CN114134449A - 一种超音速火焰喷涂异形件的保护方法 - Google Patents
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Abstract
本发明提供了一种超音速火焰喷涂异形件的保护方法,具体为:在采用超音速火焰喷涂技术对异形件外沿豁口内的两侧窄面喷涂Co‑Cr‑W耐磨涂层前,采用不同材料对其它非喷涂区域进行保护:首先采用高温压敏胶带和未退火铜皮在零件保护区进行打底,在两层高温压敏胶带之间包裹一层未经退火处理的铜皮;再将经过退火处理的铜皮进行裁剪并贴合零件喷涂区两侧表面弯折成需要的特殊形状,并将退火铜皮固定在异形件外沿上;然后用未经退火处理的铜皮在零件外圈环绕一周,并用金属或合金丝箍扎固定;最后采用超音速火焰喷涂技术对异形件外沿豁口内喷涂区域喷涂Co‑Cr‑W耐磨涂层。该方法能够解决现有技术中无法对结构复杂的异形件进行有效保护的问题。
Description
技术领域
本发明涉及复杂、奇特几何形状的航空发动机异形零部件的保护技术,特别提供一种超音速火焰喷涂异形件的保护方法。
背景技术
超音速火焰喷涂是将助燃气体与燃料在燃烧室中连续爆破燃烧,生成的火焰在燃烧室内产生高压并通过与燃烧室出口连接的膨胀喷嘴产生高速焰流,喷涂材料被送入高速射流中被加热、加速喷射到经预处理的基体表面形成涂层的一种技术。由于其超高的焰流速度和相对等离子焰流较低的温度,在喷涂金属碳化物和金属合金等材料方面具有明显优势,因而广泛应用于航空发动机零部件的抗氧化、耐磨等种类致密涂层的喷涂生产。一种航空发动机的某焊接组合零件外沿豁口内的两侧窄面(见图1所示)需超音速火焰喷涂Co-Cr-W耐磨涂层。由于零件体积大,喷涂位置形状特殊且为复杂型面,使用常规保护方法很难进行有效的非喷涂区域保护,故属于异形件喷涂。公开专利和期刊论文等文献资料中均没有超音速火焰喷涂异形件非喷涂区域的保护技术介绍,商业推销的超音速喷涂保护胶带在喷涂过程中也都存在不同程度的烧蚀,无法满足航空发动机异形件的超音速喷涂保护要求。
通常异形件喷涂过程中采用高温压敏胶带进行保护,但由于超音速火焰喷涂过程中,焰流冲击力大,常规采用的高温压敏胶带往往无法承受强大的冲击力而破损或脱离基体表面,尤其各类型高温胶带均无法对异形零件非喷涂区域起到应有的保护作用,为此设计了多种金属保护夹具,但由于喷涂区型面复杂,喷涂过程中在零件与金属夹具之间容易发生涂层粘结,结果拆卸夹具均导致涂层脱落。而且保护夹具使用一段时间后,其表面喷涂沉积的涂层也难以去除形成遮蔽(如图2所示),严重影响了零件涂层的超音速火焰喷涂质量和效果。
发明内容
为了解决上述问题,本发明提供了一种超音速火焰喷涂异形件的保护方法,以改善异形零件涂层的超音速火焰喷涂质量和效果。
本发明技术方案如下:
一种超音速火焰喷涂异形件的保护方法,其特征在于:在采用超音速火焰喷涂技术对所述异形件外沿豁口内的两侧窄面喷涂Co-Cr-W耐磨涂层前,采用不同材料对其它非喷涂区域进行保护,具体如下:
1)、采用高温压敏胶带和未退火铜皮在零件保护区进行打底,在两层高温压敏胶带之间包裹一层未经退火处理的铜皮;
2)、将经过退火处理的铜皮进行裁剪并贴合零件喷涂区两侧表面弯折成需要的特殊形状,并将退火铜皮固定在异形件外沿上;
3)、用未经退火处理的铜皮在零件外圈环绕一周,并用金属或合金丝箍扎固定;
4)、采用超音速火焰喷涂技术对异形件外沿豁口内喷涂区域喷涂Co-Cr-W耐磨涂层。
作为优选的技术方案:
步骤1)中,所述未经退火处理的铜皮仅设置在异形件外沿豁口喷涂区域下部对应的位置。
步骤2)中,根据喷涂区域几何形状所需要的铜皮硬度、柔性来确定相应的退火工艺,退火工艺为:700±50℃下保温2小时。
所述铜皮为H62黄铜带材,所述合金丝为HGH3030合金丝。
本发明采用与超音速火焰喷涂涂层结合较差的黄铜等材料,结合热处理退火制度控制铜皮柔韧度,借助于常规高温压敏胶带自制保护工装,利用不同柔韧度的铜皮对异形零件非喷涂区域进行了有效保护,同时解决了沉积涂层难以去除的问题,保护工装的主要材料可以重复利用,因而大大减小了生产成本。
本发明所述方法操作方便,解决了高温压敏胶带抗冲击力小的问题,同时节约了派制超音速火焰喷涂专用工装的高额费用,缩短了生产周期。本发明所述方法能够有效保护零件非喷涂区域,解决了喷涂保护技术的生产瓶颈与质量保证问题。
本发明所述方法已用于某型号航空发动机异形件的涂层喷涂生产,打通了喷涂工序加工阻滞通道,为某型号系列发动机顺利生产打下有力基础。同时,本发明的设计思路可推广应用于其他采用超音速喷涂的异形件。当零件形状不规则,或喷涂位置复杂时,传统工装无法起到应有的保护作用,则可采用此种方式。
附图说明
图1航空发动机某异形零件喷涂区域示意图。
图2使用常规金属保护工装与零件相邻基体之间的表面涂层沉积示意图(此过渡区堆积的涂层导致工装卸下后将涂层黏连脱落)。
图3铝箔胶带、铜胶带、退火铜皮宏观形貌示意图。
图4经超音速火焰喷涂后的各种保护材料宏观形貌示意图(由左到右分别为:铝箔胶带、铜胶带、退火铜皮)。
图5两层保护胶带中间包裹一层未退火铜皮示意图。
图6采用退火铜皮保护非喷涂的异形区域。
图7超音速火焰喷涂异形件保护状态示意图。
附图标记:1、保护胶带,2、退火铜皮,3、未退火铜皮。
具体实施方式
实施例1
一种超音速火焰喷涂异形件的保护方法,如图5~7所示,需采用不同材料组成保护工装对非喷涂区域进行保护,所述铜皮为H62黄铜带材,所述合金丝为HGH3030合金丝,具体如下:
1)、采用高温压敏胶带和未退火铜皮在零件保护区进行打底,在两层高温压敏胶带之间包裹一层未经退火处理的铜皮;
2)、将经过退火处理的铜皮进行裁剪并贴合零件喷涂区两侧表面弯折成需要的特殊形状,并将退火铜皮固定在异形件外沿上,本实施例所用铜皮经700±50℃保温2小时退火处理;
3)、用未经退火处理的铜皮在零件外圈环绕一周,并用金属或合金丝箍扎固定,此处铜皮一方面可对经过退火处理的铜皮进行加固,另一方面也可保护其余非喷涂位置;
4)、采用超音速火焰喷涂技术对异形件外沿豁口内喷涂区域喷涂Co-Cr-W耐磨涂层,喷涂后去掉保护材料,异形件表面非喷涂区域无涂层附着,且异形件与保护材料之间无涂层粘结现象。
实施例2
与实施例1的不同之处在于,采用铝箔胶带代替经过退火处理的铜皮,结果导致喷涂过程中铝箔胶带被喷枪焰流冲力破坏,未对异形件表面进行有效保护。
实施例3
与实施例1的不同之处在于,采用铜胶带代替经过退火处理的铜皮,结果导致喷涂过程中铝箔胶带被喷枪焰流冲力破坏,未对异形件表面进行有效保护。
本发明未尽事宜为公知技术。
上述实施例只为说明本发明的技术构思及特点,其目的在于让熟悉此项技术的人士能够了解本发明的内容并据以实施,并不能以此限制本发明的保护范围。凡根据本发明精神实质所作的等效变化或修饰,都应涵盖在本发明的保护范围之内。
Claims (5)
1.一种超音速火焰喷涂异形件的保护方法,其特征在于:在采用超音速火焰喷涂技术对所述异形件外沿豁口内的两侧窄面喷涂Co-Cr-W耐磨涂层前,采用不同材料对其它非喷涂区域进行保护,具体如下:
1)、采用高温压敏胶带和未退火铜皮在零件保护区进行打底,在两层高温压敏胶带之间包裹一层未经退火处理的铜皮;
2)、将经过退火处理的铜皮进行裁剪并贴合零件喷涂区两侧表面弯折成需要的特殊形状,并将退火铜皮固定在异形件外沿上;
3)、用未经退火处理的铜皮在零件外圈环绕一周,并用金属或合金丝箍扎固定;
4)、采用超音速火焰喷涂技术对异形件外沿豁口内喷涂区域喷涂Co-Cr-W耐磨涂层。
2.按照权利要求1所述超音速火焰喷涂异形件的保护方法,其特征在于:步骤1)中,所述未经退火处理的铜皮仅设置在异形件外沿豁口喷涂区域下部对应的位置。
3.按照权利要求1所述超音速火焰喷涂异形件的保护方法,其特征在于:步骤2)中,根据喷涂区域几何形状所需要的铜皮硬度、柔性来确定相应的退火工艺,退火工艺为:700±50℃下保温2小时。
4.按照权利要求1所述超音速火焰喷涂异形件的保护方法,其特征在于:所述铜皮为H62黄铜带材。
5.按照权利要求1所述超音速火焰喷涂异形件的保护方法,其特征在于:所述合金丝为HGH3030合金丝。
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