CN115351292A - 一种激光增材与后热处理复合工艺制备高塑韧性1CrMo合金修复层的方法 - Google Patents
一种激光增材与后热处理复合工艺制备高塑韧性1CrMo合金修复层的方法 Download PDFInfo
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Abstract
本发明公开了一种激光增材与后热处理复合工艺制备高塑韧性1CrMo合金修复层的方法,该方法首先在激光增材制造的参数配合下进行1CrMo合金修复层的制备,修复层具有与基体呈冶金结合,组织均匀,无气孔、裂纹缺陷、硬度较低,且组织呈现类索氏体形态的特点;之后对修复层进行调质热处理,得到回火索氏体组织,制得同时具有高强度和高塑性的高性能修复层;本发明解决了激光增材制造合金难以实现高强度和高塑韧性相匹配的问题,消除了激光增材制造边界存在现象,方法具有简单实用、生产效率高、无污染、经济的特点。
Description
技术领域
本发明涉及金属材料科学及激光增材修复技术领域,具体涉及一种激光增材与后热处理复合工艺制备高塑韧性1CrMo合金修复层的方法。
背景技术
能源动力工程领域的汽轮机转子件体积大、制作周期长,运行过程中一旦发生损伤,更换新轴耗费的成本高、周期长,将导致生产中断,造成巨大的经济损失。如能修复则将挽回经济损失,快速恢复生产。转子件运行工况复杂,常在高温、高压、复杂应力条件下高速运行,易出现磨损、拉毛、断裂等问题,因此对于修复后转子的力学性能要求较高,要求塑性和强度满足基体性能要求。另外,断裂韧性是衡量材料韧性性能的重要指标,基体修复后断裂韧性的达标能避免零部件在运行过程中突然的失稳断裂,避免事故发生,因此保证修复后材料的断裂韧性性能达标十分重要。
传统的修复技术如焊接、热喷涂、电刷镀等方法存在热影响区大、效率低、结合强度低等缺点,难以达到修复要求。基于激光熔覆或激光金属沉积技术的激光增材修复技术(LAM),是以高能激光束为热源,采用同步送粉,通过逐道逐层的叠加方式,实现零件的三维成形,将LAM技术与传统的减材(铣削)技术相结合,即可实现金属零件的修复。该技术具有柔性高、工艺灵活、对修复件热影响小、修复件强度恢复高、周期短、效率高等特点,特别适应于运行过程中遭受各种应力复合作用、修复质量和工期要求较高的大型转子轴的修复。
目前市面上用于汽轮机转子钢激光修复的材料种类十分稀少、价格昂贵,而且修复后断裂韧性性能较差。另外,激光增材制造合金很难实现高强度和高塑性相匹配,也就是说两者难以同时达到,一般是强度高,塑性差,或者塑性高,强度低。本发明选用合理的激光增材与后热处理复合工艺为激光增材后材料的高塑韧性提供了理想方案,该方法还具有方法简单实用、生产效率高、无污染、经济实惠、有应用价值的特点。目前,在激光增材修复汽轮机转子轴后,运用合理的后热处理手段调整组织结构和力学性能的方法还未见到,合理的热处理工艺还有待研究。
发明内容
本发明目的在于提供一种激光增材与后热处理复合工艺制备高塑韧性1CrMo合金修复层的方法,通过对激光功率、扫描速度、送粉量,送粉载气流量,保护气流量,搭接率等激光增材制造的参数进行优化,并结合合理的后续热处理工艺调控组织,最终制备出同时具有高强度高塑性的合金材料。
本发明的技术方案如下:
一种激光增材与后热处理复合工艺制备高塑韧性1CrMo合金修复层的方法,所述方法为:
将铁基合金粉末烘干(100~200℃)后放入送粉器中,将待修复试样置于激光器下进行激光增材修复操作,之后进行热处理,完成修复;
所述激光增材修复操作的工艺参数为:激光功率1900~2700W,激光扫描速度240~440mm/min,光斑直径4mm,送粉量8~12g/min,铁基合金粉末的送粉方式为同步同轴输送,送粉载气为高纯氩气(Ar,99%),保护气为高纯氩气(Ar,99%);单层修复层厚度介于0.5~1.5mm之间;
所述热处理的工艺参数为:淬火温度970℃,淬火时间10min,淬火冷却方式油冷;回火温度580~680℃,回火时间15min~2h,回火冷却方式空冷;通过改变调质热处理的回火加热温度和保温时间,能够得到回火索氏体组织,并且调整等轴铁素体的晶粒尺寸以改善塑性;
所述铁基合金粉末的组成为:碳C:0.05~0.15%,铬Cr:1.0~1.5%,硅Si:0.5~1.0%,锰Mn:0.6~1.0%,钼Mo:0.5~1.5%,氧O:≤0.05%,磷P:≤0.015%,硫S:≤0.03%,余量Fe;
优选的,所述铁基合金粉末的组成为:碳C:0.15%,铬Cr:1.5%,硅Si:0.8%,锰Mn:0.8%,钼Mo:1.5%,氧O:0.02%,磷P:0.01%,硫S:0.03%,铁Fe:95.19%;
同样优选的,所述铁基合金粉末的组成为:碳C:0.08%,铬Cr:1.0%,硅Si:0.5%,锰Mn:0.8%,钼Mo:0.7%,氧O:0.02%,磷P:0.01%,硫S:0.03%,铁Fe:96.86%;
所述铁基合金粉末可采用真空感应熔炼-惰性气体雾化的方式获得;对所得合金粉末进行振动筛分或气流分级处理,制备得到激光熔敷增材修复工艺用合金粉末;
所述铁基合金粉末含氧量低于600ppm,基于数量方面的空心粉率低于3%,粉末粒度介于-140~+325目之间,粉末松装密度介于3~6g/cm2之间,流动性介于12~18s之间。
本发明所述方法可用于汽轮机转子零部件受损表面的修复,通过适当的对激光功率、扫描速度、送粉量、送粉载气流量、保护气流量、搭接率等激光增材制造的参数进行优化,能够得到与基体呈冶金结合,组织均匀,无气孔、裂纹缺陷,硬度较低的修复层。
修复层激光增材制造1CrMo合金组织为类索氏体(针状铁素体+碳化物),且存在边界形貌,边界形貌的存在会对力学性能造成不利影响,随后结合合理的后续热处理工艺能够将温度提升到AC3以上,消除了边界组织,最终制备出同时具有高强度高塑性的合金材料。
合金修复层试样显微硬度范围为:240~270HV0.3,抗拉强度范围为:744~903MPa,断后伸长率范围:16.3~21.9%,断面收缩率范围为:31~48%,冲击吸收能量范围为:148~197J,断裂韧性范围:179~246kJ/m2。
热处理后抗拉强度范围为:618~780MPa,断后伸长率范围:16.1~23.3%,断面收缩率范围为:45~59%,断裂韧性由179kJ/m2提升为240kJ/m2。
与现有技术相比,本发明有益效果主要体现在:
1、本发明采用所述合金粉末及其应用方法,可在宽泛的工艺参数下获得含有特定合金元素、无气孔裂纹缺陷、综合力学性能良好,特别是断裂韧性性能良好的修复层,且激光增材操作过程灵活,重复性一致,效率高,相比于埋弧堆焊等传统技术具有巨大的优势,完全可用于汽轮机转子设备激光增材修复。
2、本发明在热处理过程中所选用的工艺参数,能有效消除常规激光增材制造合金所共有的边界形貌特征,边界的存在对试样的性能会造成不利影响。
3、本发明在热处理后得到回火索氏体组织,通过增加回火时间和回火温度能够能调整组织结构,粗化铁素体尺寸,以提高合金的塑性。解决了常规激光增材制造合金高强度和高塑性难以匹配的问题,保证强度的同时,提高了激光增材制造合金的塑韧性。
附图说明
图1为实施例3所述铁基合金粉末的未腐蚀金相。
图2为实施例4所述铁基合金粉末的组织形貌。
图3为实施例4所述铁基合金粉末的XRD。
图4为实施例3三层修复层光学显微镜金相组织图片。
图5为实施例3三层修复层显微硬度。
图6为实施例6三层修复层热处理后金相组织图片。
图7为实施例6修复层热处理前后边界形貌。
具体实施方式
下面通过具体实施例进一步描述本发明,但本发明的保护范围并不仅限于此。
实施例1
本实施例的合金粉末元素质量百分比为:
碳C:0.15%,铬Cr:1.5%,硅Si:0.8%,锰Mn:0.8%,钼Mo:1.5%,氧O:0.02%,磷P:0.01%,硫S:0.03%,铁Fe:95.19%。
实施例2
本实施例的合金粉末元素质量百分比为:
碳C:0.08%,铬Cr:1.0%,硅Si:0.5%,锰Mn:0.8%,钼Mo:0.7%,氧O:0.02%,磷P:0.01%,硫S:0.03%,铁Fe:96.86%。
实施例3激光增材实施例1所述的铁基合金粉末
采用实施例1所述的用于激光增材表面改性的铁基合金粉末,对其进行金相和扫描电镜观察,如图1所示,粉末气孔较少,随后采用的激光器光斑为直径4mm的圆形光斑,合金粉末的送粉方式为同步同轴输送。
将实施例1所述的用于激光增材表面改性的铁基合金粉末置于100~200℃烘箱保温直至烘干后放入送粉器中;
将整体切削后的试样块径置于激光器下,调整激光器位置至待加工区域;
将激光工艺参数设定如下:
激光功率至1900W,扫描速度为240mm/min,送粉量为8g/min,送粉载气流量为800L/h,保护气流量为12L/min,搭接率为45%。
激光功率至2100W,扫描速度为280mm/min,送粉量为9g/min,送粉载气流量为800L/h,保护气流量为12L/min,搭接率为45%。
激光功率至2300W,扫描速度为340mm/min,送粉量为10g/min,送粉载气流量为800L/h,保护气流量为12L/min,搭接率为45%。
激光功率至2500W,扫描速度为380mm/min,送粉量为11g/min,送粉载气流量为800L/h,保护气流量为12L/min,搭接率为45%。
激光功率至2700W,扫描速度为440mm/min,送粉量为12g/min,送粉载气流量为800L/h,保护气流量为12L/min,搭接率为45%。
通过制样观察,修复层组织致密,为类索氏体结构,无气孔、夹杂、裂纹等缺陷,组织如图4所示。
采用Hv-1000型维氏显微硬度计,进行修复层硬度测试,测试结果如图5所示,在单道和单层增材试验下,修复层硬度处于不稳定状态。在达到三层后逐步稳定,从基体表面开始,随着距离增加,修复层硬度逐渐呈下降趋势,三层激光增材修复层硬度在240HV0.3~270HV0.3之间,符合设计标准。
进行了大量试验后,择优选取激光增材工艺参数如表1所述,在表1所述激光增材工艺参数之下均可获得满意的修复层。
表1激光增材较优工艺参数
实施例4激光增材实施例2所述的铁基合金粉末
本实施例使用的粉末为实施例2合金粉末,增材工艺参数与实施例3的相同,不同之处在于合金元素含量。
对实施例2合金粉末进行金相制备,其粉末金相如图2所示,从图中可以发现铁素体的存在。
对实施例2合金粉末进行XRD测试,其XRD衍射图谱如图3所示,从图谱中发现,修复层主要由α-Fe、Fe19Mn、(Fe-Cr)、CrSi4、CrFeSSi等组成。
实施例5
选取工艺参数为激光功率2300W,扫描速度340mm/min,送粉量10g/min,修复层厚度0.7mm,光斑大小为4mm。对实施例1-2的铁基合金粉末增材后进行拉伸、冲击测试,具体的数值如下:从增材后的工件取样,分别测试了修复层的拉伸、冲击韧性测试,其结果分别见表2、表3所示。均取自上述同一参数下所做对照实验。
表2修复层拉伸测试结果
表3修复层冲击测试结果
根据测试结果可知,实施例1修复层的平均抗拉强度为880MPa,实施例2修复层的平均抗拉强度为764MPa;实施例1修复层的平均断后伸长率为17.9%,实施例2修复层的平均断后伸长率为20.4%;实施例1修复层的平均断面收缩率为33%,实施例2修复层的平均断面收缩率为42%。由以上数据可知,实施例1和实施例2修复层在保证强度的同时,也保证了其塑性指标。实施例1修复层材料的平均冲击吸收功达到154J,实施例2修复层材料的平均冲击吸收功达到191J。此外,修复层类索氏体组织具有良好的韧性和塑性,同时兼具有较高的强度,使得其能够在更为复杂的载荷条件下工作。
实施例6
对实施例1的铁基合金粉末进行激光增材修复后热处理,通过合理的热处理参数调整,对试样的热处理后拉伸、热处理前后断裂韧性性能进行测试分析。
将热处理工艺参数设定如下:
淬火温度为970℃,淬火时间为10min,淬火冷却方式油冷,回火温度580℃,回火时间15min,回火冷却方式空冷。
淬火温度为970℃,淬火时间为10min,淬火冷却方式油冷,回火温度640℃,回火时间15min,回火冷却方式空冷。
淬火温度为970℃,淬火时间为10min,淬火冷却方式油冷,回火温度680℃,回火时间15min,回火冷却方式空冷。
淬火温度为970℃,淬火时间为10min,淬火冷却方式油冷,回火温度640℃,回火时间1H,回火冷却方式空冷。
淬火温度为970℃,淬火时间为10min,淬火冷却方式油冷,回火温度640℃,回火时间2H,回火冷却方式空冷。
通过制样观察,修复层组织致密,为回火索氏体结构,无气孔、夹杂、裂纹等缺陷,金相组织如图6所示,随着回火温度和回火时间的增大,回火索氏体复相组织中的等轴铁素体发生回复,铁素体晶粒尺寸增加。小颗粒状碳化物溶解,大颗粒碳化物聚集长大,碳化物对于基体弥散强化作用削弱,激光增材制造合金的塑性性能增加,强度减弱。通过热处理,激光增材制造合金的边界形貌消失,热处理前后边界形貌如图7所示。热处理后拉伸性能见表4,热处理前后断裂韧性见表5。其中T1’~T5’分别为实例5中参数下的试样经过上述热处理后所得结果。I3’试样为实例5中参数下680℃+15min热处理后所得。
表4热处理后修复层拉伸性能测试结果
表5热处理前后修复层断裂韧性测试结果
根据测试结果可知,经热处理后拉伸试样的抗拉强度的范围为:618~780MPa,断后伸长率的范围:16.1~23.3%,断面收缩率的范围为:45~59%。热处理前实施例1修复层材料的断裂韧性J1C=179kJ/m2,实施例2修复层材料的断裂韧度J1C=246kJ/m2。对实施例1进行热处理,热处理后实施例1的断裂韧性J1C=240kJ/m2,修复层试样均断裂,满足基体修复要求。
Claims (5)
1.一种激光增材与后热处理复合工艺制备高塑韧性1CrMo合金修复层的方法,其特征在于,所述方法为:
将铁基合金粉末烘干后放入送粉器中,将待修复试样置于激光器下进行激光增材修复操作,之后进行热处理,完成修复;
所述热处理的工艺参数为:淬火温度970℃,淬火时间10min,淬火冷却方式油冷;回火温度580~680℃,回火时间15min~2h,回火冷却方式空冷;
所述铁基合金粉末的组成为:碳C:0.05~0.15%,铬Cr:1.0~1.5%,硅Si:0.5~1.0%,锰Mn:0.6~1.0%,钼Mo:0.5~1.5%,氧O:≤0.05%,磷P:≤0.015%,硫S:≤0.03%,余量Fe。
2.如权利要求1所述的激光增材与后热处理复合工艺制备高塑韧性1CrMo合金修复层的方法,其特征在于,所述激光增材修复操作的工艺参数为:激光功率1900~2700W,激光扫描速度240~440mm/min,光斑直径4mm,送粉量8~12g/min,铁基合金粉末的送粉方式为同步同轴输送,送粉载气为高纯氩气,保护气为高纯氩气;单层修复层厚度介于0.5~1.5mm之间。
3.如权利要求1所述的激光增材与后热处理复合工艺制备高塑韧性1CrMo合金修复层的方法,其特征在于,所述铁基合金粉末的组成为:碳C:0.15%,铬Cr:1.5%,硅Si:0.8%,锰Mn:0.8%,钼Mo:1.5%,氧O:0.02%,磷P:0.01%,硫S:0.03%,铁Fe:95.19%。
4.如权利要求1所述的激光增材与后热处理复合工艺制备高塑韧性1CrMo合金修复层的方法,其特征在于,所述铁基合金粉末的组成为:碳C:0.08%,铬Cr:1.0%,硅Si:0.5%,锰Mn:0.8%,钼Mo:0.7%,氧O:0.02%,磷P:0.01%,硫S:0.03%,铁Fe:96.86%。
5.如权利要求1所述的激光增材与后热处理复合工艺制备高塑韧性1CrMo合金修复层的方法,其特征在于,所述铁基合金粉末含氧量低于600ppm,基于数量方面的空心粉率低于3%,粉末粒度介于-140~+325目之间,粉末松装密度介于3~6g/cm2之间,流动性介于12~18s之间。
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