CN112077309A - Titanium alloy compressor rotor blade tip repairing method and repairing tool - Google Patents

Titanium alloy compressor rotor blade tip repairing method and repairing tool Download PDF

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Publication number
CN112077309A
CN112077309A CN202010912845.3A CN202010912845A CN112077309A CN 112077309 A CN112077309 A CN 112077309A CN 202010912845 A CN202010912845 A CN 202010912845A CN 112077309 A CN112077309 A CN 112077309A
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blade
tool
selective
repairing
tip
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CN112077309B (en
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张学军
赵海生
秦仁耀
张强
孙兵兵
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AECC Beijing Institute of Aeronautical Materials
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AECC Beijing Institute of Aeronautical Materials
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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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/003—Apparatus, e.g. furnaces
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • 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
    • 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
    • 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
    • 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
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • 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
    • B33Y80/00—Products made by additive manufacturing
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
    • 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
    • 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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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Welding Or Cutting Using Electron Beams (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

The invention belongs to the technical field of maintenance of aero-engines, and relates to a titanium alloy compressor rotor blade tip repairing method and repairing tooling; the method adopts selective laser melting or selective electron beam melting to complete restoration, a blade can be arranged in a selective laser melting or selective electron beam melting equipment forming area by means of a tool and is formed at the blade tip, data are obtained through three-dimensional scanning to perform reverse modeling to obtain a model needing restoration forming and relevant position information, the corresponding tool and blade clamping are designed, the structure and the form are not limited, and the tool can be used for completing blade clamping, 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

Titanium alloy compressor rotor blade tip repairing method and repairing tool
Technical Field
The invention belongs to the technical field of maintenance of aircraft engines, relates to repair of key parts of engines, particularly relates to a repair method and a repair tool for a blade tip of a rotor blade of a titanium alloy compressor, and particularly relates to a repair method and a repair tool for Selective Laser Melting (SLM) and selective Electron Beam Melting (EBM) of the blade tip of the rotor blade of the titanium alloy compressor.
Background
The titanium alloy compressor rotor blade rotates at a high speed in a high-pressure flowing air current environment, the blade tip is subjected to the maximum air pressure and the high air flow speed, so that the blade tip is easily abraded, and the blade tip is generally required to be repaired every time of overhauling. The traditional repair method is to adopt welding processes such as argon arc welding or laser welding to build up welding on the top of the blade, then machine and polish to remove redundant materials, and finish size recovery. 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. The 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 property, 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 (SLM) and selective Electron Beam Melting (EBM) are applied to blade tip repair to solve various problems of the traditional repair method. However, Selective Laser Melting (SLM) and selective Electron Beam Melting (EBM) are processes for directly manufacturing parts, and there is no method for repairing parts, and it is necessary to overcome many problems to repair the blade tip by using them: 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 rotor blade tip of the titanium alloy compressor are provided, the technical breakthrough that Selective Laser Melting (SLM) and selective Electron Beam Melting (EBM) are used for part repair is realized, the advantages of high selective melting size precision, small deformation, good surface roughness, high speed and the like are exerted, the positioning precision of blade repair is well controlled, and the efficiency and the quality of repair work are improved.
In order to solve the technical problem, the technical scheme of the invention is as follows:
a titanium alloy compressor rotor blade tip repairing method is characterized by comprising the following steps: the repairing method utilizes selective laser melting or selective electron beam melting to repair the tip of the rotor blade of the titanium alloy compressor; 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: titanium alloy powder with the granularity range of 10-80um is melted in a laser selection area; titanium alloy powder with the granularity range of 40-150um is melted in an electron beam selective area;
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 70-200um, and the parameters adopted by the main body part of the blade tip repairing printing are as follows: the laser power is 200-: the preheating temperature of the electron beam is 600-;
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. .
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.
A titanium alloy compressor rotor blade apex repair tool comprises a cross base block 1, a base plate base 2, a locking block 3, a bottom cushion block 4 and a bolt 5;
the height of the cross base block 1 is equal to the height of the blade tip after the clamping, the cross base block is used for positioning the height of the blade tip and is welded on the surface of the base plate base 2;
the length and the width of the base plate 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, and meanwhile, threaded holes fixedly matched with a bottom cushion block 4 and a bolt 5 are formed in the base plate base 2;
the locking block 3 is a clamping tool for clamping and fixing the blade, clamping teeth 31 are arranged at the lower part and the middle part of the side surface far away from the cross-shaped base block 1, positioning teeth 32 are arranged at the upper part, the clamping teeth at the lower part are consistent with the shape and the size of a blade tenon, the clamping teeth at the middle part are consistent with the shape and the size of the root part of a blade body of the blade, and the clamping teeth are used for fixing and clamping the tenon and the flange plate of the blade;
the positioning teeth 32 are consistent with the blade body at the position 10-20 mm away from the blade edge plate in shape and size and used for positioning and assisting in fixing the blade body of the blade and preventing the blade from deforming during repair and forming, and bolt holes matched with the bottom cushion block 4 and the bolts 5 are formed in the middle of the locking block 3;
the bottom cushion block 4 is used for positioning and assisting in fixing the blade, the inclined angle of the upper end face (the included angle between the upper end face and the base plate base 2) is equal to the included angle between the bottom face of the blade tenon and the blade tip plane so as to ensure that the blade tip plane is parallel to the base plate base, and meanwhile, the bottom cushion block 4 is provided with a threaded hole matched with the locking block 3 and a bolt hole matched with the base plate base 2;
the bolt 5 is used for clamping the blade tenon and the fixed blade by matching the substrate base 2, the locking block 3 and the bottom cushion block 4.
Preferably, the thickness of the substrate base 2 is more than or equal to 15 mm.
Preferably, the tool is made of 304 stainless steel or titanium alloy such as TC 4.
The invention has the beneficial effects that:
the invention is applicable to all types of aircraft engine compressor titanium alloy rotor blades, including but not limited to: turbofan engines, turbo propeller engines, turboshaft engines, and the like.
The method is suitable for repairing all grades of titanium alloy aero-engine compressor rotor blades.
In step S6, titanium alloy with all brands is selected as the repairing material.
The invention applies to both Selective Laser Melting (SLM) and selective Electron Beam Melting (EBM) in step S8.
The invention clamps the compressor rotor blade through the designed special tool, overcomes the outstanding problems of difficult location of a repair area, easy occurrence of unfused repair interface, air hole defect and the like when the blade tip is repaired by the laser selective melting and electron beam selective melting technology, and solves the problem that the repair part has no three-dimensional digifax through the part three-dimensional scanning and reverse modeling technology, thereby successfully applying the laser selective melting and electron beam selective melting technology to the repair of the blade tip of the compressor titanium alloy rotor blade and breaking through the limitation that the selective melting technology can only be used for part manufacturing but not part repair.
Meanwhile, compared with the existing repair technology for the blade tip damage of the rotor blade of the gas compressor (such as laser direct deposition, argon arc welding, micro-beam plasma arc welding and the like), the repair method for the blade tip damage of the rotor blade of the titanium alloy rotor has the advantages of small heat input, small near-net-shape forming machining allowance, capability of repairing a plurality of blades (6-10) 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 performance and the repair efficiency of the blade tip damage of the rotor blade of the titanium alloy 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 structural view of a repair tool;
FIG. 2 is a schematic structural view of a repair fixture 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 location block;
FIG. 5 is a schematic view of the included angle between the base of the dovetail of the blade and the plane of the tip;
the device comprises a base plate, a locking block, a clamping tooth, a positioning tooth, a bottom cushion block, a bolt, a blade and a positioning block, wherein the base plate comprises 1-a cross-shaped base block, 2-a base plate base, 3-a locking block, 31-a clamping tooth, 32-a positioning tooth, 4-a bottom cushion block, 5-a bolt, 6-a blade and 7-.
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 TC4 titanium alloy rotor blades of certain engine compressor by adopting EOS M290 laser selective melting (SLM) equipment, which comprises the following specific steps:
s1, tool design and blade clamping: a tool is designed to assist in positioning and clamping of compressor blades 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 5, the tooling of the present invention includes a cross base block 1, a base plate base 2, a locking block 3, a bottom pad 4 and a bolt 5.
The cross base block 1 has a size of 100mm (cross length) × 30mm (cross width) × 120mm (cross height), and is soldered to the surface of the base plate, as shown in fig. 1 and 2.
The size of the base plate base 2 is 252mm (length) x 252mm (width) x 20mm (thickness), the base plate base is provided with M5 threaded holes which can be matched with the bottom cushion block 4 and the bolts 5 to fix the blade, and meanwhile, four corners of the base plate base are provided with M8 threaded holes which can be connected with the lifting platform of the equipment forming cabin by bolts, as shown in figure 1, figure 2 and figure 4;
the locking block 3 has the size of 60mm (length) multiplied by 25mm (width) multiplied by 40mm (height), the lower part and the middle of the side surface far away from the cross-shaped base block 1 are both provided with clamping teeth 31, the upper part is provided with positioning teeth 32, the clamping teeth at the lower part are consistent with the appearance and the size of a blade tenon, and the clamping teeth at the middle part are consistent with the appearance and the size of the root part of a blade body of the blade and are used for fixing and clamping the tenon and the flange plate of the blade;
the positioning teeth 32 are consistent with the blade body 20mm away from the blade edge plate in shape and size, are used for positioning and assisting the blade body of the fixed blade and preventing the blade from deforming during repair forming, and bolt holes matched with the bottom cushion block 4 and the bolts 5 are arranged in the middle of the locking block 3 and are used for clamping and fixing the blade, as shown in fig. 1, 2 and 4;
the bottom cushion block 4 is used for positioning and assisting in fixing the blades, the size of the bottom surface is 60mm (length) × 60mm (width), the lowest height is 20mm, the inclination angle of the upper end surface (the included angle between the upper end surface and the base plate base 2) is equal to the included angle between the bottom surface of the blade tenon and the blade tip plane (shown in fig. 5, the included angle between the upper end surface and the bottom surface is 5 degrees), and therefore the blade tip plane is enabled to be parallel to the base plate base. The bottom cushion block 4 is provided with a threaded hole matched with the locking block 3 and a bolt hole matched with the substrate base 2, as shown in fig. 1, 2 and 4;
the tool and the components thereof are made of TC4 titanium 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 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) uses TC4 titanium alloy powder with a particle size range of 10-45 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 50um, and the parameters adopted by a main body part of the blade tip repairing printing are as follows: the laser power is 220W, the laser scanning speed is 1500mm/s, and the scanning line spacing is 0.12 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 TC4 titanium alloy compressor blades of a certain type of engine, and comprises the following specific steps:
s1, tool design and blade clamping: a tool is designed to assist in positioning, clamping and clamping of a compressor blade and selective Electron Beam 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 cross base block 1, a base plate base 2, a locking block 3, a bottom pad 4 and a bolt 5.
The cross base block 1 has a size of 100mm (cross length) × 30mm (cross width) × 120mm (cross height), and is soldered to the surface of the base plate, as shown in fig. 1 and 2.
The base plate 2 has dimensions of 252mm (length) by 252mm (width) by 25mm (thickness), and has a threaded hole M5 in the base plate, which can cooperate with the bottom block 4 and the bolt 5 to fix the blade, as shown in fig. 1, 2 and 4;
the locking block 3 has the size of 60mm (length) multiplied by 25mm (width) multiplied by 40mm (height), the lower part and the middle of the side surface far away from the cross-shaped base block 1 are both provided with clamping teeth 31, the upper part is provided with positioning teeth 32, the clamping teeth at the lower part are consistent with the appearance and the size of a blade tenon, and the clamping teeth at the middle part are consistent with the appearance and the size of the root part of a blade body of the blade and are used for fixing and clamping the tenon and the flange plate of the blade;
the positioning teeth 32 are consistent with the blade body 20mm away from the blade edge plate in shape and size, are used for positioning and assisting the blade body of the fixed blade and preventing the blade from deforming during repair forming, and bolt holes matched with the bottom cushion block 4 and the bolts 5 are arranged in the middle of the locking block 3 and are used for clamping and fixing the blade, as shown in fig. 1, 2 and 4;
the bottom cushion block 4 is used for positioning and assisting in fixing the blades, the bottom surface has the size of 60mm (length) multiplied by 60mm (width), the lowest height is 20mm, the included angle between the upper end surface and the bottom surface is 5 degrees, and the bottom cushion block is provided with a threaded hole matched with the locking block 3 and a bolt hole matched with the substrate base 2, which are shown in fig. 1, 2 and 4;
the tool and the components thereof are made of 304 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 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 TC4 titanium alloy powder with a particle size range of 45-150 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 120um, and the parameters adopted by a main body part of the blade tip repairing printing are as follows: the electron beam preheating temperature is 660 ℃, the electron beam current is 40mA, the focusing current is 130mA, the scanning speed is 30m/s, and the filling space is 0.5 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 titanium alloy compressor rotor blade tip repairing method is characterized by comprising the following steps: the repairing method utilizes selective laser melting or selective electron beam melting to repair the tip of the rotor blade of the titanium alloy compressor; 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: titanium alloy powder with the granularity range of 10-80um is melted in a laser selection area; titanium alloy powder with the granularity range of 40-150um is melted in an electron beam selective area;
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 70-200um, and the parameters adopted by the main body part of the blade tip repairing printing are as follows: the laser power is 200-: the preheating temperature of the electron beam is 600-;
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 titanium alloy compressor rotor blade tip repair method of 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 titanium alloy compressor rotor blade tip repair method of 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 titanium alloy compressor rotor blade tip repair method of 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 titanium alloy compressor rotor blade tip repair method of 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 titanium alloy compressor rotor blade tip repair method of 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 tip of the rotor blade of the titanium alloy compressor is used for realizing the method for repairing the tip of the rotor blade of the titanium alloy compressor, which is characterized in that: the repairing tool comprises a cross-shaped base block (1), a base plate base (2), a locking block (3), a bottom cushion block (4) and a bolt (5);
the height of the cross base block (1) is equal to the height of the blade tip after the clamping, the cross base block is used for positioning the height of the blade tip and is fixed on the surface of the base plate base (2);
the length and the width of the base plate 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, and meanwhile, threaded holes fixedly matched with the bottom cushion block (4) and the bolts (5) are formed in the base plate base (2);
the locking block (3) is a clamping tool for clamping and fixing the blade, clamping teeth (31) are arranged at the lower part and the middle part of the side surface far away from the cross-shaped base block (1), and positioning teeth (32) are arranged at the upper part;
the clamping teeth at the lower part are consistent with the shape and the size of the blade tenon, and the clamping teeth at the middle part are consistent with the shape and the size of the root part of the blade body of the blade and are used for fixing and clamping the tenon and the flange plate of the blade;
the positioning teeth (32) are consistent with the blade body at the position 10-20 mm away from the blade edge plate in appearance and size and used for positioning and assisting in fixing the blade body of the blade, and a bolt hole matched with the bottom cushion block (4) and the bolt (5) is formed in the middle of the locking block (3);
the bottom cushion block (4) is used for positioning and assisting in fixing the blade, the inclination angle of the upper end face is equal to the included angle between the bottom face of the tenon of the blade and the plane of the blade tip, and meanwhile, the bottom cushion block (4) is provided with a threaded hole matched with the locking block (3) and a bolt hole matched with the base plate (2);
the bolt (5) is used for being matched with the substrate base (2), the locking block (3) and the bottom cushion block (4) to clamp the blade tenon and the fixed blade.
8. The tool for repairing the tip of the rotor blade of the titanium alloy compressor as recited in claim 7, wherein: the thickness of the substrate base (2) is more than or equal to 15 mm.
9. The tool for repairing the tip of the rotor blade of the titanium alloy compressor as recited in claim 7, wherein: the tool is made of 304 stainless steel and TC4 titanium alloy.
CN202010912845.3A 2020-09-02 2020-09-02 Repairing method and repairing tool for tip of titanium alloy compressor rotor blade Active CN112077309B (en)

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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
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