CN112548106B - 超薄结构增材制造修复的方法 - Google Patents

超薄结构增材制造修复的方法 Download PDF

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CN112548106B
CN112548106B CN202110213744.1A CN202110213744A CN112548106B CN 112548106 B CN112548106 B CN 112548106B CN 202110213744 A CN202110213744 A CN 202110213744A CN 112548106 B CN112548106 B CN 112548106B
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repaired
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repair
powder
additive manufacturing
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CN112548106A (zh
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焦宗戈
付俊
付鑫
雷力明
闫雪
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AECC Commercial Aircraft Engine Co Ltd
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Abstract

本发明涉及超薄结构增材制造修复的方法。该方法包括以下步骤：将超薄结构的损伤区域机加工去除；获取超薄结构的待修复区域的三维模型；对待修复区域的三维模型进行处理；在待修复区域的底部四周构建载粉装置，使载粉装置中的粉末填充至与待修复区域的底部表面齐平或相切；通过高能束或辅助加热装置使超薄结构的外轮廓周围载粉装置内粉末熔化、烧结或固化，并与超薄结构的外轮廓结合在一起，形成外轮廓加厚结构，成为适应性工装；根据模型处理所得规划路径，通过增材制造技术对待修复区域进行修复。本发明能起到以下有益技术效果：无需超小光斑高能束设备或加厚工装，就能修复超薄结构。

Description

超薄结构增材制造修复的方法
技术领域
本发明涉及增材制造技术领域，尤其涉及超薄结构增材制造修复的方法。
背景技术
超薄结构在航空发动机叶片领域应用较广，近年来随着制造技术进一步发展，发动机叶盘和叶片整体化成为主流发展趋势。区别于常规分体叶盘，整体叶盘如若产生损伤，不能对损伤部位进行更换，需要更换整个叶盘，将大幅提高发动机使用成本。利用相关修复技术对加工过程或者服役过程中发生损伤的整体叶盘进行修复，使其恢复使用性能，避免整体叶盘报废，对于降低发动机使用成本具有重要意义。传统的修复方法如弧焊，存在热输入高、残余应力大、变形严重等一系列问题，因此适用于如整体叶盘、涡轮叶片等高附加值零部件的低成本、短流程的先进修复技术亟待发展。
激光熔化沉积（Laser Melting Deposition, LMD）技术是一种常见的增材制造技术，该技术通过高能激光束将同步输送的粉末与部分基体熔化，形成移动的非稳态熔池，并在极高温度梯度下快速凝固，逐点沉积、逐线扫描、逐层堆积，最终形成实体零件。同时相对于传统弧焊等修复技术，该技术中高能激光束能量密度集中，成形过程中对基材影响较小，且成形路径具有高度适应性，因此特别适合高附加值零部件快速修复，如航空发动机中安装节系统、后节平台、整体叶盘、涡轮叶片等零件。
如叶片叶尖、前后缘等具有超薄结构的零件修复是增材制造修复技术的一大难点，零件超薄结构位置因厚度通常小于1mm，采用成形精度较低的修复设备进行修复时，如激光光斑直径大于1mm，极易造成激光漏光，导致结构表面损伤。同时因厚度较低，空气传热速率较慢，热量累积严重，容易造成该区域过热产生塌陷、烧蚀、变形等现象。目前，超薄结构高能束修复主要通过以下两种方案：（1）采用超小光斑、高成形精度的高能束设备，（2）采用加厚工装，如定制的仿形加厚工装。第一种方案，需要特殊的修复头，设备要求高，常规设备难以满足要求，且修复过程如全程使用小光斑，修复速率较低。第二种方案，仿形工装加工需要时间较长，且因工装与试样为部分冶金结合，修复完成机加工去除过程中容易造成刀具震动，从而使机加工产生误差甚至导致超薄结构直接发生变形，造成修复后的尺寸精度难以满足设计要求。
发明内容
本发明的一个目的在于，提供一种超薄结构增材制造修复的方法，其能解决现有技术所存在的问题，无需超小光斑高能束设备或加厚工装，就能修复超薄结构。
本发明的以上目的通过一种超薄结构增材制造修复的方法来实现，超薄结构是指厚度小于1mm的结构，所述方法包括以下步骤：
（a）将所述超薄结构的损伤区域机加工去除；
（b）获取所述超薄结构的待修复区域的三维模型；
（c）对所述待修复区域的三维模型进行处理；
（d）在所述待修复区域的底部四周构建载粉装置，使载粉装置中的粉末填充至与所述待修复区域的底部表面齐平或相切；
（e）通过高能束或辅助加热装置使所述超薄结构的外轮廓周围载粉装置内粉末熔化、烧结或固化，并与所述超薄结构的外轮廓结合在一起，形成外轮廓加厚结构，成为适应性工装，起到支撑后续修复及避免零件本体烧蚀的作用；
（f）根据模型处理所得规划路径，通过增材制造技术对所述待修复区域进行修复。
根据上述技术方案，本发明的超薄结构增材制造修复的方法能起到以下有益技术效果：无需超小光斑高能束设备或加厚工装，就能修复超薄结构。
具体地说，本发明提出了一种超薄结构增材制造修复的方法，该方法修复过程简单便捷，可操作性强，适用于难修复超薄结构，成功实现短流程修复。以叶片修复为例，经测算修复时间从原来的75h（工装设计20h+工装加工30h+工装装夹1h+工装去除24h）减少至12h，大大节约材料和时间成本，实现低成本快速修复。
较佳的是，所述方法还包括步骤（g）：在步骤（f）之后，对修复后的超薄结构进行热处理，以去除应力或者调控显微组织。
根据上述技术方案，本发明的超薄结构增材制造修复的方法能起到以下有益技术效果：能有效去除修复后的超薄结构中的应力或者调控显微组织。
较佳的是，所述方法还包括步骤（h）：在步骤（g）之后，对修复区域进行打磨或机加工，以使修复区域尺寸达到最终使用要求。
根据上述技术方案，本发明的超薄结构增材制造修复的方法能起到以下有益技术效果：结合了适应性工装设计及增材制造技术，无需对设备进行改装或采购新设备，大幅降低设备成本，有效扩宽设备使用范围。
较佳的是，步骤（b）中的三维模型是通过建模软件建模或三维扫描原始零件来获取的。
根据上述技术方案，本发明的超薄结构增材制造修复的方法能起到以下有益技术效果：能较佳地获取待修复区域的三维模型。
较佳的是，步骤（c）包括：余量添加处理、分层切片处理和路径规划处理。
根据上述技术方案，本发明的超薄结构增材制造修复的方法能起到以下有益技术效果：能较佳地对待修复区域的三维模型进行处理，以便后续修复操作。
较佳的是，步骤（e）中的适应性工装由金属或非金属材料来构建，且固定至所述超薄结构。
根据上述技术方案，本发明的超薄结构增材制造修复的方法能起到以下有益技术效果：用适宜的材料、在适宜的位置构建载粉装置，以便后续填充粉末，烧结后形成适应性工装。
较佳的是，步骤（f）采用同步送粉的激光熔化沉积技术、铺粉的选区激光熔化沉积技术或其他高能束增材制造技术进行修复。
根据上述技术方案，本发明的超薄结构增材制造修复的方法能起到以下有益技术效果：用适宜的增材制造技术对待修复区域进行修复，确保较好的修复效果。
附图说明
图1A是压气机叶片叶尖损伤区域的示意图。
图1B是压气机叶片叶尖待修复区域的示意图。
图2是本发明第一实施例的压气机叶片叶尖损伤适应性装夹的示意图。
图3是本发明第二实施例的压气机叶片前后缘损伤适应性装夹的示意图。
附图标记列表
11、 损伤区域；
12、 待修复区域；
13、 底部表面；
21、 载粉装置；
22、 耐高温胶布；
23、 粉末。
具体实施方式
以下将描述本发明的具体实施方式，需要指出的是，在这些实施方式的具体描述过程中，为了进行简明扼要的描述，本说明书不可能对实际的实施方式的所有特征均作详尽的描述。应当可以理解的是，在任意一种实施方式的实际实施过程中，正如在任意一个工程项目或者设计项目的过程中，为了实现开发者的具体目标，为了满足系统相关的或者商业相关的限制，常常会做出各种各样的具体决策，而这也会从一种实施方式到另一种实施方式之间发生改变。此外，还可以理解的是，虽然这种开发过程中所作出的努力可能是复杂并且冗长的，然而对于与本发明公开的内容相关的本领域的普通技术人员而言，在本公开揭露的技术内容的基础上进行的一些设计、制造或者生产等变更只是常规的技术手段，不应当理解为本公开的内容不充分。
除非另作定义，权利要求书和说明书中使用的技术术语或者科学术语应当为本发明所属技术领域内具有一般技能的人士所理解的通常意义。本发明专利申请说明书以及权利要求书中使用的“第一”、“第二”以及类似的词语并不表示任何顺序、数量或者重要性，而只是用来区分不同的组成部分。“一个”或者“一”等类似词语并不表示数量限制，而是表示存在至少一个。“包括”或者“包含”等类似的词语意指出现在“包括”或者“包含”前面的元件或者物件涵盖出现在“包括”或者“包含”后面列举的元件或者物件及其等同元件，并不排除其他元件或者物件。“连接”或者“相连”等类似的词语并非限定于物理的或者机械的连接，也不限于是直接的还是间接的连接。
需要注意的是，在本申请中，术语“超薄结构”是指：厚度小于1mm的结构。术语“修复”是指：对损伤零件进行技术性复原。术语“激光熔化沉积”是指：采用激光将材料熔化逐层堆积的方法制造实体零件。术语“增材制造”是指：采用高能束将材料熔化逐层累加以制造实体零件。术语“适应性”是指：适应待修复区域的形状。术语“工装”是指：修复过程中所用的工具或夹具。
图1A是压气机叶片叶尖损伤区域的示意图。图1B是压气机叶片叶尖待修复区域的示意图。图2是本发明第一实施例的压气机叶片叶尖损伤适应性装夹的示意图。图3是本发明第二实施例的压气机叶片前后缘损伤适应性装夹的示意图。
如图1A—图3所示，本发明的超薄结构增材制造修复的方法包括以下步骤：
（a）将超薄结构的损伤区域11机加工去除，以最小破坏原则机加工成规则形状，避免不规则形状造成后续修复过程冶金缺陷；
（b）获取超薄结构的待修复区域12的三维模型；
（c）对待修复区域12的三维模型进行处理；
（d）在待修复区域12的底部四周构建载粉装置21，使载粉装置21中的粉末23（金属粉末或非金属粉末）填充至与待修复区域12的底部表面13齐平或相切（该底部表面可以为平面或曲面）；
（e）通过高能束（例如激光束、电子束、离子束等）或辅助加热（例如感应加热等）装置使超薄结构的外轮廓周围载粉装置21内粉末23熔化、烧结或固化，并与超薄结构所在外轮廓结合在一起，形成外轮廓加厚结构，成为适应性工装，起到支撑后续修复及避免烧蚀零件本体的作用；
（f）根据模型处理所得规划路径，通过增材制造技术对待修复区域12进行修复（修复完成之后，待修复区域12成为修复区域）。
根据上述技术方案，本发明的超薄结构增材制造修复的方法能起到以下有益技术效果：无需超小光斑高能束设备或加厚工装，就能修复超薄结构。
具体地说，本发明提出了一种超薄结构增材制造修复的方法，该方法修复过程简单便捷，可操作性强，适用于难修复超薄结构，成功实现短流程修复。以叶片修复为例，经测算修复时间从原来的75h（工装设计20h+工装加工30h+工装装夹1h+工装去除24h）减少至12h，大大节约材料和时间成本，实现低成本快速修复。
（1）本发明采用粉末适应性工装设计，无需设计、制造仿形加厚工装，减少了时间成本。同时可以避免工装缝隙造成的冶金缺陷，及工装去除过程中造成的变形，能有效提高修复质量，提高超薄结构零件修复后的尺寸精度；
（2）本发明结合适应性工装设计及增材制造技术，无需对设备进行改装或采购新设备，大幅降低设备成本，有效扩宽设备使用范围；
（3）本发明修复过程简单便捷，可操作性强，适用于难修复超薄结构。
较佳的是，本发明的超薄结构增材制造修复的方法还包括步骤（g）：在步骤（f）之后，对修复后的超薄结构进行热处理，以去除应力或者调控显微组织。
较佳的是，本发明的超薄结构增材制造修复的方法还包括步骤（h）：在步骤（g）之后，对修复区域进行打磨或机加工，以使修复区域尺寸达到最终使用要求。
较佳的是，步骤（e）中的激光参数为：激光功率300－400W，扫描速率800－1000mm/min，光斑直径1mm。通过适宜的激光参数，能较佳地对待修复区域的底部轮廓周围粉末进行烧结，从而形成适应性工装，对随后熔化沉积修复形成有效支撑。
较佳的是，步骤（f）中的激光参数为：激光功率300－500W，扫描速率400－500mm/min，光斑直径1mm，送粉速率10－12g/min。通过适宜的激光参数，能较佳地对待修复区域进行修复。
较佳的是，步骤（e）和步骤（f）中采用同一激光高能束设备。结合了适应性工装设计及增材制造技术，无需对设备进行改装或采购新设备，大幅降低设备成本，有效扩宽设备使用范围。或者，步骤（e）中也可采用区别于步骤（f）中的其他高能束（电子束、离子束等）设备。
较佳的是，步骤（b）中的三维模型是通过建模软件建模或三维扫描原始零件（原始零件即没有损伤的超薄结构）来获取的，从而能较佳地获取待修复区域的三维模型。
较佳的是，步骤（c）包括：余量添加处理、分层切片处理和路径规划处理，从而能较佳地对待修复区域的三维模型进行处理，以便后续修复操作。
较佳的是，如图2—图3所示，步骤（e）中的适应性工装由金属或非金属材料来构建，且固定至超薄结构。用适宜的材料、在适宜的位置构建载粉装置，以便后续填充粉末，烧结后形成适应性工装。
较佳的是，步骤（f）采用同步送粉的激光熔化沉积技术、铺粉的选区激光熔化沉积技术或其他高能束增材制造技术进行修复。用适宜的增材制造技术对待修复区域进行修复，确保较好的修复效果。
较佳的是，步骤（g）中的热处理参数为：热处理温度550℃，热处理时间4h。通过适宜的热处理参数，能较佳地去除修复后的超薄结构中的应力。
第一实施例：压气机叶片叶尖修复
（1）叶尖损伤机加工：将整个叶尖（含损伤区域）机加工去除。
（2）待修复区域三维建模：通过UG、CAD等建模软件对待修复区域进行三维建模。
（3）模型处理：对待修复区域三维模型进行余量添加（0.5mm）处理、分层切片处理、路径规划处理。
（4）适应性装夹待修复区域底部：通过铝箔等软性金属材料在待修复区域底部两侧适应性构建载粉装置21，并以耐高温胶布22固定到压气机叶片，如图2所示。
（5）载粉装置填充粉末：在载粉装置21内填充Ti17金属粉末23，并刮平粉末，使粉末与待修复区域底部表面13齐平。
（6）适应性工装制造：对待修复区域底部进行定位，根据模型获得待修复区域底部轮廓，设置激光器参数，使激光沿待修复区域底部轮廓扫描一周，对轮廓周围金属粉末进行烧结，从而形成适应性工装，对随后熔化沉积修复形成有效支撑。具体参数：激光功率300－400W，扫描速率800－1000mm/min，光斑直径1mm。
（7）修复区增材制造：完成适应性工装后，根据模型处理所得规划路径，采用同步送粉激光熔化沉积技术增材制造修复区（即，对待修复区域进行修复，修复完成之后，待修复区域成为修复区域）。具体参数：激光功率300－500W，扫描速率400－500mm/min，光斑直径1mm，送粉速率10－12g/min。
（8）热处理：选择合适的热处理制度，对修复后的超薄金属结构进行去应力处理。热处理参数为：热处理温度550℃，热处理时间4h。
（9）表面处理：对修复区域进行打磨或机加工，以使修复区域尺寸达到最终使用要求，恢复制件的表面质量要求Ra=0.6。
第二实施例：压气机叶片前后缘修复
（1）前后缘损伤机加工：以最小破坏原则将前后缘损伤区域机加工去除，形成规则梯形槽。
（2）待修复区域三维建模：通过UG、CAD等建模软件对待修复区域进行三维建模。
（3）模型处理：对待修复区域三维模型进行余量添加处理（0.5-1mm）、分层切片处理、路径规划处理。
（4）适应性装夹待修复区域底部：通过铝箔等软性金属材料在待修复区域底部两侧适应性构建载粉装置21，并以耐高温胶布22固定到压气机叶片，如图3所示。
（5）载粉装置填充粉末：在载粉装置21内填充TC4金属粉末23，并刮平粉末，使粉末与待修复区域底部表面13齐平。
（6）适应性工装制造：对待修复区域底部进行定位，根据模型获得待修复区域底部轮廓，设置激光器参数，使激光沿待修复区域底部轮廓扫描一周，对轮廓周围金属粉末进行烧结，从而形成适应性工装，对随后熔化沉积修复形成有效支撑。具体参数：激光功率300－400W，扫描速率800－1000mm/min，光斑直径1mm。
（7）修复区增材制造：完成适应性工装后，根据模型处理所得规划路径，采用同步送粉激光熔化沉积技术增材制造修复区（即，对待修复区域进行修复，修复完成之后，待修复区域成为修复区域）。具体参数：激光功率300－500W，扫描速率400－500mm/min，光斑直径1mm，送粉速率10－12g/min。
（8）热处理：选择合适的热处理制度，对修复后的超薄金属结构进行真空去应力处理。热处理参数为：热处理温度550℃，热处理时间4h。
（9）表面处理：对修复区域进行打磨或机加工，以使修复区域尺寸达到最终使用要求，恢复制件的表面质量要求Ra=0.6。
以上对本发明的具体实施方式进行了描述，但本领域技术人员将会理解，上述具体实施方式并不构成对本发明的限制，本领域技术人员可以在以上公开内容的基础上进行多种修改，而不超出本发明的范围。

Claims (8)

1.一种超薄结构增材制造修复的方法，超薄结构是指厚度小于1mm的结构，其特征在于，所述方法包括以下步骤：
（a）将所述超薄结构的损伤区域机加工去除；
（b）获取所述超薄结构的待修复区域的三维模型；
（c）对所述待修复区域的三维模型进行处理；
（d）在所述待修复区域的底部四周构建载粉装置，使载粉装置中的粉末填充至与所述待修复区域的底部表面齐平或相切；
（e）通过高能束或辅助加热装置使所述超薄结构的外轮廓周围载粉装置内粉末熔化、烧结或固化，并与所述超薄结构的外轮廓结合在一起，形成外轮廓加厚结构，成为适应性工装，起到支撑后续修复及避免烧蚀的作用；
（f）根据模型处理所得规划路径，通过增材制造技术对所述待修复区域进行修复。
2.如权利要求1所述的超薄结构增材制造修复的方法，其特征在于，所述方法还包括步骤（g）：
在步骤（f）之后，对修复后的超薄结构进行热处理，以去除应力或者调控显微组织。
3.如权利要求2所述的超薄结构增材制造修复的方法，其特征在于，所述方法还包括步骤（h）：
在步骤（g）之后，对修复区域进行机加工，以使修复区域尺寸达到最终使用要求。
4.如权利要求1所述的超薄结构增材制造修复的方法，其特征在于，步骤（e）采用高能束装置，步骤（f）采用与步骤（e）同一高能束装置或不同高能束装置。
5.如权利要求1所述的超薄结构增材制造修复的方法，其特征在于，步骤（b）中的三维模型是通过建模软件建模或三维扫描原始零件来获取的。
6.如权利要求1所述的超薄结构增材制造修复的方法，其特征在于，步骤（c）包括：余量添加处理、分层切片处理和路径规划处理。
7.如权利要求1所述的超薄结构增材制造修复的方法，其特征在于，步骤（e）中的适应性工装由金属或非金属材料来构建，且固定至所述超薄结构。
8.如权利要求1所述的超薄结构增材制造修复的方法，其特征在于，步骤（f）采用同步送粉的激光熔化沉积技术、铺粉的选区激光熔化沉积技术或其他类型增材制造技术进行修复。
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