CN114016018B - Workpiece with composite coating and method of manufacturing the same - Google Patents
Workpiece with composite coating and method of manufacturing the same Download PDFInfo
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- CN114016018B CN114016018B CN202111305100.1A CN202111305100A CN114016018B CN 114016018 B CN114016018 B CN 114016018B CN 202111305100 A CN202111305100 A CN 202111305100A CN 114016018 B CN114016018 B CN 114016018B
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- 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
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Abstract
The invention discloses a workpiece with a composite coating and a manufacturing method thereof, which relate to the field of composite coating manufacturing and are used for improving the service performance of the surface of the workpiece. The workpiece includes a substrate and a composite coating. The composite coating comprises a base layer and a working layer, wherein the base layer is configured as an arc-shaped bulge protruding relative to the base body, the bulge is arranged on the outer surface of the base body, and the bulge is configured as a ring shape so as to surround the outer periphery of the base body; the working layer is positioned on the outer side of the priming layer and wraps the priming layer. According to the technical scheme, the concave-convex priming layer is formed on the surface of the substrate, so that the service performance of the surface of the workpiece is remarkably improved; and after the priming layer is formed, the working layer can be directly formed on the surface of the priming layer, secondary processing, sand blasting and other surface pretreatment are not needed for the priming layer, the working layer can be directly prepared on the surface of the priming layer, and further, the traditional composite coating preparation process flow is effectively shortened, and the composite coating preparation efficiency is remarkably improved.
Description
Technical Field
The invention relates to the field of composite coating manufacturing, in particular to a workpiece with a composite coating and a manufacturing method thereof.
Background
The mechanical industry adopts coating technology to carry out strengthening treatment on the surface of a workpiece, such as electroplating, thermal spraying, laser cladding, surfacing and the like. Along with the increasing market competition, the requirements of high efficiency, high quality and the like are put forward for the coating preparation process. The hydraulic cylinder is used as an important hydraulic executive component of a host machine product, and the service performance of a piston rod of the hydraulic cylinder in a severe environment directly influences the performance of the host machine product. Under severe working conditions such as ocean and harbor, the piston rod of the hydraulic cylinder is not only subjected to high-salt, high-humidity and other corrosion environments, but also subjected to wave alternating load reciprocating impact for a long time, so that the piston rod coating is required to have comprehensive service performances of corrosion resistance, wear resistance and bending fatigue resistance. At present, the service performance of a coating prepared by a single coating technology and a coating structure is single, for example, a coating prepared by a thermal spraying technology generally has higher hardness, wear resistance and corrosion resistance, but is mainly connected by a mechanical bonding mode, so that the fatigue resistance is lower, and for example, the technology such as laser cladding, plasma surfacing and the like is adopted, and the prepared coating is high in internal compactness and metallurgically bonded, so that the coating has higher fatigue resistance and corrosion resistance, but has lower hardness and poor wear resistance.
Therefore, in order to meet the comprehensive service performance requirements of corrosion resistance, abrasion resistance and bending fatigue resistance of the coating in a severe environment, a composite coating structure and a composite forming technology are often adopted. At present, the preparation of the composite functional coating is also as follows: common laser cladding-thermal spraying methods, plasma spray welding-thermal spraying methods. The common laser cladding-thermal spraying method comprises the steps of firstly preparing a high-density metallurgical bonding primer layer on the surface of a workpiece substrate by adopting a common laser cladding/plasma surfacing technology, then turning or grinding the coating until the surface is flat, carrying out sand blasting on the coating, and finally thermally spraying a high-hardness high-wear-resistance working layer on the surface of the primer layer to obtain the composite functional coating with high service performance.
The inventor finds that the common laser cladding-thermal spraying method has the problems of large heat input, higher residual stress, easy deformation of a workpiece and the like in the preparation process of the primer layer, the primer layer needs turning and sand blasting pretreatment after cladding, the process is complicated, and the repeated clamping is needed, so that the processing efficiency is low and the processing cost is high.
The inventor also found that in the plasma spray welding-thermal spraying method, the plasma spray welding heat input is very large, on one hand, the substrate is easy to cause dilution effect on the coating, the service performance of the coating is reduced, on the other hand, the residual stress of the coating is higher, and deformation is easy to occur when a small-diameter piston rod or a thin-wall piston rod is clad. In addition, the surface roughness of the plasma spray welding priming layer is large, the thermal spraying can be carried out only by sand blasting after turning, the machining process can be completed only by clamping and positioning for many times on a plurality of machines, the consumption and the machining period of equipment are increased, the machining precision is also affected in different clamping processes, and the efficient and high-quality preparation of the composite functional coating is difficult to realize.
Disclosure of Invention
The invention provides a workpiece with a composite coating and a manufacturing method thereof, which are used for improving the service performance of the surface of the workpiece.
The embodiment of the invention provides a workpiece with a composite coating, which comprises the following components:
a base; and
a composite coating layer including a primer layer and a working layer, the primer layer being configured as an arc-shaped protrusion protruding with respect to the base body, the protrusion being provided on an outer surface of the base body, and the protrusion being configured as a ring shape so as to surround an outer periphery of the base body; the working layer is positioned on the outer side of the priming layer and wraps the priming layer.
In some embodiments, two adjacent turns of the protrusion overlap each other.
In some embodiments, two adjacent turns of the protrusion are connected and the distance between the two is 0.
In some embodiments, two adjacent turns of the protrusion are spaced apart.
In some embodiments, the number of protrusions N satisfies the following functional relationship:
wherein the number N of the protrusions in the cross section of the set length; n is the overlap ratio between two adjacent protrusions; the distance between two adjacent protrusions is (1-n) d; l is the axial length of the substrate.
In some embodiments, the radius r of the protrusion satisfies the following functional relationship:
wherein r is the radius of the protrusion; h is the maximum height of the protrusion relative to the substrate; d is the distance between the two ends of the protrusion and the connection point of the substrate.
In some embodiments, the convex central angle α satisfies the following functional relationship:
wherein alpha is the central angle corresponding to the set arc section of the bulge, and the set arc section refers to an arc section between the overlapping part of one bulge and two adjacent bulges; h is the maximum height of the protrusion relative to the substrate; d is the distance between the two ends of the bulge and the connecting points of the matrix; n is the overlap ratio between two adjacent protrusions.
In some embodiments, the arc length l of the set arc segment of the protrusion satisfies the following functional relationship:
wherein alpha is the central angle corresponding to a set arc section of the bulge, and the set arc section refers to an arc section between the lap joint of one bulge and two adjacent bulges; r is the radius of the protrusion; h is the maximum height of the protrusions relative to the surface of the substrate 1; d is the distance between the two ends of the bulge and the connecting point of the matrix (1); n is the overlap ratio between two adjacent protrusions.
In some embodiments, the total surface area S of each of the protrusions satisfies the following functional relationship over the length L:
wherein D is 1 Is the diameter of the substrate; n is the number of the protrusions; l is the length; n is the overlap ratio between two adjacent protrusions; d is the distance between the two ends of the bulge and the connecting points of the matrix; h is the maximum height of the protrusion relative to the substrate; l is the arc length of the set arc section of the bulge.
In some embodiments, the sum k of the slopes of all points of all said convex surfaces over the length L satisfies the following functional relationship:
wherein k' is the sum of the slopes of all points on the semicircular arc of the protrusion; n is the number of the protrusions; d is the distance between the two ends of the bulge and the connecting points of the matrix; h is the maximum height of the protrusion relative to the substrate; n is the overlap ratio between two adjacent protrusions.
In some embodiments, the following parameters of the ultra-high speed laser cladding technique are controlled to process the primer layer at the surface of the substrate:
n 1 ＝60*v/(π*D 1 )
v 1 ＝(1-n)*d*v/(π*D 1 )
wherein n is 1 V is the rotational speed during the processing of the substrate 1 The feeding speed of the laser light spot is; d is the size of a light spot of the ultra-high-speed laser cladding technology;f is the powder feeding speed of the ultra-high-speed laser cladding technology; n is the overlap ratio, D 1 Is the diameter of the matrix; b 1 And b 2 Coefficients obtained from regression analysis; c 1 And c 2 Coefficients obtained from regression analysis; lambda (lambda) 7 And lambda (lambda) 3 The coefficients obtained from the regression analysis.
The embodiment of the invention also provides a workpiece manufacturing method, which comprises the following steps:
calculating to obtain surface morphology parameters of the priming layer; wherein the surface topography parameters of the priming layer comprise the priming layer surface area S, the number N of the bulges and the sum k of slopes of all points of the surface of the bulges;
calculating to obtain a bottoming layer structure parameter based on the bottoming layer surface morphology parameter and a raised structure parameter calculation formula arranged on the bottoming layer surface; wherein, the parameters of the priming structure include: the width d of the priming layer, the height h of the priming layer and the lap ratio n of the priming layer;
calculating to obtain a priming layer preparation process parameter based on the priming layer structure parameter; wherein, the preparation process parameters of the priming layer comprise: the laser spot size D and the powder feeding speed f of the ultra-high-speed laser cladding technology;
calculating to obtain required laser power P and cladding speed v according to the laser spot size D, the powder feeding speed f and the power density required by cladding of the priming material;
according to the laser spot size D, the powder feeding speed f, the laser power P, the cladding speed v, the lap ratio n of the priming layer and the diameter D of the substrate 1 Calculating to obtain the rotation speed n of the part 1 And laser spot feed speed v 1 ；
According to the laser spot size D, the powder feeding speed f, the laser power P and the part rotating speed n 1 The laser spot feed speed v 1 And preparing a priming layer on the surface of the matrix.
In some embodiments, the workpiece manufacturing method further comprises the steps of:
after the preparation of the priming layer is finished, a working layer is directly prepared on the surface of the priming layer so as to finish the processing of the composite functional coating on the surface of the matrix.
In some embodiments, the calculating obtains key parameters of the priming layer, including: inquiring in a database according to the service working condition of the workpiece and the bonding strength thereof to obtain the surface morphology parameters of the priming layer meeting the requirements of the service working condition; wherein the surface topography parameters of the priming layer comprise the priming layer surface area S, the number N of the bulges and the sum k of the slopes of all points of the surface of the bulges.
In some embodiments, the relationship of the underlying surface topography parameter to the composite coating bonding performance satisfies the following functional relationship:
wherein the composite coating comprises a working layer and a priming layer; b is the bonding strength of the working layer, S is the surface area of the priming layer; n is the number of the protrusions; k is the sum of the slopes of all points of the convex surface over the length L; lambda (lambda) 1 Coefficients obtained from regression analysis; a, a 1 、a 7 、a 3 The coefficients obtained from the regression analysis.
The workpiece provided by the technical scheme comprises a substrate and a composite coating, wherein the composite coating comprises a base layer and a working layer, the base layer is attached to and fixed with the substrate, and the base layer forms a plurality of raised bulges on the surface of the substrate. The substrate surface is the lowest point, and each protrusion is higher than the substrate surface. The working layer is located the outside of priming layer and parcel live the priming layer, and the protruding of priming layer is lived in the working layer parcel. According to the technical scheme, the concave-convex priming layer is formed on the surface of the substrate, so that the service performance of the surface of the workpiece is remarkably improved; in addition, after the priming layer is formed, the working layer can be directly formed on the surface of the priming layer, secondary processing, sand blasting and other surface pretreatment are not needed for the priming layer, the working layer can be directly prepared on the surface of the priming layer, and further, the traditional composite coating preparation process flow is effectively shortened, and the composite coating preparation efficiency is remarkably improved; the development of the high-performance coating is realized, and the efficient preparation and low cost of the high-performance hydraulic cylinder and other workpieces are effectively realized.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiments of the invention and together with the description serve to explain the invention and do not constitute a limitation on the invention. In the drawings:
FIG. 1 is a schematic view of a work piece substrate according to some embodiments of the present invention;
FIG. 2 is a schematic view of a workpiece backing layer according to other embodiments of the present invention;
FIG. 3 is a schematic view of a workpiece backing layer according to further embodiments of the present invention;
FIG. 4 is a schematic view of single bump parameters of a work piece primer layer provided in some embodiments of the present invention;
FIG. 5a is a graph illustrating a plurality of bump overlap rates of a work piece primer layer according to some embodiments of the present invention;
FIG. 5b is a diagram illustrating a first example of a protrusion parameter of a primer layer of a workpiece according to some embodiments of the invention;
FIG. 5c is a second exemplary diagram of parameters of a bump of a work piece primer layer according to some embodiments of the present invention;
fig. 6 is a flow chart of a method for manufacturing a workpiece according to an embodiment of the invention.
Reference numerals:
1. a base; 2. a composite coating; 21. a bottom layer is formed; 22. a working layer.
Detailed Description
The technical scheme provided by the invention is described in more detail below with reference to fig. 1 to 6.
Referring to fig. 1 to 5c, the embodiment of the invention provides a workpiece, which can be marine equipment, a shield machine, a hydraulic cylinder piston rod of engineering machinery and the like suitable for severe environments, and the workpiece is required to have the composite functions of corrosion resistance, wear resistance, bending fatigue resistance and the like. The workpiece comprises a substrate 1 and a composite coating 2 covering the outside of the substrate 1. The composite coating 2 includes a primer layer 21 and a working layer 22, the primer layer 21 being configured as an arc-shaped protrusion. The protrusions are provided on the outer surface of the base 1, and the protrusions are configured in a ring shape so as to surround the outer circumference of the base 1; the working layer 22 is located outside the primer layer 21 and wraps around the primer layer 21.
According to the distance between two adjacent bulges, the bulges have three setting modes: first, referring to fig. 1, two adjacent rings of protrusions overlap each other; second, referring to fig. 2, two adjacent rings of protrusions are connected with a distance of 0 therebetween. Second, see fig. 3, two adjacent rings of projections are spaced apart.
In some embodiments, each protrusion is identical in structure, and the respective parameters of the protrusions are described below.
Referring to fig. 4 and 5a, each protrusion has a diameter d and a height h. When the overlap ratio of two adjacent protrusions is N, the distance between the two adjacent protrusions is (1-N) d, and the number N of protrusions in the cross section of the matrix 1 with any length L satisfies the following functional relation (1):
wherein, in the functional relation (1), the number N of the bulges in the cross section of the length is set; n is the overlap ratio between two adjacent protrusions; referring to FIG. 5a, the distance between two adjacent protrusions is (1-n) d; l is the axial length of the substrate 1; d is the width of the protrusion.
The overlap ratio n characterizes how much overlap is between two adjacent projections. Referring to fig. 5b and 5c, the overlap ratio n of two adjacent projections is the ratio of 2 times the projected length of the arc length AB in the axial direction to the AE length. The key structural parameters of the single-channel bump include bump width d and bump height h. The bulges with different surface morphologies can be obtained by adjusting the overlap ratio n of the cladding of the plurality of bulges; meanwhile, when the lap joint rate is consistent, the width d and the height h of the protrusions are changed, and the surface morphology of the protrusions can be adjusted. By controlling the lap rate n, the technical scheme realizes the structural control of the priming layer 21 distributed on the surface of the substrate 1.
Referring to fig. 5a to 5c, the arc BCD is a surface curve of the base layer 21, O is a center point of the surface curve of the base layer 21, AGE is a junction surface of the base layer 21 and the substrate 1, the length of the straight line segment AE is a protrusion width d, and the length of the straightness CG is a protrusion height h. P is any point on the arc BCD.
Referring to fig. 5b and 5c, the radius r of the protrusion satisfies the following functional relationship (2):
wherein, in the functional relation (2), r is the radius of the bulge; h is the maximum height of the protrusion relative to the substrate 1. d is the distance between the two ends of the protrusion and the connection point of the base 1, i.e. the length of the line segment AE.
How the above functional relation (2) is derived is described below.
From the geometrical relationship of right triangle OAG, OA 2 ＝AG 2 +OG 2 Where OA is r in length, AG is d/2 in length, OG is r-h in length, so the following geometrical relationship exists:
by solving the above equation, the functional relation (2) satisfied by the radius r of the surface protrusion of the primer layer 21 is obtained.
Further calculation results in an OF length OF:
further calculation results in a central angle alpha corresponding to the arc BCD of the underlying layer 21 exposing the surface of the substrate 1.
The central angle alpha of each bulge can be obtained after solving, and the following functional relation (3) is satisfied:
referring to fig. 5b and 5c, the central angle α is the magnitude of +.bod. Alpha is the central angle corresponding to a set arc section of the bulge, wherein the set arc section refers to an arc section between the lap joint of one bulge and two adjacent bulges; in the case where two protrusions illustrated in fig. 1 overlap each other, it is set that both ends B and D of the circular arc segment BCD are overlapping points with adjacent protrusions; in the case illustrated in fig. 2, two adjacent projections are just above each other but have no overlapping area with each other, and the ends B and D of the arc segment BCD are set to be the contact points of the projections themselves and the substrate 1; in the case illustrated in fig. 3, two adjacent projections are separated from each other without overlapping areas with each other, and the ends B and D of the arc segment BCD are set as the contact points of the projections themselves and the base body 1. r is the radius of the protrusion; h is the maximum height of the protrusions relative to the surface of the substrate 1; d is the distance between the two ends of the bulge and the connecting points of the matrix 1; n is the overlap ratio between two adjacent protrusions.
Referring to fig. 5b and 5c, the arc length l of the set arc segment of the protrusion satisfies the following functional relationship (4):
the arc length l of a set arc section of a bulge is the length of an arc section BCD, wherein alpha is the central angle corresponding to the set arc section of the bulge, and the set arc section is the arc section between one bulge and the lap joint of two adjacent bulges; in the case where the two protrusions illustrated in fig. 1 overlap each other, the specific explanation of the set arc segment is referred to above, and will not be repeated here.
Referring to fig. 5b and 5c, the total surface area S of each protrusion satisfies the following functional relationship (5) over the length L:
wherein D is 1 Is the diameter of the substrate 1; n is the number of protrusions; l is the length; n is the overlap ratio between two adjacent protrusions; d is the distance between the two ends of the bulge and the connecting points of the matrix 1; h is the maximum height of the protrusion relative to the substrate 1.
In the above functional relation (5), the arc length l also refers to the length of the arc-shaped segment BCD. N is the number of protrusions in the cross section of the set length.
Assuming that the slope of any point P on the surface curve BCD of the primer layer 21 is kp, the slope k 'of all points on the arc is k' = Σ|kp|.
Fig. 5a to 5C illustrate a geometrical model of slope calculation of an arbitrary point P on the surface curve BCD of the primer layer 21, if the offset ratio of the point P to the starting point D of the BCD arc is i, i.e. the arc segment DC is from the point D to the point C, i is changed from 0 to 0.5, and kp is calculated as:
further calculation shows that the slope k' of all the anchor points corresponding to the convex semicircular arc is:
further calculations may be made that the sum k of the slopes of all points of all convex surfaces over the length L satisfies the following functional relationship (6):
wherein k' is the sum of the slopes of all points on the convex semicircle; n is the number of protrusions; d is the distance between the two ends of the bulge and the connecting points of the matrix 1; h is the maximum height of the protrusion relative to the substrate 1; n is the overlap ratio between two adjacent protrusions.
The geometric model between the surface topography parameters and the structural parameters of the primer layer 21 is described in detail above by varying the structural parameters of the primer layer 21: the bump width d, the bump height h and the overlap ratio n can realize the surface morphology parameters of the priming layer 21: the regulation and control of the number N of the bulges, the total surface area S of the bulges and the sum k of slopes of all points of the surface of the bulges are realized, so that the regulation and control of the bonding performance of the composite coating 2 is realized.
In some embodiments, the following parameters of the ultra-high speed laser cladding technique are controlled to machine the primer layer 21 on the surface of the substrate 1:
n 1 ＝60*v/(π*D 1 )
v 1 ＝(1-n)*d*v/(π*D 1 )
wherein n is 1 For the rotation speed of the workpiece, v 1 For the laser spot feed speed D 1 V is the cladding speed, d is the width of the protrusions of the primer layer 21, which is the diameter of the substrate 1.
Based on the model, according to the structural parameter requirements of the primer layer 21 of the composite coating 2, the required key preparation process parameters of the spot size D and the powder feeding speed f can be calculated, and then the process parameters of the laser power P, the cladding speed v and the like in the preparation process of the primer layer 21 are matched and optimized.
The ultra-high speed laser cladding technology is used for selecting the light spot size D and the powder feeding speed f as key influencing factors of structural parameters of the priming layer 21, and a mathematical model between the width D and the height h of the priming layer 21 and each key influencing factor, namely the following two functional relation formulas, is established by utilizing an orthogonal test method and a regression analysis method.
Wherein n is 1 For the rotational speed, v, during processing of the substrate 1 1 The feeding speed of the laser light spot is; d is a facula of the ultra-high speed laser cladding technologySize of the material; f is the powder feeding speed of the ultra-high-speed laser cladding technology; n is the overlap ratio, D 1 Is the diameter of the substrate 1; b 1 And b 2 Coefficients obtained from regression analysis; c 1 And c 2 The coefficients obtained from the regression analysis. d is the width of the protrusions of the primer layer 21, and h is the height of the protrusions of the primer layer 21. Lambda (lambda) 7 And lambda (lambda) 3 The coefficients obtained from the regression analysis.
In some embodiments, the working layer 22 of the composite coating 2 is a thermal spray coating, which is connected to the base layer 21 mainly by mechanical bonding, i.e. the powder material of the working layer 22 is heated until the molten particles strike the surface of the base layer 21 and cling to the concave-convex points on the surface of the base layer 21, and shrink to bite the convex points (i.e. anchor points) during condensation, thereby realizing mechanical bonding.
In the above technical scheme, based on the influence of the surface morphology parameters of the primer layer 21 on the bonding performance of the composite coating 2, the surface area of the primer layer 21, the number of anchor points and the slope of the anchor points are taken as influencing factors, and the bonding strength of the composite coating 2 under different primer layer 21 morphologies is measured by using an orthogonal test method. Meanwhile, a regression analysis method is utilized to establish an influence model between the bonding strength of the working layer 22 and the surface area of the bottoming layer 21, the number of surface anchoring points and the slope of the anchoring points.
Assuming that the working layer 22 has a bond strength of B, the primer layer 21 has a surface area of S, and the number of surface anchor points is S, k, which is the sum of the slopes of all points of the convex surface over the length L, it is possible to obtain that the relationship of the primer layer surface topography parameter to the composite coating bond performance satisfies the following functional relationship (7).
In the above functional relation (7), the composite coating layer includes a working layer 22 and a primer layer 21; b is the bonding strength of the working layer. S is the surface area of the primer layer over the length L, also referred to as the total surface area of the individual protrusions; n is the number of protrusions; k is the sum of the slopes of all points of the convex surface over the length L; lambda (lambda) 1 Based on regressionAnalyzing the obtained coefficient; a, a 1 、a 7 、a 3 The coefficients obtained from the regression analysis. The length of the substrates corresponding to the parameter S, N, k is the same, for example, the calculated values in the range of the length L.
Referring to fig. 6, an embodiment of the present invention further provides a method for manufacturing a workpiece, where the method is used to form a workpiece provided by any one of the above-mentioned aspects. The workpiece manufacturing method comprises the following steps:
step S100, calculating to obtain the surface morphology parameters of the priming layer 21; wherein, the surface topography parameters of the primer layer 21 include: including the priming surface area S, the number of protrusions N, the sum k of the slopes of all points of all protrusion surfaces.
In some embodiments, key parameters of the primer layer 21 are obtained in the following manner: and according to the service working condition of the workpiece and the bonding strength thereof, inquiring in a database to obtain the surface morphology parameters of the primer layer 21 meeting the service working condition requirement. Wherein, the surface topography parameters of the priming layer 21 comprise the surface area S, the number of surface anchoring points N and the slope k of the anchoring points.
The database is the data sum of different surface morphology parameters and bonding strength under different processes obtained through experiments.
The key parameters include surface area S, number of surface anchoring points N, anchoring point slope k satisfying the following functional relationship (7):
in the above-mentioned functional relation (7), lambda 1 Coefficients obtained from regression analysis; a, a 1 、a 7 、a 3 The coefficients obtained from the regression analysis.
Step S200, calculating to obtain the underlying layer structural parameters based on the underlying layer surface topography parameters and the protruding structural parameter calculation formula set on the surface of the underlying layer 21. Wherein, the parameters of the priming structure include: the width d of the priming layer, the height h of the priming layer and the lap ratio n of the priming layer.
Specific calculation steps are described above, and will not be described here.
Step S300, calculating to obtain the parameters of the priming layer preparation process based on the parameters of the priming layer structure. Wherein, the preparation process parameters of the priming layer comprise: the laser spot size D and the powder feeding speed f of the ultra-high speed laser cladding technology.
And step 400, calculating to obtain the required laser power P and cladding speed v according to the laser spot size D, the powder feeding speed f and the power density required by cladding the priming material.
Step S500, according to the laser spot size D, the powder feeding speed f, the laser power P, the cladding speed v, the lapping rate n of the priming layer and the diameter D of the substrate 1 Calculating to obtain the rotation speed n of the part 1 And laser spot feed speed v 1 。
The rotation speed n of the part is calculated by adopting the following formula 1 And laser spot feed speed v 1 。
n 1 ＝60*v/(π*D 1 )
v 1 ＝(1-n)*d*v/(π*D 1 )
The ultra-high-speed laser cladding technology has the characteristics of high forming speed, thinner protrusion thickness, smoother surface morphology and easy morphology regulation and control, and is particularly suitable for the workpiece manufacturing method provided by the embodiment of the invention.
Step S600, according to the laser spot size D, the powder feeding speed f, the laser power P and the part rotating speed n 1 Laser spot feed speed v 1 A primer layer is prepared on the surface of the substrate 1. The primer layer 21 may be prepared on the surface of the part base 1 by programming.
In some embodiments, the workpiece manufacturing method further comprises the steps of:
and step S700, after the preparation of the priming layer 21 is finished, preparing a working layer 22 on the surface of the priming layer 21 directly to finish the processing of the composite functional coating on the surface of the substrate 1.
According to the workpiece manufacturing method provided by the technical scheme, the composite coating 2 with different bonding performances is obtained through the structural design of the primer layer 21 and the surface geometric parameter regulation and control of the primer layer. The workpiece manufacturing method provided by the embodiment of the invention can directly prepare the working layer 22 on the surface of the primer layer 21 without carrying out secondary processing, sand blasting and other surface pretreatment, thereby effectively shortening the preparation flow of the traditional composite coating 2 and obviously improving the preparation efficiency of the composite coating 2; the method avoids the procedures of secondary processing, pretreatment and the like required by the traditional preparation method, does not need to repeatedly clamp the workpiece, and effectively solves the problems that the existing preparation method of the composite coating 2 is easy to cause high residual stress of the composite coating 2 and poor processing precision after repeated clamping.
In the description of the present invention, it should be understood that the terms "center," "longitudinal," "lateral," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, merely to facilitate description of the present invention and simplify the description, and do not indicate or imply that the device or element being referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the protection of the present invention.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and are not limiting; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may be modified or some technical features may be replaced with others, which may not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims (14)
1. A workpiece having a composite coating, comprising:
a base body (1); and
-a composite coating (2) comprising a primer layer (21) and a working layer (22), the primer layer (21) being configured as an arc-shaped protrusion protruding relative to the substrate (1), the protrusion being provided on the outer surface of the substrate (1) and the protrusion being configured as a ring shape so as to surround the periphery of the substrate (1); the working layer (22) is positioned on the outer side of the priming layer (21) and wraps the priming layer (21);
the sum k of the slopes of all points of all said convex surfaces satisfies the following functional relationship:
wherein k' is the sum of the slopes of all points on the semicircular arc of the protrusion; n is the number of the protrusions; d is the distance between the two ends of the bulge and the connecting point of the matrix (1); h is the maximum height of the protrusion relative to the base body (1); n is the overlap ratio between two adjacent protrusions.
2. The workpiece according to claim 1, wherein two adjacent turns of the protrusions overlap each other.
3. A workpiece according to claim 2, characterized in that two adjacent turns of the protrusions are connected and the distance between them is 0.
4. The workpiece according to claim 1, wherein two adjacent turns of the protrusions are spaced apart.
5. The workpiece according to claim 1, characterized in that the number N of projections satisfies the following functional relationship:
wherein the number N of the protrusions in the cross section of the set length; n is the overlap ratio between two adjacent protrusions; the distance between two adjacent protrusions is (1-n) d; l is the axial length of the substrate (1).
6. The workpiece according to claim 5, characterized in that the radius r of the bulge satisfies the following functional relationship:
wherein r is the radius of the protrusion; h is the maximum height of the protrusion relative to the base body (1); d is the distance between the two ends of the protrusion and the connection point of the substrate (1).
7. The workpiece according to claim 6, characterized in that the central angle α of the bulge satisfies the following functional relationship:
wherein alpha is a central angle corresponding to a set arc section of the bulge, and the set arc section refers to an arc section between the bulge and the lap joint of two adjacent bulges; h is the maximum height of the protrusion relative to the base body (1); d is the distance between the two ends of the bulge and the connecting point of the matrix (1); n is the overlap ratio between two adjacent protrusions.
8. The workpiece according to claim 7, characterized in that the arc length l of the set arc segment of the bulge satisfies the following functional relationship:
wherein alpha is a central angle corresponding to a set arc section of the bulge, and the set arc section refers to an arc section between the bulge and the lap joint of two adjacent bulges; r is the radius of the protrusion; h is the maximum height of the protrusions relative to the surface of the substrate (1); d is the distance between the two ends of the bulge and the connecting point of the matrix (1); n is the overlap ratio between two adjacent protrusions.
9. The workpiece according to claim 8, wherein the total surface area D of each of the projections satisfies the following functional relationship over the length L:
wherein D is 1 Is the diameter of the substrate (1); n is the number of the protrusions; l is the length; n is the overlap ratio between two adjacent protrusions; d is the distance between the two ends of the bulge and the connecting point of the matrix (1); h is the maximum height of the protrusion relative to the base body (1); l is the arc length of the set arc section of the bulge.
10. Workpiece according to claim 1, characterized in that the following parameters of the ultra-high speed laser cladding technique are controlled to obtain the primer layer (21) on the surface of the substrate (1):
n 1 ＝60*v/(π*D 1 )
v 1 ＝(1-n)*d*v/(π*D 1 )
wherein n is 1 For the rotational speed, v, during processing of the substrate (1) 1 The feeding speed of the laser light spot is; d is the size of a light spot of the ultra-high-speed laser cladding technology; f is the powder feeding speed of the ultra-high-speed laser cladding technology; n is the overlap ratio, D 1 Is the diameter of the substrate (1); b 1 And b 2 Coefficients obtained from regression analysis; c 1 And c 2 Coefficients obtained from regression analysis; lambda (lambda) 2 And lambda (lambda) 3 The coefficients obtained from the regression analysis.
11. A method of manufacturing a workpiece, characterized in that the workpiece is a workpiece having a composite coating according to any one of claims 1 to 10, the method comprising the steps of:
calculating to obtain surface morphology parameters of the priming layer; wherein the surface topography parameters of the priming layer comprise the priming layer surface area S, the number N of the bulges and the sum k of slopes of all points of the surface of the bulges;
calculating to obtain a bottoming layer structure parameter based on the bottoming layer surface morphology parameter and a raised structure parameter calculation formula arranged on the bottoming layer surface; wherein, the parameters of the priming structure include: the width d of the priming layer, the height h of the priming layer and the lap ratio n of the priming layer;
calculating to obtain a priming layer preparation process parameter based on the priming layer structure parameter; wherein, the preparation process parameters of the priming layer comprise: the laser spot size D and the powder feeding speed f of the ultra-high-speed laser cladding technology;
calculating to obtain required laser power P and cladding speed v according to the laser spot size D, the powder feeding speed f and the power density required by cladding of the priming material;
according to the laser spot size D, the powder feeding speed f, the laser power P, the cladding speed v, the lap ratio n of the priming layer and the diameter D of the substrate 1 Calculating to obtain the rotation speed n of the part 1 And laser spot feed speed v 1 ；
According to the laser spot size D, the powder feeding speed f, the laser power P and the part rotating speed n 1 The laser spot feed speed v 1 And preparing a priming layer on the surface of the matrix.
12. The method of manufacturing a workpiece according to claim 11, further comprising the step of:
after the preparation of the priming layer is finished, a working layer is directly prepared on the surface of the priming layer so as to finish the processing of the composite functional coating on the surface of the matrix.
13. The method of claim 11, wherein the calculating key parameters of the underlying layer comprises: inquiring in a database according to the service working condition of the workpiece and the bonding strength thereof to obtain the surface morphology parameters of the priming layer meeting the requirements of the service working condition; wherein the surface topography parameters of the priming layer comprise the priming layer surface area S, the number N of the bulges and the sum k of the slopes of all points of the surface of the bulges.
14. The method of claim 13, wherein the relationship of the underlying surface topography parameter to the composite coating bonding performance satisfies the following functional relationship:
wherein the composite coating comprises a working layer and a priming layer; b is the bonding strength of the working layer, S is the surface area of the priming layer; n is the number of the protrusions; k is the sum of the slopes of all points of all the convex surfaces; lambda (lambda) 1 Coefficients obtained from regression analysis; a, a 1 、a 2 、a 3 The coefficients obtained from the regression analysis.
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