CN112877689A - Process for repairing surface defects of metal parts through full-angle posture of laser cladding head - Google Patents
Process for repairing surface defects of metal parts through full-angle posture of laser cladding head Download PDFInfo
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- CN112877689A CN112877689A CN202110171789.7A CN202110171789A CN112877689A CN 112877689 A CN112877689 A CN 112877689A CN 202110171789 A CN202110171789 A CN 202110171789A CN 112877689 A CN112877689 A CN 112877689A
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- 238000004372 laser cladding Methods 0.000 title claims abstract description 92
- 239000002184 metal Substances 0.000 title claims abstract description 50
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 50
- 238000000034 method Methods 0.000 title claims abstract description 41
- 230000007547 defect Effects 0.000 title claims abstract description 35
- 230000008569 process Effects 0.000 title claims abstract description 33
- 239000000843 powder Substances 0.000 claims abstract description 59
- 230000008439 repair process Effects 0.000 claims abstract description 35
- 230000001681 protective effect Effects 0.000 claims abstract description 29
- 238000005253 cladding Methods 0.000 claims abstract description 26
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 14
- 239000000956 alloy Substances 0.000 claims abstract description 13
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 13
- 230000003287 optical effect Effects 0.000 claims abstract description 9
- 239000000758 substrate Substances 0.000 claims abstract description 8
- 229910052742 iron Inorganic materials 0.000 claims abstract description 7
- 238000001514 detection method Methods 0.000 claims abstract description 5
- 238000012545 processing Methods 0.000 claims description 13
- 239000002245 particle Substances 0.000 claims description 4
- 238000012795 verification Methods 0.000 claims description 3
- 230000035515 penetration Effects 0.000 claims 1
- 238000010276 construction Methods 0.000 abstract 1
- 238000007781 pre-processing Methods 0.000 abstract 1
- 238000005516 engineering process Methods 0.000 description 5
- 230000000694 effects Effects 0.000 description 3
- 230000005484 gravity Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 230000009471 action Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000007689 inspection Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000012895 dilution Substances 0.000 description 1
- 238000010790 dilution Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000002715 modification method Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
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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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
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Abstract
The invention discloses a process for repairing surface defects of a metal part in a full-angle posture by a laser cladding head, and belongs to the technical field of laser repairing of metal parts. The specific construction process comprises the following steps: A. preprocessing a region to be repaired; B. drawing a related three-dimensional model to generate a six-axis manipulator motion program; C. taking iron-based self-fluxing alloy powder as cladding powder, setting the diameter of a laser spot to be 1.5-2.5mm, the laser power to be 600-800W, the scanning speed to be 10-15mm/s, the powder carrying airflow to be 6-8L/min, the powder feeding speed to be 8-16g/min and the multi-channel cladding overlap ratio to be 35-50%, selecting the proper pipe diameter size of a protective gas outlet of a laser cladding head and the protective gas flow, and performing laser cladding repair on a defect area on the surface of a to-be-repaired substrate of the large metal part by using an optical outer coaxial powder feeding method by using the laser cladding head in any posture; D. and (5) quality detection. The invention reduces the offset of the molten pool through the process parameters of the laser spot diameter and the like of the small spot, and realizes the full-angle repair of the laser cladding head to the surface of the metal part.
Description
Technical Field
The invention belongs to the technical field of laser repair of metal parts, and particularly relates to a process for repairing surface defects of metal parts in a full-angle posture by a laser cladding head.
Background
The laser repairing technology is an advanced surface repairing technology, and the process method for repairing the surface is achieved by adding special cladding materials on the surface to be repaired in different modes, enabling the cladding materials and the surface to be repaired to be simultaneously melted through interaction with laser, forming a low dilution rate after the cladding materials and the surface to be repaired are rapidly solidified in a very short time, and forming a coating which is in metallurgical bonding with the surface to be repaired.
Most of the existing laser repair technologies are based on a horizontal base surface for repairing, namely a laser cladding head always keeps a vertical position with the horizontal base surface and then processes on the horizontal base surface, but for some large-scale equipment, structural members and parts, there is no way to incline a base body to enable a defect area of the base body to be just in a horizontal position, when damage occurs on the non-horizontal base surface of a metal part, when the repair is carried out by adopting the laser cladding technology, liquid drops in a molten pool can flow downwards under the action of gravity, and sent powder can also bounce back to a protective lens so as to damage an instrument, so that cladding and repairing processing are difficult to carry out.
At present, laser cladding on non-horizontal base surfaces is mainly classified into two types, one is cladding on non-horizontal base surfaces based on light external powder feeding, and the other is cladding on non-horizontal base surfaces based on light internal powder feeding. The multi-angle cladding on the non-horizontal base surface based on the light external powder feeding can only realize the three-dimensional repair of a small angle through a single inclined base body or an inclined cladding head or realize the repair on a specific position through designing a special cladding head at present, and the laser cladding repair can not be carried out on the damaged area on the large-angle inclined base surface. And multi-angle cladding on a non-horizontal base surface based on optical internal powder feeding needs to modify a laser beam, and the beam modification method is not mature at present and is not beneficial to popularization and application. Moreover, multi-angle cladding is realized based on an optical inner powder feeding mode, and at present, the method is only in an initial research stage, and a plurality of technical difficulties are not solved.
The problems certainly limit the popularization and application of the laser repair technology in practical production, and in order to solve the problems, a process method based on light external coaxial powder feeding needs to be provided to meet the requirements in practical production and application.
Disclosure of Invention
In order to solve the problems, the invention aims to provide a process for repairing the surface defects of the metal parts in a full-angle posture by using a laser cladding head.
In order to achieve the purpose, the following technical scheme is provided:
a process for repairing surface defects of metal parts by a laser cladding head in a full-angle posture comprises the following steps:
A. processing the surface of the area to be repaired of the metal part;
B. measuring the size of the area to be repaired, drawing a three-dimensional model of the area to be repaired, and generating a six-axis manipulator motion program of a laser cladding head scanning track in the laser cladding process;
C. executing the planned cladding repair scanning path program in the step B, taking the iron-based self-fluxing alloy powder as cladding powder, setting the diameter of a laser spot to be 1.5-2.5mm, setting the laser power to be 600-800W, setting the scanning speed to be 10-15mm/s, setting the powder carrying airflow to be 6-8L/min, setting the powder feeding speed to be 8-16g/min and the multi-channel cladding lap-joint rate to be 35-50%, selecting the proper pipe diameter size of a protective gas outlet of a laser cladding head and the protective gas flow, and performing laser cladding repair on the defect area on the surface of the to-be-repaired substrate of the large metal part by adopting an optical outer coaxial powder feeding method, wherein the laser cladding head performs laser cladding repair on the defect area on the surface;
D. and (4) processing the surface of the repaired metal part until the surface meets the drawing requirements, and finally detecting the surface of the repaired area.
Preferably, the treatment in the step a is to remove oxide skin, fatigue layer and cracks existing on the surface of the area to be repaired of the metal part by adopting a mechanical processing mode, and then clean up oil stains on the surface of the area to be repaired.
Preferably, the process for repairing the surface defects of the metal part in the full-angle posture by using the laser cladding head is characterized in that when the laser cladding head repairs the defects on the surface of the large metal part to be repaired, the posture adjustment realized by driving the laser cladding head by using the six-axis manipulator is realized, and the axis direction of the laser cladding head is always vertical to the repaired surface so as to ensure that the powder pipe is vertical to the repaired surface for powder feeding.
Preferably, when the laser cladding head repairs the defects at the vertical face of the metal part to be repaired, the distance between the outlet of the laser cladding head and the surface to be repaired is kept constant at 8-12 mm.
Preferably, the particle size of the iron-based self-fluxing alloy powder is 200-300 meshes (48-75 micrometers), the sphericity of powder particles is high, the powder flowability is good, and the porosity is low.
Preferably, the pipe diameter of the protective gas outlet of the laser cladding head is 4-6 mm.
Preferably, the protective gas flow is 12-18L/min, when the laser cladding head performs laser cladding in an elevation posture, alloy powder is very easy to rebound into the cladding head to damage the protective lens, and the laser cladding head is damaged to a certain extent, the rebound alloy powder can be effectively blown out by the protective gas in the laser cladding head to prevent the protective lens from being polluted, under the condition that the pipe diameter of a protective gas outlet of the laser cladding head is determined, the fallen alloy powder cannot be blown out by too low protective gas flow, and the molten pool is deformed by too high protective gas flow to influence the morphology of a deposition layer, so that the influence of the protective gas on the molten pool is reduced as much as possible under the condition that the fallen alloy powder is blown out by the protective gas.
Preferably, when the laser cladding head repairs the defects on the surface of the large metal part to be repaired, the power density of laser cladding is kept constant.
Preferably, in step B, an offline programming is adopted when generating a six-axis robot program of the scanning trajectory of the laser cladding head.
Preferably, the detection in the step D is to perform penetrant inspection and verification to ensure the quality of the repaired metal part.
The method comprises the steps that the downward force of molten drops at the non-horizontal base surface of a metal part is the component force of the gravity of the molten drops in the downward direction along the inclined surface, the more the non-horizontal base surface is close to vertical, the larger the component force is, the larger the offset of a molten pool is, the smaller laser spot diameter of 1.2-2.5mm is selected, the scanning speed is 10-15mm/s, the adopted laser power is 600 plus 800w, the obtained molten pool is small, on one hand, the constraint effect of the surface tension in the small molten pool on the molten pool is strong, and therefore the offset of the molten pool appearance is small under the action of the gravity; on the other hand, under the same scanning speed, the heat input of a small molten pool is small, the small molten pool can be rapidly cooled and solidified, the flow of the molten pool on a non-horizontal base surface is reduced, the selected powder carrying airflow is 6-8L/min, the powder carrying airflow is reduced as far as possible under the condition that a powder beam has good convergence, the divergence of powder is reduced, the forming quality is improved, meanwhile, under the accurate matching of other various process parameters, the stable growth of a cladding layer on different positions of the outer surface of a large-scale metal part is ensured under the condition that a large-angle inclined laser cladding head is realized, and the rapid repair of the outer surface in a full angle is realized.
Compared with the prior art, the invention has the beneficial effects that:
1) the six-axis manipulator is used as a moving machine to drive the laser cladding head to realize large-angle posture adjustment, and when the laser cladding repair is carried out on the to-be-repaired area on the vertical surface of the metal part, the special cladding head is not required to be designed to realize the repair of a specific position, and the metal part is not required to be inclined, so that the laser field repair can be carried out on the large metal part;
2) when the invention adopts the mode of optical outer coaxial powder feeding to carry out laser cladding repair on the defect area on the surface of the non-horizontal matrix, the offset of a molten pool is reduced by controlling each process parameter, particularly adopting the smaller laser spot diameter of 1.5-2.5 mm; under the condition that the diameter of a protective gas outlet of the laser cladding head is determined, the flow of protective gas is accurately controlled, and the influence of the protective gas on a molten pool is reduced as much as possible under the condition that the protective gas blows back fallen alloy powder; the powder carrying airflow is accurately controlled, the rigidity of the powder flow of the laser cladding head is kept, the divergence of the powder flow is reduced as much as possible, and the forming quality is improved.
3) Compared with a laser cladding head realized in an optical inner powder feeding mode, the laser cladding head carries out laser cladding repair on the defect area on the surface of the substrate to be repaired, which forms an angle of more than 90 degrees with the horizontal direction, in any posture, does not need to transform laser beams, and has lower application cost.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments described in the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
Fig. 1 is a schematic diagram of a laser cladding head performing a repairing motion according to a generated scanning track path, wherein the laser cladding head with a dotted line represents that the laser cladding head moves to different processing positions;
FIG. 2 is a vertically upward metallographic view of a laser cladding head for repairing a surface of a metal part obtained by the process of the present invention;
FIG. 3 is a vertically downward metallographic view of a laser cladding head for repairing a surface of a metal part obtained by the process of the present invention.
Detailed Description
The invention is further described in the following with reference to the drawings and examples of the description, but the scope of the invention is not limited thereto.
The surface repair process of the invention adopts a mode of optical outer coaxial powder feeding to carry out laser cladding repair on the defect area on the outer surface of the large metal part substrate, and reduces the offset of a molten pool by controlling each process parameter, particularly adopting a smaller laser spot diameter of 1.5-2.5 mm; under the condition that the diameter of a protective gas outlet of the laser cladding head is determined, the flow of protective gas is accurately controlled, and the influence of the protective gas on a molten pool is reduced as much as possible under the condition that the protective gas blows back fallen alloy powder; the powder carrying airflow is accurately controlled, the rigidity of the powder flow of the laser cladding head is kept, the divergence of the powder flow is reduced as much as possible, and the forming quality is improved; as shown in figure 1, the laser cladding head can carry out laser cladding repair on the defect area on the outer surface of the large-sized metal part substrate in any posture. The repair process comprises the following steps:
A. processing the surface of the area to be repaired;
the surface treatment is to remove oxide skin, fatigue layer and cracks existing on the surface of an area to be repaired of the metal part by adopting a mechanical processing mode, and then clean oil stains on the surface of the area to be repaired;
B. measuring the size of the area to be repaired, drawing a three-dimensional model of the area to be repaired, and generating a six-axis manipulator motion program of a laser cladding head scanning track in the laser cladding process;
when the laser cladding head carries out laser cladding repair on the to-be-repaired defect area on the outer surface of the large metal part base body in any posture, the six-axis manipulator drives the laser cladding head to realize posture adjustment so as to ensure that the axis direction of the laser cladding head is always vertical to the repaired surface, and thus, the powder tube is ensured to be vertical to the repaired surface to feed powder.
When the laser cladding head carries out laser cladding repair on the to-be-repaired defect area on the outer surface of the large metal part substrate in an elevation posture, the distance between the end face of the outlet of the laser cladding head and the repaired surface is kept constant and is selected to be 8-12 mm.
Wherein, the off-line programming is adopted when the six-axis manipulator program of the laser cladding head scanning track is generated. The off-line programming can be used for importing a three-dimensional model and automatically generating a track path under the condition of adopting third-party programming software, so that the running process of the laser cladding head is simulated, and the conditions of interference, collision and the like of the processing head in the repairing process are avoided.
C. B, executing the planned cladding repair scanning path program in the step B, taking the iron-based self-fluxing alloy powder as cladding powder, selecting proper technological parameters, and performing laser cladding repair on a defect area on the surface of the substrate, which forms an angle larger than 90 degrees with the horizontal direction, by a laser cladding head in any posture by adopting an optical outer coaxial powder feeding method;
wherein the carbon content of the iron-based self-fluxing alloy powder is 0.01-0.03%, the granularity is 200-300 meshes (48-75 mu m), the sphericity of powder particles is high, the fluidity of the powder is good, and the porosity is low. In the process parameters, the diameter of a laser spot is 1.5-2.5mm, the laser power is 600-800W, the scanning speed is 10-15mm/s, the powder carrying gas flow is 6-8L/min, the pipe diameter of a laser cladding head protective gas outlet is 4-6mm, the cladding head protective gas flow is 12-18L/min, the powder feeding rate is 8-16g/min, and the multi-channel cladding lap joint rate is 35-50%.
The distance between the laser cladding head outlet and the repaired surface and the laser power are kept constant, so that the size of a processing light spot is kept stable, and a stable molten pool is formed.
D. And (4) processing the surface of the repaired metal part until the surface meets the drawing requirements, and finally detecting the surface of the repaired area.
In order to ensure the quality of the repaired metal parts, the detection refers to penetrant inspection and verification, and as shown in fig. 2 and 3, the process can achieve a good repairing effect, and the laser cladding head has a good repairing effect vertically upwards and does not drip.
It should be understood that the above examples are only for clearly illustrating the present invention and are not intended to limit the embodiments of the present invention. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. And such obvious variations or modifications which fall within the spirit of the invention are intended to be covered by the scope of the present invention.
Claims (9)
1. A process for repairing surface defects of metal parts by a laser cladding head in a full-angle posture is characterized by comprising the following steps:
A. processing the surface of the area to be repaired of the metal part;
B. measuring the size of the area to be repaired, drawing a three-dimensional model of the area to be repaired, and generating a six-axis manipulator motion program of a laser cladding head scanning track in the laser cladding process;
C. executing the planned cladding repair scanning path program in the step B, taking the iron-based self-fluxing alloy powder as cladding powder, setting the diameter of a laser spot to be 1.5-2.5mm, setting the laser power to be 600-800W, setting the scanning speed to be 10-15mm/s, setting the powder carrying airflow to be 6-8L/min, setting the powder feeding speed to be 8-16g/min and the multi-channel cladding lap-joint rate to be 35-50%, selecting the proper pipe diameter size of a protective gas outlet of a laser cladding head and the protective gas flow, and performing laser cladding repair on the defect area on the surface of the to-be-repaired substrate of the large metal part by adopting an optical outer coaxial powder feeding method, wherein the laser cladding head performs laser cladding repair on the defect area on the surface;
D. and (4) processing the surface of the repaired metal part until the surface meets the drawing requirements, and finally detecting the surface of the repaired area.
2. The process for repairing the surface defects of the metal part in the full-angle posture of the laser cladding head as claimed in claim 1, wherein the treatment in the step a is to remove oxide skin, fatigue layer and cracks existing on the surface of the area to be repaired of the metal part by adopting a mechanical processing mode, and then clean up oil stains on the surface of the area to be repaired.
3. The process for repairing the surface defect of the metal part in the full-angle posture of the laser cladding head as claimed in claim 1, wherein when the laser cladding head repairs the surface defect of the large metal part to be repaired, the axial direction of the laser cladding head is always perpendicular to the repaired surface, so as to ensure that the powder pipe is perpendicular to the repaired surface for powder feeding.
4. The process for repairing the surface defect of the metal part in the full-angle posture of the laser cladding head as claimed in claim 1, wherein when the laser cladding head repairs the defect at the facade of the metal part to be repaired, the distance between the outlet of the laser cladding head and the surface to be repaired is kept constant and is selected to be 8-12 mm.
5. The process for repairing surface defects of metal parts through the full-angle posture of the laser cladding head as claimed in claim 1, wherein the particle size of the iron-based self-fluxing alloy powder is 200-300 meshes (48-75 μm).
6. The process for repairing the surface defects of the metal part in the full-angle posture of the laser cladding head as claimed in claim 1, wherein the diameter of the pipe of the protective gas outlet of the laser cladding head is 4-6 mm.
7. The process for repairing the surface defects of the metal part in the full-angle posture of the laser cladding head as claimed in claim 6, wherein the flow of the protective gas is 12-18L/min.
8. The process for repairing the surface defects of the metal part in the full-angle posture of the laser cladding head as claimed in claim 1, wherein the power density of laser cladding is kept constant when the laser cladding head repairs the defects on the surface of the large metal part to be repaired.
9. The process for repairing the surface defects of the metal part in the full-angle posture of the laser cladding head as claimed in claim 1, wherein the detection in the step D is penetration flaw detection and verification.
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Cited By (5)
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| CN113878119A (en) * | 2021-09-18 | 2022-01-04 | 航发优材(镇江)增材制造有限公司 | Laser direct deposition repair method for abrasion of tight-lock coupler for high-speed rail |
| CN114147234A (en) * | 2021-12-08 | 2022-03-08 | 苏州中科煜宸激光智能科技有限公司 | Laser cladding accumulation experimental method for vertical-face inclined wall |
| CN114505493A (en) * | 2022-01-29 | 2022-05-17 | 中车工业研究院有限公司 | Method for repairing 7-series aluminum alloy through small-spot laser additive under atmosphere protection condition |
| CN114749680A (en) * | 2022-04-15 | 2022-07-15 | 武汉轻工大学 | Additive manufacturing method, equipment, device, storage medium and metallurgical bonding part |
| CN116005152A (en) * | 2022-12-28 | 2023-04-25 | 广东省科学院智能制造研究所 | Laser material-increasing self-adaptive repairing method and system based on machine vision |
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| CN116005152A (en) * | 2022-12-28 | 2023-04-25 | 广东省科学院智能制造研究所 | Laser material-increasing self-adaptive repairing method and system based on machine vision |
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