CN112663043A - Ultrasonic shot blasting assisted laser additive repair device and repair method thereof - Google Patents
Ultrasonic shot blasting assisted laser additive repair device and repair method thereof Download PDFInfo
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Abstract
The invention discloses an ultrasonic shot blasting auxiliary laser additive repairing device and a repairing method thereof, wherein the repairing device comprises a workbench for placing a workpiece to be repaired, an ultrasonic shot blasting tool head, a powder feeder and a laser cladding tool head which are driven to move above the workbench, wherein a driving robot of the ultrasonic shot blasting tool head is controlled by an ultrasonic shot blasting processing module to plan the motion track of the ultrasonic shot blasting tool head, the driving robot of the laser cladding tool head is controlled by a laser to plan the motion track of the laser cladding tool head, the powder feeder is driven by a powder spreader to control the motion track of the powder feeder, and an infrared temperature monitor is further arranged above the workbench. The invention ensures the synergistic effect of the rapid laser solidification and the ultrasonic impact by realizing the synergistic effect of the ultrasonic shot blasting and the laser cladding, greatly reduces the crack rate and the residual stress level, and realizes the laser additive repair of the high-temperature damaged parts of the nickel-based alloy with high precision, high performance and high efficiency.
Description
Technical Field
The invention relates to the technical field of material repair, in particular to a method for repairing a nickel-based superalloy by using ultrasonic shot blasting to assist laser material increase.
Background
At present, with the high-speed development of the aerospace level in China, the total amount of the market accumulated demands of domestic main passenger planes on engines will exceed 6000, and the opening of a low-altitude airspace will further stimulate the demands of general airplanes on the engines. Therefore, the matched maintenance service of the aero-engine will meet a huge market prospect, and the research on the repair technology of the damaged part after service has considerable commercial and application values.
At present, the solution for repairing the combustion chamber of the aero-engine mainly depends on manual operation, process separation, low efficiency and poor stability of repairing quality. The aeroengine combustion chamber generally adopts nickel-based high-temperature alloy, such as Hastelloy X and the like, and the repair by fusion welding has large residual stress and large heat input, so that the repair structure is easy to change, the deformation after repair is large, and the repair of high-precision damaged parts is difficult to realize. Although the laser repair method can avoid the defects of large heat input and the like in conventional fusion welding repair and realize the effects of low heat input, low residual stress and low deformation, the defects of air holes, cracks and the like are easily generated in the repair process of the nickel-based superalloy, the repair of high-strength aviation high-temperature components cannot be realized, and the repair of a nickel-based superalloy combustor and the development of a service life prolonging technology are seriously restricted.
Disclosure of Invention
The invention aims to provide ultrasonic shot blasting auxiliary laser additive adsorption equipment aiming at the problem that pores and crack defects are easy to generate when a nickel-based superalloy is repaired by a laser repair method in the prior art.
The invention provides an ultrasonic shot blasting auxiliary laser additive repair method for the nickel-based superalloy, so that a complete three-dimensional model of a high-temperature damaged part of the nickel-based superalloy is accurately constructed for repair, and the repair period is short.
The technical scheme adopted for realizing the purpose of the invention is as follows:
the utility model provides an ultrasonic peening auxiliary laser vibration material disk prosthetic devices, is including being used for placing the workstation of treating the restoration work piece, driven ultrasonic peening tool head, powder feeder, the laser cladding tool head that moves in workstation top, wherein the drive robot of ultrasonic peening tool head is controlled in order to plan the motion track of ultrasonic peening tool head by ultrasonic peening processing module, the drive robot of laser cladding tool head is controlled in order to plan the motion track of laser cladding tool head by the laser instrument, the powder feeder is driven in order to control its motion track by powder feeder, the workstation top still is equipped with infrared temperature monitor, laser instrument, powder spreader, infrared temperature monitor, powder feeder all are connected with laser control system communication, ultrasonic peening processing module and cooperative control system communication connection.
In another aspect of the invention, an ultrasonic shot blasting assisted laser additive repairing method comprises the following steps:
And 2, cleaning the surface of the workpiece to be repaired.
Step 3, planning a laser additive repair path and the number of cladding layers according to the planned shape and size of the patching area, and specifically:
establishing a model of the workpiece to be repaired, performing semi-ellipsoidal patching on the defect part, cutting the semi-ellipsoidal model obtained by patching by adopting a group of cutting planes which are parallel to the XZ coordinate plane and have a distance of delta, so as to obtain a group of intersecting trajectories, namely corresponding cladding trajectories,
laser cladding path spacing, namely spacing delta between tangent planes, is determined by lap joint rateThen the width of the slice is calculated by the formula (1), and the corresponding lap joint rate is obtained by substituting the formula (2)s；
In the formulas (1) and (2), l is the width of a single-channel cladding layer and the unit is mm; h is the height of the single-pass cladding layer, and the unit is mm;
the lifting amount Δ Z (in mm) of each cladding layer Z axis is obtained by the formula (3):
then planning a laser additive repair track by taking the slice width delta and the lifting amount of the Z axis as delta Z (unit is mm);
simultaneously planning the powder feeding amount and the powder feeding speed of a powder feeder, the power density of laser additive repair in a laser, the laser pulse width, the repair speed and the flow of protective gas as well as ultrasonic shot blasting process parameters in an ultrasonic shot blasting processing module according to the number of layers of the cladding layer and the specific size of each layer, determining the synchronous distance between ultrasonic shot blasting and laser additive repair at different repair positions, and preparing for the subsequent cladding repair processing;
step 4, fixing the workpiece to be repaired on a workbench by using a clamp, and performing ultrasonic shot blasting assisted laser additive repair according to the parameters obtained in the step 3;
and 5, monitoring the repair depth and size of each cladding layer by using an infrared temperature monitoring system, continuously adjusting the process parameters of laser additive repair and ultrasonic shot blasting, and repeating the processes of the steps 3-4 until the defect area is completely repaired.
And 6, removing redundant repairing layers on the workpiece to be repaired by using a machining method, and ensuring that the size of the repaired workpiece is the same as the original design size.
In the above technical solution, in the step 1, the semi-ellipsoidal shape and size to be patched are planned, and then the defect region is excavated according to the planned shape and size by using a mechanical method or a laser cutting method.
In the above technical solution, in step 3, the first single pass of the weld pass is combined with the actual optimal cladding process test to determine the specific value thereof, the optimal laser cladding process parameter is selected as the experimental parameter, after the first weld pass is welded by the process parameter, the width and height of the single pass of the weld pass are obtained by measuring with a vernier caliper, and the subsequent weld pass parameters are calculated by the formulas (1) - (3).
In the above technical solution, in the step 4, the controller sends a signal to the ultrasonic shot blasting control module to control the ultrasonic shot blasting tool head, selects a proper ultrasonic shot blasting head according to the repaired shape and size, then respectively opens the laser control system and the cooperative control system, and controls laser additive repair and ultrasonic shot blasting work by using two independent mechanical arms; the method comprises the steps of adopting the Hastelloy X powder with the same component, completing the powder feeding and powder laying process by using a powder feeder matched with a powder laying device through a powder feeding control module of a controller, monitoring the temperature of a repair area by using an infrared temperature monitor, feeding the temperature back to a cooperative control system to change the synchronous distance and the synchronous time interval of laser material increase repair, starting an ultrasonic shot blasting system after the temperature reaches a set temperature, and continuously keeping the distance from a laser cladding head until the repair is completed.
Compared with the prior art, the invention has the beneficial effects that:
1. the invention ensures the synergistic effect of the rapid laser solidification and the ultrasonic impact by realizing the synergistic effect of the ultrasonic shot blasting and the laser cladding, greatly reduces the crack rate and the residual stress level, and realizes the laser additive repair of the high-temperature damaged parts of the nickel-based alloy with high precision, high performance and high efficiency.
2. By adopting the ultrasonic shot blasting and laser cladding cooperative motion repairing method, a complete three-dimensional model of the damaged part can be accurately constructed.
3. In the process of repairing cracks in a defect area by laser additive, the residual stress is reduced by utilizing the micro forging and pressing effect of ultrasonic shot blasting high-speed impact, the heat treatment quenching crack and deformation are greatly reduced, and the defect rate is obviously reduced.
4. The invention realizes high-performance and high-quality welding repair by utilizing the accurate control and the cooperative control of the ultrasonic shot blasting and the laser additive synchronous distance, and prolongs the service life of the damaged part after service.
5. The invention has short repair period, less material loss and low use cost, is suitable for batch production and has extremely high economic value.
Drawings
FIG. 1 is a three-dimensional view of a prototype with ultrasonic shot blasting and micro forging auxiliary laser additive repair
FIG. 2 is an operation schematic diagram of an ultrasonic shot blasting micro-forging auxiliary laser additive repair prototype
FIG. 3 is a schematic structural diagram of an apparatus of an embodiment of ultrasonic peening micro forging and pressing assisted laser additive repair
FIG. 4 is a schematic diagram of a semi-ellipsoidal patch shape processing
FIG. 5 is a slice view of a patch model
FIG. 6 is a schematic diagram of multilayer cladding Z-axis lifting amount model calculation
In the figure: 1-ultrasonic shot blasting tool head, 2-ultrasonic shot blasting processing module, 3-laser, 4-powder laying device, 5-infrared temperature monitor, 6-powder feeding device, 7-laser cladding tool head, 8-cooperative control system, 9-laser control system, 10-workpiece to be repaired, and 11-workbench.
Detailed Description
The present invention will be described in further detail with reference to specific examples. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Example 1
As shown in fig. 1 to 3, the ultrasonic shot-peening auxiliary laser additive repair device of the present invention includes a laser tool head, an ultrasonic shot-peening tool head, a workbench 11, a powder feeder, a gas cylinder gas valve, and other welding auxiliary equipment. The integrated processing equipment has high efficiency, multiple functions and high precision.
FIG. 4 shows an embodiment of the laser additive repair device assisted by ultrasonic peening and micro forging, which comprises a worktable 11 for placing a workpiece 10 to be repaired, an ultrasonic peening tool head 1 driven to move above the worktable, a powder feeder 6, a laser cladding tool head 7, wherein the driving robot of the ultrasonic peening tool head 1 is controlled by the ultrasonic peening module 2 to plan the motion track of the ultrasonic peening tool head 1, the driving robot of the laser cladding tool head 7 is controlled by the laser 3 to plan the motion track of the laser cladding tool head 7, the powder feeder 6 is controlled by the powder spreader 4, the workstation top still is equipped with infrared temperature monitor 5, and laser instrument 3, shop's powder ware 4, infrared temperature monitor 5, powder feeder 6 are connected with the communication of laser control system 9, ultrasonic peening processing module 2 is connected with the communication of cooperative control system 8.
Example 2
Based on the equipment of embodiment 1, the ultrasonic shot blasting assisted laser additive repairing method comprises the following steps:
And 2, cleaning the surface of the workpiece 10, removing an oxidation layer and metal residues on the surface of the test piece 10, and preventing impurities from entering the repair layer to influence the quality and the performance of the repair layer.
Step 3, planning a laser additive repair path and the number of cladding layers according to the planned shape and size of the patching area, and specifically:
as shown in fig. 2, a set of cut planes parallel to the XZ coordinate plane and having a distance of δ are used to cut the semi-ellipsoidal model obtained by patching, so as to obtain a set of intersecting trajectories (intersecting lines of the cut planes and the semi-ellipsoidal patch area), which are corresponding cladding trajectories, wherein:
the slice width delta (i.e. of two adjacent slice planes) is controlled by the overlap ratioSpacing between the two weld beads), determining specific values of the weld beads by combining with an optimal cladding process test in practice, selecting optimal laser cladding process parameters as experimental parameters, obtaining the optimal laser cladding process parameters by repeated experimental search according to repair materials, taking a nickel-based superalloy as an example, obtaining the width and the height of a single weld bead by measuring a vernier caliper after the first weld bead is welded by using working parameters under the conditions of laser power 1700w, laser scanning speed 5mm/s and powder feeding amount 15g/min as the optimal parameters, (the single weld bead is a basic weld bead forming a cladding track, the cladding track is formed by a plurality of single weld beads, the first weld bead is measured by the vernier caliper, and the subsequent weld bead parameters are obtained by calculating as follows. ) Then calculating by formula (1) to obtain the slice width, substituting formula (2) to obtain the corresponding lap joint rates；
In the formulas (1) and (2), l is the width of a single-channel cladding layer and the unit is mm; h is the height of the single-pass cladding layer and the unit is mm.
As shown in fig. 3, a rectangular plane coordinate system XOY is established in the cladding plane, according to the characteristics of multilayer cladding, the lifting amount of the Z axis of each cladding layer is assumed to be Δ Z when single-pass multilayer cladding is performed, each cladding layer is assumed to be an arc with an equal cross-sectional area for the model, and the curvature of the track after cladding is kept unchanged. Theoretically, the relative flatness of the front layer and the rear layer before cladding is ensured. This makes it possible to obtain:
SEFH＝SADE+SCFG (3)
SACGD＝SOAHC-SOAC (4)
let AC ═ L, CH ═ h, AD ═ Δ Z, and arc radius r. Can be substituted by the formulas (3) and (4):
then planning the track of the laser additive repair by the slice width delta and the lifting amount of the Z axis delta Z (in mm).
Meanwhile, according to the number of layers and the specific size of each layer, parameters such as the powder feeding amount and the powder feeding speed of the powder feeder 6, the power density of laser additive repair, the laser pulse width, the repair speed and the flow of protective gas in the laser 3, and ultrasonic shot blasting process parameters in the ultrasonic shot blasting processing module 2 are planned, the synchronous distance between ultrasonic shot blasting and laser additive repair at different repair positions shown in fig. 3 is determined, and preparation is made for subsequent cladding repair processing, taking a nickel-based alloy material as an example, working parameters under the conditions that the laser power is 1700w, the laser scanning speed is 5mm/s and the powder feeding amount is 15g/min are taken as optimal parameters.
And 4, fixing the nickel-based alloy part 10 to be repaired on the workbench by using a clamp. The laser cladding device is arranged in a computer, the controller 8 is used for determining the movement track and the cladding parameters of the laser cladding tool head 7, signals are sent to the laser 3, and the laser cladding tool head 7 is controlled to excite laser beams to a corresponding damage area so as to carry out the subsequent additive material repairing process. The controller 9 sends a signal to the ultrasonic shot blasting control module 2 to control the ultrasonic shot blasting tool head 1, and an appropriate ultrasonic shot blasting head is selected according to the repaired shape and size. Then respectively opening the laser control system and the cooperative control system, and controlling laser additive repair and ultrasonic shot blasting work by using two independent mechanical arms as shown in figure 1; the powder feeding and powder laying process is completed by adopting the hastelloy X powder with the same component and matching the powder feeder 6 with the powder laying device 4 through a powder feeding control module of the controller 8. The infrared temperature monitor 5 is used for monitoring the temperature of the repair area and feeding back the temperature to the cooperative control system 8 so as to change the synchronous distance and the synchronous time interval of laser material increase repair, and after the set temperature is reached, the ultrasonic shot blasting system is started and the distance between the ultrasonic shot blasting system and the laser cladding head is continuously kept, as shown in fig. 3. Until the repair is completed.
And 5, monitoring the repair depth and size of each layer by using an infrared temperature monitoring system 5, and continuously adjusting the process parameters of laser additive repair and ultrasonic shot blasting. And then repeating the processes of the steps 3 and 4 in sequence until the defect area is completely repaired.
And 6, removing the redundant repairing layer on the workpiece 10 to be repaired by using a machining method, and ensuring that the size of the repaired nickel-based alloy part is the same as the original design size.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.
Claims (5)
1. The utility model provides a supplementary laser vibration material disk prosthetic devices of ultrasonic peening, its characterized in that is in including being used for placing the workstation of treating the restoration work piece, driven ultrasonic peening tool head, powder feeder, the laser cladding tool head that the workstation top removed, wherein the drive robot of ultrasonic peening tool head is controlled in order to plan the motion track of ultrasonic peening tool head by ultrasonic peening processing module, the drive robot of laser cladding tool head is controlled in order to plan the motion track of laser cladding tool head by the laser instrument, the powder feeder is driven in order to control its motion track by powder spreader, the workstation top still is equipped with infrared temperature monitor, laser instrument, powder spreader, infrared temperature monitor, powder feeder all are connected with laser control system communication, ultrasonic peening processing module and cooperative control system communication are connected.
2. The ultrasonic shot blasting assisted laser additive repairing method is characterized by comprising the following steps of:
step 1, according to a workpiece to be repaired, a damaged part and a defect specification size are determined through scanning, and semi-ellipsoidal patching is performed on the defect part.
And 2, cleaning the surface of the workpiece to be repaired.
Step 3, planning a laser additive repair path and the number of cladding layers according to the planned shape and size of the patching area, specifically:
establishing a model of the workpiece to be repaired, performing semi-ellipsoidal patching on the defect part, cutting the semi-ellipsoidal model obtained by patching by adopting a group of cutting planes which are parallel to the XZ coordinate plane and have a distance of delta, so as to obtain a group of crossed trajectories, namely corresponding cladding trajectories,
the laser cladding path distance, namely the distance delta between the cutting planes is controlled by the lap joint rate, then the slice width is calculated by the formula (1), and the corresponding lap joint rate is obtained by substituting the formula (2)s；
In the formulas (1) and (2), l is the width of a single-channel cladding layer; h is the height of a single cladding layer;
the lifting amount Δ Z of each cladding layer Z axis is obtained by the formula (3):
planning a laser additive repair track for delta Z according to the slice width delta and the lifting amount of the Z axis;
simultaneously planning the powder feeding amount, the powder feeding speed, the power density of laser additive repair, the laser pulse width, the repair speed, the flow of protective gas and ultrasonic shot blasting process parameters in an ultrasonic shot blasting processing module according to the number of layers of the cladding layer and the specific size of each layer, and determining the synchronous distance between ultrasonic shot blasting and laser additive repair at different repair positions to prepare for subsequent cladding repair processing;
step 4, fixing the workpiece to be repaired on a workbench by using a clamp, and performing ultrasonic shot blasting assisted laser additive repair according to the parameters obtained in the step 3;
and 5, monitoring the repair depth and size of each cladding layer by using an infrared temperature monitoring system, continuously adjusting the process parameters of laser additive repair and ultrasonic shot blasting, and repeating the processes of the steps 3-4 until the defect area is completely repaired.
And 6, removing redundant repairing layers on the workpiece to be repaired by using a machining method, and ensuring that the size of the repaired workpiece is the same as the original design size.
3. The ultrasonic shot-peening-assisted laser additive repairing method according to claim 2, wherein in the step 1, semi-ellipsoidal repair shapes and sizes are planned, and then defect regions are excavated according to the planned shapes and sizes by a mechanical method or a laser cutting method.
4. The ultrasonic shot-peening-assisted laser additive repairing method as claimed in claim 2, wherein in the step 3, a first single welding pass is combined with an actual optimal cladding process test to determine a specific value, an optimal laser cladding process parameter is selected as an experimental parameter, after the first welding pass is welded according to the process parameter, the width and the height of the single welding pass are obtained through measurement of a vernier caliper, and subsequent welding pass parameters are calculated through the formulas (1) - (3).
5. The ultrasonic shot-peening assisted laser additive repairing method according to claim 2, wherein in the step 4, the controller sends a signal to the ultrasonic shot-peening control module to control the ultrasonic shot-peening tool head, an appropriate ultrasonic shot-peening head is selected according to the repaired shape and size, and then the laser control system and the cooperative control system are respectively opened to control laser additive repairing and ultrasonic shot-peening work by two independent mechanical arms; adopting hastelloy X powder with the same composition, completing the powder feeding and powder laying process by using a powder feeder matched with a powder laying device through a powder feeding control module of a controller, monitoring the temperature of a repair area by using an infrared temperature monitor, and feeding back to a cooperative control system to change the synchronous distance and synchronous time interval of laser material increase repair, starting an ultrasonic shot blasting system after the set temperature is reached, and continuously keeping the distance with a laser cladding head until the repair is completed.
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