CN112760637A - Remanufacturing and repairing method for failed gas turbine blade - Google Patents
Remanufacturing and repairing method for failed gas turbine blade Download PDFInfo
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- CN112760637A CN112760637A CN202011544159.1A CN202011544159A CN112760637A CN 112760637 A CN112760637 A CN 112760637A CN 202011544159 A CN202011544159 A CN 202011544159A CN 112760637 A CN112760637 A CN 112760637A
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
- C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/10—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/021—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/027—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal matrix material comprising a mixture of at least two metals or metal phases or metal matrix composites, e.g. metal matrix with embedded inorganic hard particles, CERMET, MMC.
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Composite Materials (AREA)
- Inorganic Chemistry (AREA)
- Thermal Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Laser Beam Processing (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
The invention discloses a remanufacturing and repairing method for a failed gas turbine blade. The invention is carried out according to the following steps: firstly, adopting a laser cladding process to recover the size of a failed gas turbine blade, then carrying out shot blasting strengthening treatment on the outer surface of the gas turbine blade after the first step, wherein the shot blasting material is glass shots with the diameter of 0.8-1.2mm, the shot blasting pressure of 0.4-0.5MPa and the shot blasting time of 80-100s, and finally adopting a plasma spraying process to spray the blade through shot blasting treatment, wherein the spraying material is WC-12Co metal ceramic powder, the thickness of a spraying layer is 240-280 mu m at the windward side part, and the thickness of a non-windward side part is 180-220 mu m. The gas turbine blade repaired by the process method has good wear resistance and corrosion resistance, and the service life of the blade can be greatly prolonged by 2-3 times of that of the original blade.
Description
Technical Field
The invention relates to the field of gas turbines, in particular to a remanufacturing and repairing process method for a gas turbine blade.
Background
Gas turbines have been widely used in power generation, marine, aviation, and other industries as an important power output device. The core part of the engine mainly comprises a compressor (namely a compressor), a combustion chamber and a turbine. The working process of the gas turbine is that the compressor continuously sucks air from the atmosphere and compresses the air; the compressed air enters a combustion chamber, is mixed with the injected fuel and then is combusted to form high-temperature fuel gas, and then flows into a gas turbine to expand and do work, so that a turbine impeller is pushed to drive a compressor impeller to rotate together, and the chemical energy of the fuel is finally converted into mechanical energy.
Gas turbine blades are important components of gas turbines. The gas generated after the fuel and the air are mixed and combusted pushes the blades to do work, and kinetic energy is provided for the gas turbine. Nickel alloys are the primary material used to make gas turbine blades. Nickel alloys used in gas turbine engine manufacturing generally have high long-term strength, fatigue strength, and long-term plasticity characteristics, and are highly structurally and mechanically stable at the operating temperatures of the gas turbine engine assembly.
The turbine blade of the gas turbine fails and is discarded due to the defects of abrasion, corrosion, cracks and the like caused by the effects of abrasion, impact, high-temperature gas, cold and hot fatigue and the like for a long time. Failure mechanisms are mainly cavitation, corrosion, wear, high temperature oxidation and fracture by fatigue. Thus, the high requirements are provided for the wear resistance, the corrosion resistance, the high-temperature oxidation resistance and the mechanical property of the material of the gas turbine blade.
At present, the repair method of the failed gas turbine blade is mainly fusion welding repair, and mainly comprises argon arc welding, plasma arc welding, laser welding, micro-arc spark welding and the like. In addition, the repair method comprises brazing, laser cladding, powder metallurgy and the like. These methods are limited to restoring the blade function and do not improve or improve very little the blade life.
Disclosure of Invention
The present invention is directed to overcoming the above-mentioned deficiencies in the prior art and providing a method for remanufacturing and repairing a failed gas turbine blade.
The invention relates to a remanufacturing and repairing method of a failed gas turbine blade, which comprises the following steps of firstly recovering the size of the failed gas turbine blade by adopting a laser cladding process, then carrying out shot blasting strengthening treatment on the surface of the repaired gas turbine blade by adopting a shot blasting process, and then spraying a metal ceramic coating by adopting a plasma spraying process to obtain a new blade with a composite coating, namely remanufacturing the gas turbine blade is completed, and the method comprises the following steps:
the first step is as follows: the method comprises the following steps of (1) recovering the size of a failed gas turbine blade by adopting a laser cladding process, wherein a repair material is low-melting-point nickel-based alloy powder, the laser scanning power is 2.5-4 KW, and the scanning speed is 200-400 mm/min;
the second step is that: after the blade is subjected to laser cladding treatment, shot blasting treatment is carried out on the outer surface of the blade, the shot blasting material is glass shots, the diameter is 0.8-1.2mm, the shot blasting pressure is 0.4-0.5MPa, the shot blasting time is 80-100s, and a compressive stress sub-surface layer with the thickness of 150 mu m is generated on the blade through shot blasting treatment, so that the fatigue resistance of the material is improved;
the third step: and (2) spraying the gas turbine blade after the first step and the second step by adopting a plasma spraying process, wherein the spraying material is WC-12Co cermet powder, the powder granularity is 35-75 mu m, the plasma spraying power is 40KW, the spraying distance is 70-120mm, the main gas flow is 30-40L/min, the thickness of a spraying layer is 240-280 mu m of the windward side part, and 180-220 mu m of the non-windward side part.
The gas turbine blade repaired by the process method has good wear resistance and corrosion resistance, and the service life of the blade can be greatly prolonged by 2-3 times of that of the original blade.
The method adopts three composite processes of a laser cladding process, a shot peening strengthening process and a plasma spraying process to repair the gas turbine blade, not only recovers the size, but also forms a layer of metal ceramic coating on the surface of the blade, and greatly prolongs the service life of the gas turbine blade.
Detailed Description
The present invention is further illustrated by the following specific examples.
The invention mainly relates to three processes of laser cladding, shot peening strengthening and plasma spraying, which are respectively introduced as follows:
laser cladding process
The laser cladding process is a technology which is widely applied in recent years, and the laser cladding refers to that under the irradiation of laser beams, a selected coating material is quickly melted and solidified on the surface of a cladded substrate in different material adding modes to form a surface coating with extremely low dilution and metallurgical bonding with the substrate, so that the wear resistance, corrosion resistance, heat resistance, oxidation resistance and other properties of the surface of the substrate are obviously improved, and the purpose of surface modification or repair is achieved. Compared with the processes of overlaying welding, spraying, electroplating, vapor deposition and the like, the laser cladding has the characteristics of small dilution, compact structure, good combination of a coating and a matrix, more suitable cladding materials and the like, and is widely applied.
Shot peening process
Shot peening is one of effective methods for reducing fatigue of parts and prolonging service life, wherein shot peening is to spray high-speed shot flow to the surface of the parts to enable the surface layers of the parts to generate plastic deformation to form a strengthening layer with a certain thickness, and higher residual stress is formed in the strengthening layer. The shot blasting material mainly comprises steel shots, glass shots and the like.
Plasma spraying process
Plasma spraying is a technology for strengthening and modifying the surface of a material, and can enable the surface of a matrix to have the performances of wear resistance, corrosion resistance, high-temperature oxidation resistance, electric insulation, heat insulation, radiation protection, wear reduction, sealing and the like. The plasma coating technique is a method of heating a material such as ceramics, alloys, metals, etc. to a molten or semi-molten state by using a plasma arc driven by a direct current as a heat source, and spraying the material at a high speed onto the surface of a pretreated workpiece to form a firmly adhered surface layer.
The plasma spraying technology is a novel multipurpose precision spraying method which is developed after flame spraying, and has the following characteristics:
the energy beam is concentrated and can melt all the high-hardness and high-melting-point powder, so that the energy beam can be used as a spraying material with wide range and can be used for preparing various coatings.
Secondly, because the flying speed of the sprayed particles is high, the obtained coating is flat and smooth, the density is high, and the powder deposition rate is high.
And thirdly, the base body is not electrified and does not melt in the spraying process, and the relative movement speed of the base body and the spray gun is high, so that the structure of the base body is not changed. The shape and the performance of the matrix cannot be affected by heat.
Fourthly, the working gas is inert gas, the matrix and the powder are protected from oxidation, and impurities in the coating are few.
Simple operation, low equipment maintenance cost and good regulation performance.
The invention adopts a laser cladding process, a shot blasting process and a plasma spraying process to repair the failed gas turbine blade. There are three main process steps.
The first step is as follows: and (3) recovering the size of the failed gas turbine blade by adopting a laser cladding process, wherein the repair material is low-melting-point NiCrBSi nickel-based alloy powder. The laser scanning power is 2.5-4 KW, and the scanning speed is 200-400 mm/min.
The second step is as follows: and (3) performing shot peening treatment on the outer surface of the gas turbine blade after the first step is finished. The shot blasting material is glass shot with the diameter of 0.8-1.2mm, the shot blasting pressure of 0.4-0.5MPa and the shot blasting time of 80-100 s. By shot peening, a compressive stress sub-surface layer of about 150 μm thickness can be created on the blade to improve the fatigue resistance of the material. Shot blasting is also a process before plasma spraying, and the bonding strength between the plasma sprayed layer and the substrate can be improved by shot blasting.
The third step: and spraying the gas turbine blade subjected to the first step and the second step by adopting a plasma spraying process. The spraying material is WC-12Co metal ceramic powder with the particle size of 35-75 μm. The plasma spraying power is 40KW, the spraying distance is 70-120mm, and the main gas flow is 30-40L/min. The thickness of the spray coating is 240-280 μm at windward part and 180-220 μm at non-windward part.
The gas turbine blade repaired by the process method has good wear resistance and corrosion resistance, and the service life of the blade can be greatly prolonged by 2-3 times of that of the original blade.
Claims (1)
1. A remanufacturing and repairing method for a failed gas turbine blade is characterized by comprising the following steps of:
the first step is as follows: adopting a laser cladding process to recover the size of the failed gas turbine blade, wherein the repair material is low-melting-point NiCrBSi nickel-based alloy powder;
the second step is that: shot blasting strengthening treatment is carried out on the outer surface of the gas turbine blade after the first step, shot blasting materials are glass shots, the diameter of the glass shots is 0.8-1.2mm, the shot blasting pressure is 0.4-0.5MPa, the shot blasting time is 80-100s, and a compressive stress sub-surface layer with the thickness of 150 mu m is generated on the blade through shot blasting treatment;
the third step: and (3) spraying the gas turbine blade subjected to the first step and the second step by adopting a plasma spraying process, wherein the spraying material is WC-12Co metal ceramic powder, and the thickness of a spraying layer is 240-280 mu m of the windward part and 180-220 mu m of the non-windward part.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011544159.1A CN112760637A (en) | 2020-12-24 | 2020-12-24 | Remanufacturing and repairing method for failed gas turbine blade |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011544159.1A CN112760637A (en) | 2020-12-24 | 2020-12-24 | Remanufacturing and repairing method for failed gas turbine blade |
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| Publication Number | Publication Date |
|---|---|
| CN112760637A true CN112760637A (en) | 2021-05-07 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202011544159.1A Withdrawn CN112760637A (en) | 2020-12-24 | 2020-12-24 | Remanufacturing and repairing method for failed gas turbine blade |
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| Country | Link |
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| CN (1) | CN112760637A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114657490A (en) * | 2022-03-22 | 2022-06-24 | 合肥学院 | Titanium-zirconium-based alloy surface treatment process and shot peening strengthening device |
| CN115466912A (en) * | 2022-08-22 | 2022-12-13 | 昆山西诺巴精密模具有限公司 | Surface enhancement processing method for titanium alloy blade disc blade and application of method |
-
2020
- 2020-12-24 CN CN202011544159.1A patent/CN112760637A/en not_active Withdrawn
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114657490A (en) * | 2022-03-22 | 2022-06-24 | 合肥学院 | Titanium-zirconium-based alloy surface treatment process and shot peening strengthening device |
| CN115466912A (en) * | 2022-08-22 | 2022-12-13 | 昆山西诺巴精密模具有限公司 | Surface enhancement processing method for titanium alloy blade disc blade and application of method |
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| WW01 | Invention patent application withdrawn after publication |
Application publication date: 20210507 |
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| WW01 | Invention patent application withdrawn after publication |