CN112427637B - 定向凝固晶涡轮叶片叶尖深裂纹的修复材料及修复方法 - Google Patents
定向凝固晶涡轮叶片叶尖深裂纹的修复材料及修复方法 Download PDFInfo
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Abstract
本发明公开了一种定向凝固晶涡轮叶片叶尖深裂纹的修复材料及修复方法，涉及航空发动机叶片维修领域，解决采用现有修复材料容易产生微裂纹的问题。本发明采用的技术方案是：定向凝固晶涡轮叶片叶尖深裂纹的修复材料，按质量计，由35％～45％的Inconel625合金粉末与55％～65％的Rene142合金粉末充分混合而成。定向凝固晶涡轮叶片叶尖深裂纹的修复方法，高压涡轮工作叶片分解后，先探伤，确定裂纹位置并开坡口；然后，采用前述的修复材料进行激光增材；再对修复区进行打磨，将叶片放置于真空炉中进行退火处理；最后对叶片进行探伤检测。本发明适用于对定向凝固镍基高温合金DZ125涡轮转子叶片叶尖的深裂纹进行修复。
Description
技术领域
本发明涉及航空发动机叶片维修技术领域，具体是一种对定向凝固镍基高温合金DZ125涡轮转子叶片叶尖深裂纹进行修复的方法。
背景技术
某型国产航空发动机高压涡轮工作叶片采用镍基高温合金DZ125定向凝固结晶精密铸造而成，高压涡轮工作叶片盖板与叶身为钎焊连接。该型高压涡轮工作叶片分解后故障检查显示，因叶尖深裂纹(裂纹最长4mm，扩展至盖板及盖板以下)而报废的叶片高达70％以上，部分台次报废率达到100％。由于高压涡轮工作叶片铸造工艺复杂、加工精度要求高、制造合格率低，因此价格昂贵，如果对损伤叶片采用换件修理，将大大提高发动机维修成本；同时由于叶片备件供应周期往往无法保证，如果不对损伤叶片进行增材修复实现再生使用，还将影响发动机维修周期。
申请人前期开发的涡轮转子叶片叶尖修复技术采用“高强度抗氧化镍基高温合金粉末”进行激光熔覆修复，具体参见公告号为CN 106591826 B的专利文献。该修复技术需要采用仿形铜合金空心管来完成惰性气氛高频感应对涡轮叶片叶尖进行预热，操作步骤比较繁琐。更重要的是，按照该修复技术修复叶尖深裂纹时，受盖板钎焊缝的影响，焊接过程中合金粉末与B、Si元素形成质地比较脆的低熔点共晶体，从而产生微裂纹，导致修复失败，因此修复的合格率非常低。
发明内容
本发明首先提供一种用于修复定向凝固晶涡轮叶片叶尖深裂纹的材料，解决采用现有修复材料容易产生微裂纹，导致修复失败的问题。
本发明解决其技术问题采用的技术方案是：定向凝固晶涡轮叶片叶尖深裂纹的修复材料，按质量计，由35％～45％的Inconel625合金粉末与55％～65％的Rene142合金粉末充分混合而成。例如：Inconel625合金粉末与Rene142合金粉末的质量比为40∶60。
具体的，为了使Inconel625合金粉末与Rene142合金粉末均匀混合，Inconel625合金粉末与Rene142合金粉末按比例混合后，机械搅拌至少24小时。
本发明还提供一种对定向凝固晶涡轮叶片叶尖深裂纹进行修复方法，解决现有修复技术操作繁琐，以及盖板钎焊缝中B、Si等降熔元素影响叶尖增材质量，导致修复合格率低下的问题。
本发明解决上述技术问题采用的技术方案是：定向凝固晶涡轮叶片叶尖深裂纹的修复方法，包括以下步骤：
S1.高压涡轮工作叶片分解后，进行探伤，确定裂纹的位置及长度并进行标识；
具体的，步骤S1中，采用荧光探伤确定裂纹的位置及长度。
S2.在裂纹处开坡口，使裂纹彻底排除；
具体的：步骤S2中，采用A1.5打磨头手工排除裂纹并开V型坡口，采用荧光探伤确认裂纹排除彻底。
S3.采用前述“定向凝固晶涡轮叶片叶尖深裂纹的修复材料”对坡口位置进行激光增材；
具体的：步骤S3中，激光增材参数为：功率为300～400W，送粉速率3～4g/min，扫描速度为8～10mm/s。
更具体的：步骤S3中，激光增材参数为：功率为360W，送粉速率为3.2g/min，扫描速度为8mm/s。
S4.对叶片的修复区进行打磨，使叶片外型面与基体圆滑过渡；
S5.将叶片放置于真空炉中进行退火处理；
S6.对叶片进行探伤检测，并判定合格与否。
具体的：步骤S6中，对叶片进行荧光探伤，若不存在裂纹、未熔合缺陷，则判定合格，否则判定为不合格。
本发明的有益效果是：定向凝固晶涡轮叶片叶尖深裂纹的修复材料中铝元素低，可焊性增强，塑性好，不容易形成裂纹。定向凝固晶涡轮叶片叶尖深裂纹的修复方法无需预热，工序简单；利用定向凝固晶涡轮叶片叶尖深裂纹的修复材料进行修复，解决了盖板钎焊缝中B、Si等降熔元素影响叶尖增材质量的难题，既可保证整个修复区的强度，又能防止修复区开裂，适合修复定高压涡轮工作叶片叶尖深裂纹，能确保零部件修复质量、降低发动机维修成本，并缩短维修周期。
附图说明
图1是采用现有修复涡轮叶片叶尖裂纹的修复材料及修复方法进行修复后钎焊缝区的金相图。
图2是按照本发明进行修复后钎焊缝区的金相图。
附图说明：由于图1和图2均为金相图，因此均为灰度化处理的照片。
具体实施方式
下面结合实施例对本发明作进一步说明。
本发明的第一个主题是：定向凝固晶涡轮叶片叶尖深裂纹的修复材料，按质量计，由35％～45％的Inconel625合金粉末与55％～65％的Rene142合金粉末充分混合而成。Inconel625合金粉末的百分比可选择35～45之间的任意整数，例如：Inconel625合金粉末与Rene142合金粉末的质量比为40∶60。修复材料由两种合金粉末混合制得，为物理性混合，这两种合金粉末均为现有的。为了保证两种合金粉末混合后的均匀性，Inconel625合金粉末与Rene142合金粉末按比例混合后，机械搅拌至少24小时，使得均匀混合。
本发明的第二个主题是：定向凝固晶涡轮叶片叶尖深裂纹的修复方法，包括以下步骤：
S1.高压涡轮工作叶片分解后，进行荧光探伤，确定裂纹的位置及长度并进行标识。
S2.对S1标识裂纹处，采用A1.5打磨头手工排除裂纹并开V型坡口，采用荧光探伤确认裂纹排除彻底。
S3.采用前述第一个主题“定向凝固晶涡轮叶片叶尖深裂纹的修复材料”对坡口位置进行激光增材。实施例中，Inconel625合金粉末与Rene142合金粉末的质量比为40∶60；激光增材参数为：功率为360W，送粉速率为3.2g/min，扫描速度为8mm/s。
S4.采用自适应打磨方式使叶片外型面与基体圆滑过渡。
S5.将叶片放置在真空炉中进行退火处理。
S6.叶片出炉后进行荧光探伤检测，并判定合格与否。若是不存在裂纹、未熔合缺陷，则判定合格，否则不合格。
按照上述方法对涡轮叶片叶尖裂纹进行修复，修复区的金相图如图2所示。根据图2可见，修复区并不存在裂纹、未熔合等缺陷。对比例为采用公告号为CN 106591826 B的专利文献所述的方法进行的对比试验，修复区的金相图如图1所示，从图1可见，修复区存在未熔合的缺陷。
Claims (8)
1.镍基高温合金DZ125定向凝固结晶涡轮叶片叶尖深裂纹的修复材料，其特征在于：按质量计，由35%～45%的Inconel625合金粉末与55%～65%的Rene142合金粉末充分混合而成。
2.如权利要求1所述的镍基高温合金DZ125定向凝固结晶涡轮叶片叶尖深裂纹的修复材料，其特征在于：Inconel625合金粉末与Rene142合金粉末的质量比为40∶60。
3.如权利要求1或2所述的镍基高温合金DZ125定向凝固结晶涡轮叶片叶尖深裂纹的修复材料，其特征在于：Inconel625合金粉末与Rene142合金粉末按比例混合后，机械搅拌至少24小时。
4.镍基高温合金DZ125定向凝固结晶涡轮叶片叶尖深裂纹的修复方法，其特征在于：包括以下步骤：
S1.高压涡轮工作叶片分解后，进行探伤，确定裂纹的位置及长度并进行标识；
S2.在裂纹处开坡口，使裂纹彻底排除；
S3.采用权利要求1、2或3所述的修复材料对坡口位置进行激光增材；
S4.对叶片的修复区进行打磨，使叶片外型面与基体圆滑过渡；
S5.将叶片放置于真空炉中进行退火处理；
S6.对叶片进行探伤检测，并判定合格与否。
5.如权利要求4所述的镍基高温合金DZ125定向凝固结晶涡轮叶片叶尖深裂纹的修复方法，其特征在于：步骤S1中，采用荧光探伤确定裂纹的位置及长度。
6.如权利要求4所述的镍基高温合金DZ125定向凝固结晶涡轮叶片叶尖深裂纹的修复方法，其特征在于：步骤S2中，采用A1.5打磨头手工排除裂纹并开V型坡口，采用荧光探伤确认裂纹排除彻底。
7.如权利要求4～6任一项所述的镍基高温合金DZ125定向凝固结晶涡轮叶片叶尖深裂纹的修复方法，其特征在于：步骤S3中，激光增材参数为：功率为300～400W，送粉速率3～4g/min，扫描速度为8～10mm/s。
8.如权利要求7述的镍基高温合金DZ125定向凝固结晶涡轮叶片叶尖深裂纹的修复方法，其特征在于：步骤S3中，激光增材参数为：功率为360W，送粉速率为3.2g/min，扫描速度为8mm/s。
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| US20160167172A1 (en) * | 2014-08-26 | 2016-06-16 | Liburdi Engineering Limited | Method of cladding, additive manufacturing and fusion welding of superalloys and materialf or the same |
| DE102015214613A1 (de) * | 2015-07-31 | 2017-02-02 | MTU Aero Engines AG | Verfahren zum Reparieren einer wenigstens einen Hohlraum aufweisenden Schaufel einer Gasturbine |
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