tool and clamping a blade: the tool is arranged on a mounting substrate of the laser selective melting equipment or the electron beam selective melting equipment, clamps and assists in positioning the blade, and calibrates the position of the blade; and assisting laser selective melting or electron beam selective melting to repair the blade tip of the blade;
step two, surface grinding: fixing the blade on a tool, and grinding the blade to be flush with the top of the tool;
three-dimensional scanning: carrying out three-dimensional scanning on the blade and the whole tool in the clamping state to obtain complete point cloud data, and measuring and determining the relative positions between the blade and the tool;
fourth, reverse modeling: performing geometric reconstruction by utilizing 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 tip of the blade to be repaired at the top of the blade;
fifthly, positioning a printing space: the method comprises the steps of completing the printing space positioning of a three-dimensional digital model of a blade and a tool in model processing software of a laser selective melting or electron beam selective melting process, and setting the three-dimensional model of a part to be repaired of the blade tip as a printing part;
step six, selecting repair materials and setting technological parameters:
materials: melting high-temperature alloy powder with granularity ranging from 10 um to 80um in a laser selective area; melting high-temperature alloy powder with granularity ranging from 40 to 150 mu m in an electron beam selective area;
technological parameters: the thickness of the laser selective melting powder spreading layer is 20-90um, the thickness of the electron beam selective melting powder spreading layer is 60-200um, and the parameters adopted in the main body part of the blade tip repairing and printing are as follows: the laser power is 80-180W, the laser scanning speed is 400-1200mm/s, and the scanning line spacing is 0.08-0.16mm; and (3) fusing and repairing the printed main body part in the tip electron beam selected area by adopting the following parameters: the preheating temperature of the electron beam is 900-1050 ℃, the beam current of the electron beam is 5-45mA, the focusing current is 40-200mA, the scanning speed is 5-50m/s, and the filling interval is 0.2-1.5mm;
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: the data is led into a laser selective melting or electron beam selective melting device, the blade and the tool are installed, the leveling, the powder spreading and the printing are completed by an operation device, the part to be repaired of the blade tip is printed on the top of the blade, and the blade tip is repaired;
step nine, post-treatment: milling, grinding, polishing or sand blasting is carried out on the repairing area, so that the surface quality of the repairing area meets the requirement of repairing the blade.
The repair method further comprises the step of detecting the repaired part of the blade tip of the blade: and detecting whether the repaired part of the blade tip of the blade has defects or not by using nondestructive detection methods such as industrial CT, X-ray radiography, penetration detection, forming process monitoring, ultrasonic detection and the like.
3. The second surface grinding adopts any one of the following modes:
a. grinding the blades and the fixture after clamping;
b. firstly, respectively grinding the blade and the tool, and then clamping the blade and the tool, so that the tops of the blade and the tool after grinding are positioned on the same plane.
And thirdly, determining the relative positions of the blade and the tool by measuring the distance and angle data between the blade and the tool and between the blade and the tool.
And step three, three-dimensional scanning is performed after the blade is clamped by the tool but not installed in the laser selective melting equipment or the electron beam selective melting equipment, and three-dimensional scanning can also be performed after the blade is clamped by the tool and already installed in the equipment.
And fifthly, adjusting the coordinates of the blade and the tool in a printing space coordinate system of software by utilizing the relative positions of the blade and the tool obtained in the step three, keeping the relative positions of the blade and the tool, aligning the tool with a substrate plane of the printing space in the X, Y direction, and aligning the top surface of the blade tip of the blade with the substrate plane of the printing space in the Z direction.
In another aspect, a repair fixture for casting an equiaxed grain superalloy turbine rotor blade tip is provided, the repair fixture comprising: the device comprises a base block 1, a substrate 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 of the clamped blade, the base block 1 is welded and fixed on the surface of the base plate base, and the included angle of the two base blocks is 90 DEG and the two base blocks are placed at right angles;
the length and width of the base plate 2 are equal to the length and width of the cross section of a forming cabin of the laser selective melting or electron beam selective melting equipment, sinking grooves matched with the locking blocks 4 are uniformly distributed in the base plate 2, and meanwhile, threaded holes for fixedly matching with the bolts 3 and the locking blocks 4 are formed in the base plate 2;
the bolts 3 are used for clamping and fixing the blades by matching with the substrate base 2 and the locking blocks 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 is 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 35mm.
Preferably, the tool and the components thereof are made of 304, 316L stainless steel or GH3536 superalloy and other metal materials.
The beneficial effects of the invention are as follows:
the present invention is applicable to all types of aero-engine turbine rotor blades, including but not limited to: turbofan engines, turboprop engines, turboshaft engines, turbojet engines, and the like.
The method is suitable for repairing the turbine rotor blade of the aeroengine with all grades of cast equiaxed crystal superalloy.
The repairing material is selected to be applicable to casting equiaxed crystal superalloy of all grades.
Laser selective melting (SLM) and electron beam selective melting (EBM) are suitable for use in the present invention.
According to the invention, the turbine blade is clamped by the designed special tool, the outstanding problems that the repair area is difficult to position, the repair interface is easy to have unfused and air hole defects and the like when the blade tip is repaired by the laser selective melting and electron beam selective melting technology are overcome, and the problem that the repair part has no three-dimensional mould is solved by the three-dimensional scanning and reverse modeling technology of the part, so that the laser selective melting and electron beam selective melting technology is successfully applied to the blade tip repair of the cast equiaxial crystal high-temperature alloy turbine blade, and the limitation that the selective melting technology can only be used for part manufacture but not for part repair is broken through.
Meanwhile, 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 laser selective melting (SLM) and electron beam selective melting (EBM) repair method has the advantages of small heat input, small near net forming machining allowance, capability of repairing a plurality of (20-40) blades at one time and the like, so that the repair joint has the advantages of small crystal grains, no deformation, good mechanical property, high dimensional accuracy and the like, and the repair efficiency and quality of turbine blade tip damage can be greatly improved.
Drawings
In order to more clearly illustrate the technical solution of the implementation of the present invention, the following description will briefly explain the drawings that need to be used in the examples of the present invention. It is evident that the drawings described below are only some embodiments of the invention and that other drawings may be obtained from these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of a tooling structure;
FIG. 2 is a schematic view of a tooling clamping 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 positioning block;
wherein, 1-basic block, 2-base plate base, 3-bolt, 4-latch segment, 5-blade, 6-locating piece.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. It will be apparent that the described embodiments are some, but not all, embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without making any inventive effort are intended to fall within the scope of the present invention.
Features of various aspects of embodiments of the invention are described in detail below. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the 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 for a better understanding of the invention by showing examples of the invention. The present invention is not limited to any particular arrangement and method provided below, but covers any modifications, substitutions, etc. of all product constructions, methods, and the like covered without departing from the spirit of the invention.
Well-known structures and techniques have not been shown in detail in the various drawings and the following description in order not to unnecessarily obscure the present invention.
Description of the preferred embodiments
The EOS M290 laser selective melting (SLM) equipment is adopted to repair the blade tip abrasion damage of the equiaxed crystal superalloy turbine blade cast by a certain engine K4002, and the method comprises the following specific steps:
s1, tool design and blade clamping: a tool is designed to assist in blade positioning, clamping and laser selective melting (SLM) repair. The appearance and the clamping mode of the designed tool are shown in fig. 1 and 2.
Referring to fig. 1 to 4, the tooling designed in the present invention includes a base block 1, a substrate base 2, a bolt 3 and a locking block 4.
The size of the base block 1 is 150mm (length) ×50mm (width) ×120mm (height), the base block is welded on the surface of the base plate base, and the two base blocks are placed at a right angle of 90 degrees;
the size of the base plate base 2 is 252mm (length) ×252mm (width) ×45mm (thickness), M5 threaded holes are formed in the base plate base and can be matched with the bolts 3 and the locking blocks 4 to fix the blades, M8 threaded holes are formed in four corners of the base plate base, and the base plate base can be connected with a lifting platform of the equipment forming cabin through bolts;
the bolts 3 are M5 standard bolts and are used for clamping and fixing the blade by matching with the base plate 2 and the locking blocks 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 is used for clamping and fixing the blade by matching the base plate 2 and the bolts 3;
the tool and the components thereof are made of 316L stainless steel.
S2, surface grinding: after the blade is fixed on the tool, the blade is ground and leveled with the top of the base block by a grinder, the surface roughness reaches Ra1.6um after grinding, the flatness reaches 0.1mm, and the blade and the tool can be respectively ground and clamped first, so that the ground blade and the top of the base block are required to be in the same plane.
S3, three-dimensional scanning: and carrying out three-dimensional scanning on the blade and the whole tool in the clamping state to obtain complete point cloud data, measuring the distance, angle and other data between the blade and each side surface of the base block, measuring the distance, angle and other data between each side surface of the base block and each side surface of the base plate base, and determining the relative positions among 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 removing noise from the point cloud data obtained by three-dimensional scanning, smoothing the surface, geometrically reconstructing, completing reverse modeling, obtaining a three-dimensional digital model of the blade and the tool, and designing a three-dimensional model of a repairing part at the tip of the blade needing repairing by utilizing three-dimensional modeling software.
S5, printing space positioning: and (3) guiding the three-dimensional digital model 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 base in a printing space coordinate system of the software by utilizing the relative positions of the blade, the base block and the base plate base obtained in the step (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 a X, Y direction, aligning the top surface of the base block with the base plate plane of the printing space in a Z direction, completing the printing space positioning of the three-dimensional digital model of the blade and the tool in the model processing software, and setting the three-dimensional model of a blade tip repairing part as a printing part.
S6, repairing material selection and process parameter setting:
materials: laser selective melting (SLM) is used for casting equiaxed crystal superalloy powder by using K4002 with granularity ranging from 10 to 80 mu m;
technological parameters: according to different parameters selected by different brands of materials, the thickness of a laser selective melting (SLM) powder paving layer is 45um, and parameters adopted in the main body part of the blade tip repairing and printing are as follows: the laser power is 100W, the laser scanning speed is 1200mm/s, and the scanning line interval is 0.10mm.
S7, position calibration: the blade and the fixture are installed in a laser selective melting (SLM), the installation position is consistent with the installation position of a substrate required by the equipment, model processing software and equipment of the laser selective melting (SLM) process are used, position calibration patterns, namely positioning blocks, are printed on the surface of a base block, the shape, the size and the number of the positioning blocks are not limited, the positioning blocks can be conveniently measured, the positions of the positioning blocks in a software printing space and the actual positions of the positioning blocks on the base block after printing are measured, position deviation is calculated, the deviation is compensated back into the software printing space, and the positions of the three-dimensional models of blade tip repairing parts are correspondingly adjusted.
S8, printing, repairing and forming: and (3) finishing slicing treatment and process parameter setting of the three-dimensional model of the blade tip repairing part, introducing data into laser selective melting (SLM) equipment, and installing the blade and the fixture in the laser selective melting (SLM) equipment, wherein the installation position is consistent with the installation position of a substrate required by the equipment. The operation equipment finishes leveling, powder spreading and printing, and the blade tip repairing part is printed on the top of the blade, so that the blade tip is repaired.
S9, post-processing: and taking the repaired blade off the tool, and milling, grinding, polishing or sandblasting the repaired area to ensure that the surface quality of the repaired area meets the blade repairing requirement.
S10, detecting: and detecting whether the repaired part of the blade tip of the blade has defects or not by using nondestructive detection methods such as industrial CT, X-ray radiography, penetration detection, forming process monitoring, ultrasonic detection and the like.
Examples II
Repairing the blade tip abrasion damage of an equiaxed crystal superalloy turbine blade cast by a certain engine K4002 by adopting Arcam A2X electron beam selective melting (EBM) equipment, and specifically comprising the following steps of:
s1, tool design and blade clamping: a tooling is designed to assist in blade positioning, clamping and electron beam selective melting (EBM) repair. The appearance and the clamping mode of the designed tool are shown in fig. 1 and 2.
Referring to fig. 1 to 4, the tooling designed in the present invention includes a base block 1, a substrate base 2, a bolt 3 and a locking block 4.
The size of the base block 1 is 150mm (length) ×50mm (width) ×120mm (height), the base block is welded on the surface of the base plate base, and the two base blocks are placed at a right angle of 90 degrees;
the size of the base plate base 2 is 252mm (length) ×252mm (width) ×45mm (thickness), and an M5 threaded hole is formed in the base plate base and 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 in cooperation with the 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 is used for clamping and fixing the blade by matching the base plate 2 and the bolts 3;
the tooling and the components thereof are made of GH3536 superalloy.
S2, surface grinding: after the blade is fixed on the tool, the blade is ground and leveled with the top of the base block by a grinder, the surface roughness reaches Ra1.6um after grinding, the flatness reaches 0.1mm, and the blade and the tool can be respectively ground and clamped first, so that the ground blade and the top of the base block are required to be in the same plane.
S3, three-dimensional scanning: and carrying out three-dimensional scanning on the blade and the whole tool in the clamping state to obtain complete point cloud data, measuring the distance, angle and other data between the blade and each side surface of the base block, measuring the distance, angle and other data between each side surface of the base block and each side surface of the base plate base, and determining the relative positions among 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 removing noise from the point cloud data obtained by three-dimensional scanning, smoothing the surface, geometrically reconstructing, completing reverse modeling, obtaining a three-dimensional digital model of the blade and the tool, and designing a three-dimensional model of a repairing part at the tip of the blade needing repairing by utilizing three-dimensional modeling software.
S5, printing space positioning: and (3) guiding the three-dimensional digital model of the blade and the tool into model processing software of an electron beam selective melting (EBM) process, adjusting coordinates of the blade, the base block and the base plate base in a printing space coordinate system of the software by utilizing the relative positions of the blade, the base block and the base plate base obtained in the step (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 a X, Y direction, aligning the top surface of the base block with the base plate plane of the printing space in a Z direction, completing the printing space positioning of the three-dimensional digital model of the blade and the tool in the model processing software, and setting the three-dimensional model of a blade tip repairing part as a printing part.
S6, repairing material selection and process parameter setting:
materials: electron beam selective melting (EBM) using a K4002 equiaxed grain superalloy powder having a particle size range of 40-150 um;
technological parameters: according to different parameters selected by different brands of materials, the thickness of an electron beam selective melting (EBM) powder paving layer is 100um, and the parameters adopted in the main body part of the blade tip repairing and 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 interval is 0.50mm.
S7, position calibration: the method comprises the steps of installing a blade and a tool in electron beam selective melting (EBM) equipment, enabling the installation position to be consistent with the installation position of a substrate required by the equipment, using model processing software and equipment of the electron beam selective melting (EBM) technology, printing position calibration patterns, namely positioning blocks, on the surface of a base block, enabling the shape, the size and the number of the positioning blocks to be unlimited, facilitating measurement, measuring the position of the positioning blocks in a software printing space, measuring the actual position of the positioning blocks 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 (3) finishing the slicing treatment and process parameter setting of the three-dimensional model of the blade tip repairing part, introducing data into electron beam selective melting (EBM) equipment, and installing the blade and the tool in the electron beam selective melting (EBM) equipment, wherein the installation position is consistent with the installation position of a substrate required by the equipment. The operation equipment finishes leveling, powder spreading and printing, and the blade tip repairing part is printed on the top of the blade, so that the blade tip is repaired.
S9, post-processing: and taking the repaired blade off the tool, and milling, grinding, polishing or sandblasting the repaired area to ensure that the surface quality of the repaired area meets the blade repairing requirement.
S10, detecting: and detecting whether the repaired part of the blade tip of the blade has defects or not by using nondestructive detection methods such as industrial CT, X-ray radiography, 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 solution of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily think about various equivalent modifications or substitutions within the technical scope of the present invention, and these modifications or substitutions should be covered in the scope of the present invention.
Claims (7)
1. A repairing method for the blade tip of a cast equiaxed crystal superalloy turbine rotor blade utilizes selective laser melting or selective electron beam melting to repair the blade tip of the cast equiaxed crystal superalloy turbine rotor blade; spreading powder layer by layer on the surface of the blade tip of the blade by using laser selective melting equipment or electron beam selective melting equipment, and scanning and forming by using laser or electron beam; comprises the following steps:
step one, designing a tool and clamping a blade: the tool is arranged on a mounting substrate of the laser selective melting equipment or the electron beam selective melting equipment, clamps and assists in positioning the blade, and calibrates the position of the blade; and assisting laser selective melting or electron beam selective melting to repair the blade tip of the blade;
the repair tooling 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 of the blade after clamping, the base block is fixed on the surface of the base plate base, and the included angle of the two base blocks is 90 DEG and the two base blocks are placed at right angles;
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 the 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 simultaneously, threaded holes for fixedly matching with the bolts (3) and the locking blocks (4) are formed in the substrate base (2);
the bolts (3) are used for clamping and fixing the blades by matching with the substrate base (2) and the locking blocks (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 is used for clamping and fixing a clamping tool of the blade;
step two, surface grinding: fixing the blade on a tool, and grinding the blade to be flush with the top of the tool; the surface grinding adopts any one of the following modes:
a. grinding the blades and the fixture after clamping;
b. firstly, respectively grinding the blade and the tool, and then clamping the blade and the tool so that the tops of the blade and the tool after grinding are positioned on the same plane;
three-dimensional scanning: carrying out three-dimensional scanning on the blade and the whole tool in the clamping state to obtain complete point cloud data, and measuring and determining the relative positions between the blade and the tool;
fourth, reverse modeling: performing geometric reconstruction by utilizing 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 tip of the blade to be repaired at the top of the blade;
fifthly, positioning a printing space: the method comprises the steps of completing the printing space positioning of a three-dimensional digital model of a blade and a tool in model processing software of a laser selective melting or electron beam selective melting process, and setting the three-dimensional model of a part to be repaired of the blade tip as a printing part;
step six, selecting repair materials and setting technological parameters:
materials: melting high-temperature alloy powder with granularity ranging from 10 um to 80um in a laser selective area; melting high-temperature alloy powder with granularity ranging from 40 to 150 mu m in an electron beam selective area;
technological parameters: according to different brands of casting superalloy, different parameters are selected, the thickness of the melting powder layer in the selected area of the laser is 20-90um, the thickness of the melting powder layer in the selected area of the electron beam is 60-200um, and the parameters adopted in the main body part of the tip repair printing are as follows: the laser power is 80-180W, the laser scanning speed is 400-1200mm/s, and the scanning line spacing is 0.08-0.16mm; and (3) fusing and repairing the printed main body part in the tip electron beam selected area by adopting the following parameters: the preheating temperature of the electron beam is 900-1050 ℃, the beam current of the electron beam is 5-45mA, the focusing current is 40-200mA, the scanning speed is 5-50m/s, and the filling interval is 0.2-1.5mm;
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: the data is led into a laser selective melting or electron beam selective melting device, the blade and the tool are installed, the leveling, the powder spreading and the printing are completed by an operation device, the part to be repaired of the blade tip is printed on the top of the blade, and the blade tip is repaired;
step nine, post-treatment: milling, grinding, polishing or sand blasting is carried out on the repairing area, so that the surface quality of the repairing area meets the requirement of repairing the blade.
2. The method of repairing a cast equiaxed grain turbine rotor blade tip of claim 1, wherein: the repair method further comprises the step of detecting the repaired part of the blade tip of the blade: the blade tip repair portion is inspected for defects using industrial CT, radiography, penetration inspection, forming process monitoring, or ultrasonic inspection non-destructive inspection methods.
3. The method of repairing a cast equiaxed grain turbine rotor blade tip of claim 1, wherein: and thirdly, determining the relative positions of the blade and the tool by measuring the distance and angle data between the blade and the tool and between the blade and the tool.
4. The method of repairing a cast equiaxed grain turbine rotor blade tip of claim 1, wherein: and step three, three-dimensional scanning is performed after the blade is clamped by the tool but not installed in the laser selective melting equipment or the electron beam selective melting equipment, and three-dimensional scanning can also be performed after the blade is clamped by the tool and already installed in the equipment.
5. The method of repairing a cast equiaxed grain turbine rotor blade tip of claim 1, wherein: and fifthly, adjusting the coordinates of the blade and the tool in a printing space coordinate system of software by utilizing the relative positions of the blade and the tool obtained in the step three, keeping the relative positions of the blade and the tool, aligning the tool with a substrate plane of the printing space in the X, Y direction, and aligning the top surface of the blade tip of the blade with the substrate plane of the printing space in the Z direction.
6. The method of repairing a cast equiaxed grain turbine rotor blade tip of claim 1, wherein: the thickness of the substrate base (2) is more than or equal to 35mm.
7. The method of repairing a cast equiaxed grain turbine rotor blade tip of claim 1, wherein: the tool and the components thereof are made of 304, 316L stainless steel or GH3536 high-temperature alloy gold.
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| DE102021105918A1 (en) * | 2021-03-11 | 2022-09-15 | Lufthansa Technik Aktiengesellschaft | Additive repair system |
| CN114309645A (en) * | 2021-12-13 | 2022-04-12 | 东方电气集团东方汽轮机有限公司 | Method for repairing turbine blade of gas turbine |
| CN114686732B (en) * | 2022-04-19 | 2022-10-18 | 北航（四川）西部国际创新港科技有限公司 | High-temperature alloy repair material and preparation method thereof, and additive remanufacturing method and re-service evaluation method of high-temperature alloy repair part |
| CN114515837B (en) * | 2022-04-21 | 2022-06-24 | 北京煜鼎增材制造研究院有限公司 | Laser selective melting repair method for blade tip of single crystal turbine blade |
| DE102022118664A1 (en) | 2022-07-26 | 2024-02-01 | Lufthansa Technik Aktiengesellschaft | Construction platform for additive repair of components and their use |
| CN115475962A (en) * | 2022-09-29 | 2022-12-16 | 中国航发动力股份有限公司 | Integrated device for additive forming and material reducing processing and design method |
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| US20150275687A1 (en) * | 2011-01-13 | 2015-10-01 | Siemens Energy, Inc. | Localized repair of superalloy component |
| US9522426B2 (en) * | 2012-11-08 | 2016-12-20 | Georgia Tech Research Corporation | Systems and methods for additive manufacturing and repair of metal components |
| EP2772329A1 (en) * | 2013-02-28 | 2014-09-03 | Alstom Technology Ltd | Method for manufacturing a hybrid component |
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