CN115710703A - Method and machine tool for preparing corrosion-resistant and wear-resistant cladding layer by ultrahigh-speed laser cladding - Google Patents
Method and machine tool for preparing corrosion-resistant and wear-resistant cladding layer by ultrahigh-speed laser cladding Download PDFInfo
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- 238000005253 cladding Methods 0.000 title claims abstract description 93
- 230000007797 corrosion Effects 0.000 title claims abstract description 29
- 238000005260 corrosion Methods 0.000 title claims abstract description 29
- 238000000034 method Methods 0.000 title claims abstract description 27
- 238000004372 laser cladding Methods 0.000 title claims abstract description 24
- 239000000843 powder Substances 0.000 claims abstract description 82
- 239000000956 alloy Substances 0.000 claims abstract description 33
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 32
- 238000012545 processing Methods 0.000 claims abstract description 16
- 239000000463 material Substances 0.000 claims abstract description 13
- 238000002844 melting Methods 0.000 claims abstract description 7
- 238000012216 screening Methods 0.000 claims abstract description 5
- 239000007789 gas Substances 0.000 claims description 9
- 238000000227 grinding Methods 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 239000012159 carrier gas Substances 0.000 claims description 3
- 238000007599 discharging Methods 0.000 claims description 3
- 239000011261 inert gas Substances 0.000 claims description 3
- 239000002245 particle Substances 0.000 claims description 2
- 238000005299 abrasion Methods 0.000 abstract description 5
- 238000005336 cracking Methods 0.000 abstract description 5
- 239000011148 porous material Substances 0.000 abstract description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 238000005516 engineering process Methods 0.000 description 5
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- 239000000243 solution Substances 0.000 description 3
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- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
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- 229910052742 iron Inorganic materials 0.000 description 2
- 230000009191 jumping Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
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- 238000009659 non-destructive testing Methods 0.000 description 2
- 238000011056 performance test Methods 0.000 description 2
- 238000011160 research Methods 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
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- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
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Abstract
The invention provides a method and a machine tool for preparing a corrosion-resistant and wear-resistant cladding layer by ultrahigh-speed laser cladding, wherein (1) the surface of a workpiece to be clad is pretreated; (2) Screening alloy powder, placing the screened alloy powder in an oven for baking, keeping the temperature for a set time, and adding the screened alloy powder into a powder feeder of inner wall cladding equipment for later use; (3) clamping the workpiece on an inner Kong Chaogao fast-melting covering machine tool; (4) Adjusting the size of a light spot and the height of a powder feeding head, and determining the coordinates of a fusion-covering starting point and a terminal point; (5) Setting processing parameters, starting a processing program, and cladding an alloy cladding layer with a certain thickness on the inner wall of the workpiece. The obtained alloy cladding layer has compact internal structure, no pore and cracking problems, presents good metallurgical bonding with a base material, and has excellent wear resistance and corrosion resistance. Solves a series of problems of corrosion, abrasion and the like which are easy to appear in the use process of the inner walls of the workpieces such as partial pipe fittings, cylinder bodies and the like.
Description
Technical Field
The invention relates to the technical field of workpiece inner wall cladding, in particular to a method and a machine tool for preparing a corrosion-resistant and wear-resistant cladding layer by ultrahigh-speed laser cladding.
Background
In the fields of engineering machinery, petrochemical industry, aerospace and the like, a series of problems of corrosion, abrasion and the like gradually occur on the inner walls of a plurality of pipe fittings or cylinder bodies under severe working environments of weak acidity, humidity, high-pressure impact and the like, the service life of the pipe fittings or the cylinder bodies is severely limited, and thus a plurality of potential production safety hazards can be brought.
The traditional surface processing methods such as electroplating, surfacing, spraying and the like have certain limitations in the aspect of inner wall surface processing, for example, the electroplating process has the problems of thin coating, falling, pollution and the like, the surfacing process has large heat input amount and is easy to cause workpiece deformation and cracking, and the coating prepared by the spraying process is poor in combination with a base material, so that a new surface processing technology is urgently needed to realize low-cost and high-efficiency workpiece inner wall additive manufacturing, and the wear resistance and corrosion resistance of the workpiece inner wall additive manufacturing are practically improved.
The ultra-high speed laser cladding technology is a laser surface modification technology, adopts a synchronous powder feeding mode, utilizes a high-energy laser beam to simultaneously melt alloy powder and the surface of a base material moving at a high speed, and quickly solidifies to form a cladding layer which has a low dilution rate and is metallurgically combined with the base material. The technology can realize the preparation of the cladding layers with different performances by adjusting alloy materials while efficiently preparing the cladding layer with extremely low surface roughness and compact internal structure. Compared with the traditional methods of electroplating, surfacing, spraying and the like, the method has great advantages.
At present, researches and applications of ultra-high-speed cladding technology mainly focus on laser cladding on the outer surface of a shaft part of a revolving body structure, the researches on the ultra-high-speed laser cladding of the inner wall are relatively few, and the cladding layer is sparse in structure, has pores and is easy to crack.
Disclosure of Invention
The invention provides a method and a machine tool for preparing a corrosion-resistant and wear-resistant cladding layer by ultrahigh-speed laser cladding, which are used for solving the problems of sparse structure, pores and easiness in cracking of the cladding layer on the inner wall of the conventional workpiece.
In order to achieve the purpose, the invention adopts the following technical scheme:
the invention provides a method for preparing a corrosion-resistant and wear-resistant cladding layer by ultrahigh-speed laser cladding, which comprises the following steps:
(1) Pretreating the surface of the workpiece to be clad;
(2) Screening alloy powder, placing the screened alloy powder in an oven for baking, keeping the temperature for a set time, and adding the baked alloy powder into a powder feeder of inner wall cladding equipment for later use;
(3) Clamping a workpiece on an inner Kong Chaogao fast-melting covering machine tool;
(4) Adjusting the size of a light spot and the height of a powder feeding head, and determining the coordinates of a fusion-covering starting point and a terminal point;
(5) Setting processing parameters, starting a processing program, and cladding an alloy cladding layer with a certain thickness on the inner wall of the workpiece.
Further, after cladding, the workpiece is detached from the machine tool and placed in air for natural cooling; and grinding the cladding layer of the cooled workpiece to the using size.
Further, the size before cladding in the step (1) is two times of the target using size + the thickness of the reserved cladding layer.
Further, in the step (2), the particle size of the alloy powder is 80-600 meshes, and the Hall flow rate is 12-20 (sec/50 g).
Further, the baking temperature of the alloy powder in the step (2) is 80-120 ℃, and the time is not less than 60min.
Further, the alloy powder in the step (2) comprises the following components: the weight portions are as follows: 0.05-0.2% of C, 0.5-3% of Si, 15-30% of Cr, 2.5-10% of Ni, 0.25-1.5% of B, mn:0.5 to 1.5 percent of Mo, 1 to 5 percent of Mo and the balance of Fe.
Further, in the step (3), the workpiece is fixed and aligned, and the requirement for aligning the workpiece is that the circumferential runout of the front end and the rear end of the surface to be clad of the workpiece is not more than 0.3mm.
Further, in the step (4), the size of the light spot is 1.2mm-1.8mm, the height of the cladding head is required to be 12mm-16mm higher than the workpiece, and the powder spot is 1mm-2mm above the workpiece.
Further, in the step (5), the processing parameters comprise that the laser power is 5000W-8000W, the cladding linear velocity is 25 m/min-50 m/min, the lap joint rate is 70% -80%, and the cladding thickness is 0.2mm-1mm; the powder feeder has a powder feeding amount of 20-100 g/min per unit time, the powder feeding mode is carrier gas type powder feeding, inert gas is selected as the gas, and the gas flow is 5-30L/min.
The machine tool for preparing the corrosion-resistant and wear-resistant cladding layer by ultrahigh-speed laser cladding comprises a machine tool body, a numerical control system, a chuck and a bracket for fixing a workpiece, and further comprises a movable upright column, a powder feeder, a laser and a cladding head which are arranged on the machine tool body; the rotating shaft of the chuck is used as a main shaft, the powder feeder and the laser are sequentially started during cladding, cladding on the whole surface to be machined of the workpiece is achieved in a spiral line mode, when the program is finished, the laser stops emitting light, the powder feeder stops discharging powder, and the cladding head moves to a safe position after retreating from the workpiece.
The effect provided in the summary of the invention is only the effect of the embodiment, not all the effects of the invention, and one of the above technical solutions has the following advantages or beneficial effects:
1. the alloy cladding layer obtained by the method for cladding the inner wall of the workpiece has compact internal structure, has no problems of pores and cracking, presents good metallurgical bonding with a base material, and has excellent wear resistance and corrosion resistance. Solves a series of problems of corrosion, abrasion and the like which are easy to occur in the using process of the inner walls of the workpieces such as partial pipe fittings, cylinder bodies and the like.
2. Meanwhile, the method has the advantages of high production efficiency, low cost, high material utilization rate, accurate and controllable thickness of the cladding layer and stable processing process.
Drawings
In order to more clearly illustrate the embodiments or prior art solutions of the present invention, the drawings used in the description of the embodiments or prior art will be briefly described below, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
FIG. 1 is a metallographic structure of a cladding layer according to the present invention;
FIG. 2 is a perspective view of the machine of the present invention;
fig. 3 is a front view of the machine tool of the present invention.
Detailed Description
In order to clearly explain the technical features of the present invention, the following detailed description of the present invention is provided with reference to the accompanying drawings. The following disclosure provides many different embodiments, or examples, for implementing different features of the invention. To simplify the disclosure of the present invention, specific example components and arrangements are described below. Furthermore, the present invention may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. It should be noted that the components illustrated in the figures are not necessarily drawn to scale. Descriptions of well-known components and processing techniques and procedures are omitted so as to not unnecessarily limit the invention.
A method for preparing a corrosion-resistant wear-resistant cladding layer by ultrahigh-speed laser cladding comprises the following steps:
(1) The surface of the workpiece to be clad is pretreated, the workpiece is machined to the size before cladding by machining modes such as turning, grinding and the like, and rust and oil stains on the surface are cleaned.
(2) And screening the alloy powder by a screen mesh, placing the alloy powder in an oven for baking, preserving heat for a certain time, and adding the alloy powder into a powder feeder of inner wall cladding equipment for later use.
(3) Clamping a workpiece on an inner Kong Chaogao fast-melting covering machine tool, fixing the workpiece by matching a chuck and a bracket, and aligning the workpiece by using a dial indicator.
(4) And adjusting the size of the light spot to be proper, adjusting the height of the powder feeding head to be proper, and determining the coordinates of the fusion covering starting point and the end point.
(5) Setting processing parameters and editing a processing program, wherein the program comprises switching instructions of a laser and a powder feeder and a motion instruction of a machine tool.
(6) Starting a machining program, starting a machine tool spindle (a rotating shaft for fixing a workpiece chuck), a powder feeder and a laser in sequence, realizing cladding on the whole surface to be machined of the workpiece in a spiral line mode, stopping the light emission of the laser when the program is finished, stopping the powder discharge of the powder feeder, and moving a cladding head to a safe position after exiting the workpiece. At the moment, the inner wall of the workpiece is added with an alloy cladding layer with a certain thickness and excellent wear resistance and corrosion resistance. The equipment composition is shown in attached figures 2 and 3.
(7) And after cladding, detaching the workpiece from the machine tool, and naturally cooling the workpiece in the air.
(9) And grinding the cooled workpiece to a use size by using a honing mode to the cladding layer.
The size before cladding in the step (1) is twice of the target using size plus the thickness of the reserved cladding layer.
In the step (2), the granularity of the alloy powder is 80-600 meshes, and the Hall flow rate is 12-20 (sec/50 g).
In the step (2), the baking temperature of the alloy powder is 80-120 ℃, and the time is not less than 60min.
The alloy powder in the step (2) comprises the following components: the weight portion of the material is as follows: 0.05-0.2% of C, 0.5-3% of Si, 15-30% of Cr, 2.5-10% of Ni, 0.25-1.5% of B, mn:0.5 to 1.5 percent of Mo, 1 to 5 percent of Mo and the balance of Fe.
And (3) fixing the workpiece, and aligning the workpiece, wherein the workpiece alignment requirement is that the circumferential runout requirements of the front end and the rear end of the surface to be clad of the workpiece are not more than 0.3mm.
In the step (4), the spot size is 1.2mm-1.8mm, the height of the cladding head is required to be 12mm-16mm higher than the workpiece, and the powder spot is 1mm-2mm above the workpiece.
In the step (5), the processing parameters comprise that the laser power is 5000W-8000W, the cladding linear velocity is 25 m/min-50 m/min, the lap joint rate is 70% -80%, and the cladding thickness is 0.2mm-1mm; the powder feeder has a powder feeding amount of 20-100 g/min per unit time, the powder feeding mode is carrier gas type powder feeding, inert gas is selected as the gas, and the gas flow is 5-30L/min.
Example 1:
the workpiece to be processed is a cylinder body at a certain part in the engineering machinery, the outer diameter is 440mm, the inner diameter is 380mm, the wall thickness is 30mm, and the material is 27SiMn.
(1) The inner wall of the workpiece cylinder body is pretreated, the wall thickness is reduced by 0.4mm after the inner wall is processed by a boring mill, and alcohol is used for cleaning oil stains on the surface.
(2) Sieving metallic powder of 431-mesh stainless steel, placing in an oven, drying at 100 deg.C for 60min, and adding the dried powder into a powder feeder of ultrahigh-speed equipment.
(3) Clamping a workpiece on an inner Kong Chaogao fast-melting covering machine tool, fixing the workpiece by using a chuck and a bracket, and jumping by 0.1-0.2 mm at the front end and the rear end of the workpiece.
(4) The size of the light spot is adjusted to 1.5mm, the distance between the powder feeding head and the workpiece is about 15mm, and the powder coke is positioned 1-2 mm above the workpiece, so that about 80% of energy of the laser is ensured to be used for melting the powder.
5) Setting processing parameters, wherein the laser power is 6000W, the cladding linear speed is 30m/min, the lapping rate is 75 percent, the powder feeding amount of the powder feeder in unit time is 60g/min, and the powder feeding gas is N 2 The flow rate is 5L/min.
6) And editing the program, and after confirming that the parameters and the coordinates are correct, operating the program until the ultra-high-speed laser cladding of the inner wall of the whole workpiece is completed. The cladding thickness is 0.6mm.
7) And the workpiece is placed in the air for natural cooling after being disassembled.
8) And (4) grinding the inner wall of the clad workpiece, and processing the single side to remove 0.2mm to obtain the use size.
The performance test of the obtained cladding layer reaches the following indexes: and the cladding layer has no crack through nondestructive testing. The Rockwell hardness of the cladding layer is 52-55HRC, and the corrosion resistance of the cladding layer is 9 grades according to the national standard GB/T6461-2002. The abrasion resistance is improved by more than 10 times compared with the base material.
Example 2:
1) The workpiece to be processed is a valve seat at a certain position in the engineering machinery, the outer diameter is 220mm, the inner diameter is 170mm, the wall thickness is 25mm, the material is 40Cr, the inner wall of a cylinder body of the workpiece is pretreated, and the thickness of a single side is 0.2mm.
2) Screening the iron-based alloy powder by a 150-mesh screen, placing the iron-based alloy powder in a drying oven, keeping the temperature for 60min at 100 ℃, drying, and adding the dried powder into a powder feeder of an inner-wall ultra-high-speed device for later use.
3) Clamping a workpiece on an inner Kong Chaogao fast-melting covering machine tool, fixing the workpiece by using a chuck and a bracket, and jumping by 0.1-0.2 mm at the front end and the rear end of the workpiece.
4) The size of the light spot is adjusted to 1.6mm, the distance between the powder feeding head and the workpiece is about 15mm, and the powder coke is positioned 1-2 mm above the workpiece, so that 80% of energy of the laser is absorbed by the powder.
5) Setting processing parameters, setting the laser power to be 6000W, the cladding linear velocity to be 40m/min, the lap joint rate to be 75 percent, the powder feeding amount of the powder feeder in unit time to be 50g/min, carrying gas type powder feeding, and selecting nitrogen as gas.
6) And editing the program, and operating the program until the ultrahigh-speed laser cladding of the inner wall of the whole workpiece is completed after the parameters and the coordinates are confirmed to be correct. The cladding thickness is 0.35mm.
7) And the workpiece is placed in the air for natural cooling after being disassembled.
8) And (4) grinding the inner wall of the clad workpiece, and processing the single side to remove 0.15mm to obtain the use size.
The obtained cladding layer (figure 1) is subjected to a performance test, and the following indexes are achieved: and the cladding layer has no crack through nondestructive testing. The Rockwell hardness of the cladding layer is 45-48HRC, and the corrosion resistance is rated as 9 according to the national standard GB/T6461-2002. The abrasion resistance is improved by more than 10 times compared with the base material.
The alloy cladding layer obtained by cladding processing of the invention has good metallurgical bonding with a substrate, compact internal structure and no defects of air holes, cracking and the like. The surface finish of the cladding layer is good, the cladding layer can be directly ground, and the production efficiency is high. By matching with proper alloy powder, the corrosion resistance and the wear resistance of the base material are greatly improved, and the service life of a workpiece or equipment is obviously prolonged.
As shown in fig. 2 and 3, a machine tool for preparing a corrosion-resistant and wear-resistant cladding layer by ultra-high-speed laser cladding comprises a tool body 1, a numerical control system 2, a chuck 3 and a bracket 4 (capable of moving and adjusting positions along a linear guide rail) for fixing a workpiece, and further comprises a moving upright column 5, a powder feeder 6, a laser and a cladding head 7 which are arranged on the tool body; the movable upright post can move along the slide rail on the lathe bed. The rotating shaft of the chuck is used as a main shaft, when cladding is carried out, the main shaft, the powder feeder and the laser are sequentially started, cladding is carried out on the whole surface to be machined of the workpiece in a spiral line mode, when a program is finished, the laser stops emitting light, the powder feeder stops discharging powder, and the cladding head moves to a safe position after exiting from the workpiece.
Although the embodiments of the present invention have been described with reference to the accompanying drawings, it is not intended to limit the scope of the present invention, and it should be understood by those skilled in the art that various modifications and variations can be made without inventive efforts by those skilled in the art based on the technical solution of the present invention.
Claims (10)
1. The method for preparing the corrosion-resistant and wear-resistant cladding layer by ultrahigh-speed laser cladding is characterized by comprising the following steps of:
(1) Pretreating the surface of the workpiece to be clad;
(2) Screening alloy powder, placing the screened alloy powder in an oven for baking, keeping the temperature for a set time, and adding the screened alloy powder into a powder feeder of inner wall cladding equipment for later use;
(3) Clamping a workpiece on an inner Kong Chaogao fast-melting covering machine tool;
(4) Adjusting the size of a light spot and the height of a powder feeding head, and determining the coordinates of a fusion-covering starting point and a terminal point;
(5) Setting processing parameters, starting a processing program, and cladding an alloy cladding layer with a certain thickness on the inner wall of the workpiece.
2. The method for preparing the corrosion-resistant and wear-resistant cladding layer by the ultra-high speed laser cladding as claimed in claim 1, wherein after the cladding is finished, the workpiece is detached from a machine tool and is naturally cooled in air; and grinding the cooled workpiece to the use size of the cladding layer.
3. The method for preparing a corrosion-resistant and wear-resistant cladding layer by ultra-high speed laser cladding as claimed in claim 1, wherein the pre-cladding size in step (1) is twice the target use size + the thickness of the reserved cladding layer.
4. The ultra high speed laser cladding method for producing a corrosion-resistant and wear-resistant cladding layer according to claim 1, wherein the alloy powder in step (2) has a particle size of 80-600 mesh and a hall flow rate of 12-20 (sec/50 g).
5. The method for preparing the corrosion-resistant and wear-resistant cladding layer by ultra-high speed laser cladding as claimed in claim 1, wherein the baking temperature of the alloy powder in the step (2) is 80-120 ℃ and the baking time is not less than 60min.
6. The method for preparing the corrosion-resistant and wear-resistant cladding layer by ultra-high speed laser cladding according to claim 1, wherein the alloy powder in the step (2) comprises the following components: the weight portion of the material is as follows: 0.05-0.2% of C, 0.5-3% of Si, 15-30% of Cr, 2.5-10% of Ni, 0.25-1.5% of B, mn:0.5 to 1.5 percent of Mo, 1 to 5 percent of Mo and the balance of Fe.
7. The method for preparing the corrosion-resistant and wear-resistant cladding layer by ultra-high speed laser cladding as claimed in claim 1, wherein in the step (3), the workpiece is fixed and aligned, and the requirement on the alignment of the workpiece is that the circumferential runout of the front end and the rear end of the surface to be clad of the workpiece is not more than 0.3mm.
8. The method for preparing the corrosion-resistant and wear-resistant cladding layer by ultra-high speed laser cladding according to claim 1, wherein in the step (4), the size of a light spot is 1.2mm-1.8mm, the height of a cladding head is required to be 12mm-16mm higher than a workpiece, and a powder spot is 1mm-2mm above the workpiece.
9. The method for preparing a corrosion-resistant and wear-resistant cladding layer by ultra-high speed laser cladding as claimed in claim 1, wherein in the step (5), the processing parameters comprise laser power of 5000W-8000W, cladding linear velocity of 25 m/min-50 m/min, lap joint rate of 70% -80%, and cladding thickness of 0.2mm-1mm; the powder feeder has a powder feeding amount of 20-100 g/min per unit time, the powder feeding mode is carrier gas type powder feeding, inert gas is selected as the gas, and the gas flow is 5-30L/min.
10. A machine tool for preparing a corrosion-resistant and wear-resistant cladding layer by ultra-high speed laser cladding as claimed in any one of claims 1 to 9, which comprises a machine tool body, a numerical control system, a chuck and a bracket for fixing a workpiece, and is characterized by further comprising a movable upright column, a powder feeder, a laser and a cladding head which are arranged on the machine tool body; the rotating shaft of the chuck is used as a main shaft, when cladding is carried out, the main shaft, the powder feeder and the laser are sequentially started, cladding is carried out on the whole surface to be machined of the workpiece in a spiral line mode, when a program is finished, the laser stops emitting light, the powder feeder stops discharging powder, and the cladding head moves to a safe position after exiting from the workpiece.
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