CN116121687A - Method for repairing high-pressure turbine clearance valve rotating shaft deeply - Google Patents
Method for repairing high-pressure turbine clearance valve rotating shaft deeply Download PDFInfo
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- CN116121687A CN116121687A CN202211216581.3A CN202211216581A CN116121687A CN 116121687 A CN116121687 A CN 116121687A CN 202211216581 A CN202211216581 A CN 202211216581A CN 116121687 A CN116121687 A CN 116121687A
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- 238000000034 method Methods 0.000 title claims abstract description 59
- 239000011248 coating agent Substances 0.000 claims abstract description 56
- 238000000576 coating method Methods 0.000 claims abstract description 56
- 238000005507 spraying Methods 0.000 claims abstract description 52
- 230000008569 process Effects 0.000 claims abstract description 35
- 230000008439 repair process Effects 0.000 claims abstract description 31
- 238000005299 abrasion Methods 0.000 claims abstract description 18
- 238000003754 machining Methods 0.000 claims abstract description 15
- 238000000227 grinding Methods 0.000 claims abstract description 13
- 239000000463 material Substances 0.000 claims abstract description 13
- 238000012545 processing Methods 0.000 claims abstract description 10
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims abstract description 8
- 229910018487 Ni—Cr Inorganic materials 0.000 claims abstract description 7
- VNNRSPGTAMTISX-UHFFFAOYSA-N chromium nickel Chemical compound [Cr].[Ni] VNNRSPGTAMTISX-UHFFFAOYSA-N 0.000 claims abstract description 7
- 238000007689 inspection Methods 0.000 claims abstract description 6
- 238000004140 cleaning Methods 0.000 claims abstract description 5
- 238000010285 flame spraying Methods 0.000 claims abstract description 5
- 238000004372 laser cladding Methods 0.000 claims abstract description 5
- 230000035515 penetration Effects 0.000 claims abstract description 4
- 238000005488 sandblasting Methods 0.000 claims description 18
- 230000007547 defect Effects 0.000 claims description 7
- 238000013461 design Methods 0.000 claims description 7
- 238000005253 cladding Methods 0.000 claims description 6
- 230000002950 deficient Effects 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 5
- 238000007751 thermal spraying Methods 0.000 claims description 5
- 230000001788 irregular Effects 0.000 claims description 4
- 238000003801 milling Methods 0.000 claims description 4
- 238000005498 polishing Methods 0.000 claims description 4
- 238000007517 polishing process Methods 0.000 claims description 4
- 239000000126 substance Substances 0.000 claims description 4
- 230000003746 surface roughness Effects 0.000 claims description 4
- 238000001514 detection method Methods 0.000 claims description 3
- 238000005516 engineering process Methods 0.000 claims description 3
- 229910000816 inconels 718 Inorganic materials 0.000 claims description 3
- 239000000843 powder Substances 0.000 claims description 3
- 230000002035 prolonged effect Effects 0.000 claims description 3
- 239000004576 sand Substances 0.000 claims description 3
- 238000005201 scrubbing Methods 0.000 claims description 3
- 239000002390 adhesive tape Substances 0.000 claims description 2
- 239000010410 layer Substances 0.000 description 21
- 238000012423 maintenance Methods 0.000 description 7
- 230000000873 masking effect Effects 0.000 description 4
- 238000005422 blasting Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000002203 pretreatment Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 230000004083 survival effect Effects 0.000 description 1
- 238000011179 visual inspection 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
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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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/01—Selective coating, e.g. pattern coating, without pre-treatment of the material to be coated
-
- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
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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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/20—Hydro energy
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- Chemical & Material Sciences (AREA)
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- Chemical Kinetics & Catalysis (AREA)
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- Coating By Spraying Or Casting (AREA)
Abstract
The invention discloses a method for repairing the depth of a rotating shaft of a clearance valve of a high-pressure turbine. The method comprises the following steps of: the abrasion area is treated in a machining mode, abrasion marks are removed, an oxide film is removed, and the surface is metallic bright; step 2: processing before spraying; step 3: carrying out laser cladding material adding on the worn part; step 4: performing fluorescent penetration inspection on the repaired and ground cylindrical surface, wherein no crack exists; step 5: cleaning dirt on the surface of the part by using acetone, and cleaning the part by using an ultrasonic cleaner; step 6: shielding protection; step 7: pretreatment; step 8: spraying nickel chromium carbide on the outer circular surface by adopting a supersonic flame spraying process; step 9: removing residual stress; step 10: and grinding the parts by adopting an external circle grinder until the requirements of drawings are met. Step 11: and after finishing, checking the repair coating. The invention has the advantages of saving cost and improving reliability.
Description
Technical Field
The invention relates to the technical field of aviation, in particular to a method for repairing the depth of a rotating shaft of a clearance valve of a high-pressure turbine. More particularly it is a method of repairing the depth of a shaft on a high pressure turbine clearance flap on a CFM56-7B engine.
Background
For each part repair of the aircraft, reference must be made to the CMM service manual published by the corresponding OEM manufacturer, on which there are inspection and repair specifications for the part. Thereby ensuring the standardization of the maintenance operation of the parts and the navigability of the parts delivery. At present, foreign OEM manufacturers have monopoly and protectiveness of technical data and design schemes, so that related repair technical parameters are not provided for certain parts, and only scrapping and new replacement treatment can be performed after damage, thereby ensuring profits of the OEM manufacturers.
With the gradual increase of the maintenance amount of domestic civil aviation aircrafts, the demand of aircraft part maintenance is increased year by year, and each airline company has improvement requirements on the maintenance quality, cost and period of the part, so that severe requirements are provided for domestic maintenance factories how to continue survival development under the condition of technical locking of OEM factories. At present, under the condition that domestic manufacturers cannot obtain technical data of OEM manufacturers and support of original design schemes, a plurality of parts of the parts number also need to be purchased from the OEM manufacturers.
Therefore, it is necessary to develop a method for repairing the high-pressure turbine clearance valve shaft in depth, which saves cost and improves reliability.
Disclosure of Invention
The invention aims to provide a method for repairing the rotating shaft depth of a gap valve of a high-pressure turbine, which is a method for repairing shaft parts in a high-temperature environment (300-627 ℃), saves cost, improves reliability, does not damage the appearance structure of the rotating shaft in the repairing process, and can meet the use requirement in the high-temperature and high-pressure environment.
In order to achieve the above purpose, the technical scheme of the invention is as follows: the method for repairing the high-pressure turbine clearance valve rotating shaft deeply is characterized by comprising the following steps of: the method comprises the following steps:
step 1: the abrasion area of the workpiece is treated in a machining mode, abrasion marks are removed, an oxide film is removed, and the surface is metallic bright;
step 2: processing before spraying:
machining the irregular surface of the workpiece to a groove with a certain size, so that the repairing coating is embedded in the groove; wherein, adopt the engraving and milling technology to process the groove;
step 3: carrying out laser cladding material adding on the worn part of the workpiece, wherein the adopted cladding material is inconel 718 powder, and the adopted cladding process ensures that the strength is more than or equal to 90% of the strength of the part body;
step 4: flaw detection:
performing fluorescent penetration inspection on the cylindrical surface of the repaired and ground workpiece in sequence until no crack exists;
step 5: scrubbing dirt on the surface of a workpiece by using acetone, and cleaning the workpiece by using an ultrasonic cleaner;
step 6: shielding protection:
shielding and protecting a non-spraying area and the side wall of the middle vent hole of the machined part by using a shielding adhesive tape;
step 7: pretreatment:
before thermal spraying, sand with 36-60 meshes is used for carrying out sand blasting treatment on a workpiece by adopting a jet-suction type sand blasting process;
after the sand blasting treatment, checking sand blasting quality, and checking whether the surface roughness is uniform and consistent or not, and whether the sand blasting is good at the rounded positions of the side surface and the bottom end of the groove or not;
step 8: and (3) coating spraying:
spraying a nickel-chromium carbide coating on the outer circular surface of the machined part by adopting a supersonic flame spraying process, so that the hardness and wear resistance of the surface of the machined part are improved, and the service life is prolonged;
step 9: removing residual stress;
step 10: grinding the machined part by adopting an external circle grinder until the requirement of a drawing is met; when the grinding allowance is 30-50 mu m, polishing to the final size by a fine polishing process;
step 11: after finishing, checking the repair coating of the workpiece, checking whether the surface is defective, checking whether the inlaid periphery of the coating on the surface of the workpiece is well bonded, and checking whether gaps exist;
if the surface of the machined part is defect-free, finishing the machining;
and if the surface of the workpiece is defective, repeating the steps 1 to 11.
In the above technical scheme, in step 2, the machined workpiece to-be-sprayed area is a flat circular arc, and the machining depth of the machined workpiece to-be-sprayed area reaches the bottom end of abrasion;
a certain chamfering treatment is arranged on the periphery of the undercut groove;
the top end of the undercut groove keeps a distance of 1mm from the edge of the workpiece, and the bottom of the groove is rounded by R1mm;
chamfering the edges of the through holes in the middle of the rotating shaft; the undercut range of the through hole is expanded outwards by 2mm on the basis of the worn area to be repaired; the bottom of the groove is a plane.
In the above technical scheme, in step 8, the workpiece is cooled during the coating spraying process, so that the temperature of the workpiece is less than or equal to 180 ℃.
In the technical scheme, in the step 8, when the groove of the region to be repaired of the workpiece is in a step shape, firstly, coating spraying is carried out on the outer ring of the whole groove, and the thickness of the sprayed coating is controlled to be 0.05-0.1 mm;
secondly, spraying the deeper area of the groove, wherein the thickness of a sprayed coating is 0.05-0.1 mm;
spraying the whole groove area, wherein the thickness of the sprayed coating is 0.05-0.1 mm; the process is circularly carried out until the thickness of the groove coating in the area to be repaired meets the design requirement;
reserving 0.3-0.5 mm finishing allowance after the groove coating of the area to be repaired reaches the working size until the spraying is finished;
and naturally cooling the machined part, removing the shielding substance when the machined part is cooled to 40-50 ℃, and checking the quality of the coating of the machined part to see whether the machined part has defects.
In the technical scheme, in the step 8, the bonding strength of the spray coating of the workpiece is more than 70MPa, and the microscopic strength of the coating is more than 700Hv.
The invention has the following advantages:
(1) The laser cladding and thermal spraying repair process has the characteristics of short flow, small deformation of parts and good wear resistance; the service life of the rotating shaft is prolonged through repair;
(2) The cost is saved, the reliability is improved, and the maintenance period is shortened (about 10 days in the whole repair process of the invention); in the repairing process, the appearance structure of the rotating shaft is not damaged, and the use requirement under the high-temperature and high-pressure environment can be met; breaks the technical barriers of foreign OEM manufacturers, and overcomes the defects of high maintenance cost and period (a few months are required for purchasing new finished products under general conditions).
Drawings
FIG. 1 is a graph showing the damage condition before repair according to the present invention.
FIG. 2 is a schematic diagram of a groove structure for machining a part substrate before spraying according to the invention.
FIG. 3 is a schematic view of the structure of the area of the sprayed nickel chromium carbide coating of the present invention.
FIG. 4 is a schematic illustration of the present invention using a supersonic flame spraying process to spray nickel chromium carbide on an outer circumferential surface.
Fig. 5 is a state diagram of the present invention after repair.
Fig. 6 is a flow chart of the present invention.
In fig. 1, G represents a damaged region of the workpiece, i.e., a region to be repaired.
In fig. 2, a represents a thermal spray coating; b represents a rounded corner; c represents a base material; d represents a groove; a represents the horizontal angle of the groove side, generally 30 °.
In fig. 3, a represents a thermal spray coating; b1 represents a first minimum chamfer condition of the thermal spray coating region; b2 represents a second minimum chamfer condition of the thermal spray coating region.
In fig. 4, E represents a sprayed nickel chromium carbide coating.
In fig. 5, F represents a repair area of the workpiece repaired by the method of the present invention.
Detailed Description
The following detailed description of the invention is, therefore, not to be taken in a limiting sense, but is made merely by way of example. While making the advantages of the present invention clearer and more readily understood by way of illustration.
The repairing method is mainly used for filling the worn area of the rotating shaft so as to restore the worn area to a regular and complete size. The repairing coating has high temperature resistance, certain wear resistance and self-lubricating performance. And when repairing the rotor with deeper abrasion, adopting a measure of combining the bottom layer and the surface layer. The bottom layer material is a material with higher bonding performance and good high temperature resistance. And the thickness of the bottom layer is controlled stepwise according to the abrasion condition of the rotating shaft, so that the defects of internal stress of the surface layer, insufficient bonding strength caused by the later coating and the like are reduced.
As can be seen with reference to the accompanying drawings: the method for repairing the high-pressure turbine clearance valve rotating shaft deeply comprises the following steps of:
step 1: the abrasion area of the workpiece is treated in a machining mode, abrasion marks are removed, an oxide film is removed, and the surface is metallic bright;
step 2: processing before spraying: machining the irregular surface of the workpiece to a groove with a certain size requirement, so that the repairing coating is embedded in the groove; wherein, adopt carving and milling technology to process the recess. The area to be sprayed of the machined workpiece is a flat circular arc, and the machining depth of the area to be sprayed of the machined workpiece reaches the bottom end of abrasion. The periphery of the undercut groove should be subjected to a certain chamfering process, and the right angle of the groove periphery is forbidden. The top end of the undercut groove is kept at a distance of 1mm from the edge of the workpiece, and the bottom of the groove is rounded by R1mm. And chamfering the edges of the through holes in the middle of the rotating shaft. The undercut range of the through hole should include all worn areas to be repaired and should be enlarged outwardly by 2mm. The bottom of the groove is a plane, so that the thickness of the sprayed coating is ensured to be uniform;
step 3: carrying out laser cladding material adding on the worn part of the workpiece, wherein the adopted cladding material is inconel 718 powder, and the adopted cladding process ensures that the strength is not less than 90% of the strength of the part body;
step 4: flaw detection: performing fluorescence penetration inspection on the cylindrical surface of the repaired and ground workpiece in sequence according to the ASTM E1417 and Type 1,Method A,C or D Level 3 or 4 method, wherein no crack exists;
step 5: scrubbing dirt on the surface of a workpiece by using acetone, and cleaning the workpiece by using an ultrasonic cleaner;
step 6: shielding protection: masking and protecting a non-spraying area of a workpiece by using a masking tape, and masking and protecting the side wall of the middle vent hole by using the masking tape;
step 7: pretreatment: before thermal spraying, 36-60 mesh sand is used, and a jet-suction type sand blasting process is used for carrying out sand blasting treatment on the workpiece. After the sand blasting treatment, checking sand blasting quality, and checking whether the surface roughness is uniform and consistent or not, and whether the sand blasting is good at the rounded positions of the side surface and the bottom end of the groove or not;
step 8: and (3) coating spraying: and spraying a nickel-chromium carbide coating on the outer circular surface of the machined part by adopting a supersonic flame spraying process, wherein the machined part is cooled in the coating spraying process, so that the temperature of the machined part is prevented from being too high, and the temperature of the machined part added in the spraying process is ensured to be less than or equal to 180 ℃.
If the groove of the region to be repaired of the workpiece is stepped, firstly spraying the whole groove, wherein the thickness of a sprayed coating is controlled to be 0.05-0.1 mm; secondly, spraying the deeper area of the groove, wherein the thickness of the sprayed coating is 0.05-0.1 mm; spraying the whole groove area, wherein the thickness of the sprayed coating is 0.05-0.1 mm; and the process is circularly carried out until the thickness of the groove coating in the area to be repaired meets the design requirement. When the thickness of the sprayed coating is less than 0.05mm, the coating is easy to fall off; when the thickness of the sprayed coating is more than 0.1mm, the brittleness of the coating is increased, and the coating is easy to fall off in the matching process.
And reserving 0.3-0.5 mm of finishing allowance after the groove coating of the area to be repaired reaches the working size until the spraying is finished. And naturally cooling the machined part, and removing the shielding substance when the machined part is cooled to 40-50 ℃. And the coating quality of the machined part is checked visually to see whether the machined part has defects. The bonding strength of a spray coating of a workpiece is greater than 70MPa, the microscopic strength of the coating is greater than 700Hv, and the physical characteristics and bonding force of the thermal spraying of the workpiece are ensured;
step 9: and the residual stress is removed, the residual stress of the material is eliminated, and surface cracks are avoided.
Step 10: and grinding the machined part by adopting an external circle grinder until the requirement of a drawing is met. When the grinding allowance is 30-50 mu m, polishing to the final size by a fine polishing process;
step 11: after finishing, checking the repair coating of the workpiece to check whether the surface of the workpiece has defects, whether the inlaid periphery of the coating is well adhered, whether gaps exist or not and the like;
if the surface of the machined part is defect-free, finishing the machining;
and if the surface of the workpiece is defective, repeating the steps 1 to 11.
Examples
The invention will now be described in detail with the present invention being applied to a method for repairing a high pressure turbine clearance valve shaft in depth as an example, and the present invention is also directed to the application of the present invention to the repair of other high pressure turbine clearance valve shafts in depth.
In this embodiment, the damage condition of the rotating shaft of the clearance valve of a certain high-pressure turbine is: the abrasion of the cylindrical sealing surface exceeds the standard, and the detail is shown in figure 1.
In this embodiment, the method for repairing the rotating shaft of the clearance valve of a certain high-pressure turbine, as shown in fig. 6, includes the following steps:
step one: determining a damage level and a repair level;
as shown in fig. 1, the abrasion depth of the rotating shaft is judged according to the performance of the repair layer, the abrasion depth of the repair layer is classified into 5 grades, and different repair layer system schemes are adopted for different abrasion depths, as shown in the following table 1.
TABLE 1 repair layer wear depth grading Table
Step two: processing before spraying;
before spraying, the rotating shaft to be maintained should be mechanically pretreated, and the worn irregular surface is processed into a groove with certain requirement, so that the repairing layer is embedded in the groove.
The processing requirements are as follows:
1) According to the specific shape and the specificity of the rotating shaft, the position to be repaired is a semicircular area, which cannot be realized in a turning or grinding process, and a numerical control milling process is recommended. The area to be sprayed after processing is a flat circular arc, and the processing depth reaches the bottom end of abrasion.
2) The periphery of the undercut groove should be subjected to a certain chamfering process, and the right angle of the groove periphery is forbidden. Chamfering is required as shown in fig. 2. The top end of the undercut groove is kept at a distance of 1mm from the edge of the part, and the bottom of the groove is rounded by R1mm. For the through hole in the middle of the rotating shaft, the edge is subjected to chamfering treatment, and chamfering requirements are shown in fig. 3.
3) The undercut range should include all worn areas to be repaired and should be enlarged outwardly by 2mm.
4) The bottom of the groove is a plane, so that the thickness uniformity of the repair layer is ensured.
5) The machining is finished, and the drawing is shown in fig. 4.
6) If the middle part area of a certain part is excessively worn, the middle area can be deeply processed, a gradient ladder is formed, and the ladder knot part is subjected to corresponding chamfering treatment.
Step three: spraying;
the specific spraying process comprises the following steps:
3.1 Data measurement record;
the depth measurement should be performed on the groove area before spraying, and the preparation of the process before spraying is performed according to the repairing layer scheme. And corresponding data is recorded according to the part number, and a process data table is filled in.
3.2 Shielding protection;
shielding and protecting the non-spraying area by using a shielding material, and protecting the side wall of the middle vent hole;
3.3 Pre-treatment;
the blasting process is used to perform the blasting treatment. After sand blasting, the sand blasting quality is checked, whether the surface roughness is uniform or not, and whether the sand blasting is good at the rounded positions of the side surface and the bottom end of the groove or not is performed.
3.4 Coating spraying;
the repair layer material and thickness are described with reference to the repair layer design using a thermal spray process for spraying. During the spraying process, the cooling of the parts is paid attention to, so that the excessive temperature (less than or equal to 180 ℃) of the parts is prevented.
If the groove of the area to be repaired is stepped, firstly, the thickness of the sprayed repairing layer of the whole groove is controlled to be 0.05-0.1 mm; secondly, spraying the deeper area of the groove, wherein the thickness of the repair layer is 0.05-0.1 mm; spraying the whole area, wherein the thickness of the repair layer is 0.05-0.1 mm; and the process is circularly carried out until the thickness of the repair layer meets the design requirement.
And reserving a finishing allowance of 0.3-0.5 mm after the layer to be repaired reaches the working size, and finishing spraying. And naturally cooling the part, and dismantling the shielding substance when the part is cooled to 40-50 ℃. And visual inspection is carried out on the quality of the coating to check whether the coating has defects. And recording spraying related data.
Step four: finishing the repairing layer;
the part repair layer is in the form of a partial inlay, not a circumferential overall coating, so that grinding is recommended for subsequent processing. The single feeding amount in the processing process should be relatively small (the feeding amount in accurate grinding can be referred to), and the feeding amount can be specifically set according to the parameters of the grinding machine.
And when the grinding allowance is 30-50 mu m, polishing to the final size by a fine polishing process.
Step five: inspection of finished products
And after finishing, checking the repair layer to see whether the surface is defective, whether the inlaid periphery of the repair layer is well adhered, whether gaps exist or not and the like. Fig. 5 is a state after the finish grinding repair. Other non-illustrated parts are known in the art.
Claims (5)
1. The method for repairing the high-pressure turbine clearance valve rotating shaft deeply is characterized by comprising the following steps of: the method comprises the following steps:
step 1: the abrasion area of the workpiece is treated in a machining mode, abrasion marks are removed, an oxide film is removed, and the surface is metallic bright;
step 2: processing before spraying:
machining the irregular surface of the workpiece to a groove with a certain size, so that the repairing coating is embedded in the groove; wherein, adopt the engraving and milling technology to process the groove;
step 3: carrying out laser cladding material adding on the worn part of the workpiece, wherein the adopted cladding material is inconel 718 powder, and the adopted cladding process ensures that the strength is more than or equal to 90% of the strength of the part body;
step 4: flaw detection:
performing fluorescent penetration inspection on the cylindrical surface of the repaired and ground workpiece in sequence until no crack exists;
step 5: scrubbing dirt on the surface of a workpiece by using acetone, and cleaning the workpiece by using an ultrasonic cleaner;
step 6: shielding protection:
shielding and protecting a non-spraying area and the side wall of the middle vent hole of the machined part by using a shielding adhesive tape;
step 7: pretreatment:
before thermal spraying, sand with 36-60 meshes is used for carrying out sand blasting treatment on a workpiece by adopting a jet-suction type sand blasting process;
after the sand blasting treatment, checking sand blasting quality, and checking whether the surface roughness is uniform and consistent or not, and whether the sand blasting is good at the rounded positions of the side surface and the bottom end of the groove or not;
step 8: and (3) coating spraying:
spraying a nickel-chromium carbide coating on the outer circular surface of the machined part by adopting a supersonic flame spraying process, so that the hardness and wear resistance of the surface of the machined part are improved, and the service life is prolonged;
step 9: removing residual stress;
step 10: grinding the machined part by adopting an external circle grinder until the requirement of a drawing is met; when the grinding allowance is 30-50 mu m, polishing to the final size by a fine polishing process;
step 11: after finishing, checking the repair coating of the workpiece, checking whether the surface is defective, checking whether the inlaid periphery of the coating on the surface of the workpiece is well bonded, and checking whether gaps exist;
if the surface of the machined part is defect-free, finishing the machining;
and if the surface of the workpiece is defective, repeating the steps 1 to 11.
2. The high-pressure turbine clearance valve spindle depth repair method of claim 1, wherein: in the step 2, the machined workpiece to-be-sprayed area is a flat circular arc, and the machining depth of the machined workpiece to-be-sprayed area reaches the bottom end of abrasion;
a certain chamfering treatment is arranged on the periphery of the undercut groove;
the top end of the undercut groove keeps a distance of 1mm from the edge of the workpiece, and the bottom of the groove is rounded by R1mm;
chamfering the edges of the through holes in the middle of the rotating shaft; the undercut range of the through hole is expanded outwards by 2mm on the basis of the worn area to be repaired; the bottom of the groove is a plane.
3. The high-pressure turbine clearance valve spindle depth repair method of claim 2, wherein: in step 8, the workpiece is cooled during the coating spraying process to a workpiece temperature of 180 ℃ or less.
4. A method of repairing a high pressure turbine clearance valve spindle depth as claimed in claim 3, wherein: in the step 8, when the groove of the area to be repaired of the workpiece is in a step shape, firstly, coating spraying is carried out on the outer ring of the whole groove, and the thickness of the sprayed coating is controlled to be 0.05-0.1 mm;
secondly, spraying the deeper area of the groove, wherein the thickness of a sprayed coating is 0.05-0.1 mm;
spraying the whole groove area, wherein the thickness of the sprayed coating is 0.05-0.1 mm; the process is circularly carried out until the thickness of the groove coating in the area to be repaired meets the design requirement;
reserving 0.3-0.5 mm finishing allowance after the groove coating of the area to be repaired reaches the working size until the spraying is finished;
and naturally cooling the machined part, removing the shielding substance when the machined part is cooled to 40-50 ℃, and checking the quality of the coating of the machined part to see whether the machined part has defects.
5. The method for repairing the rotating shaft depth of the clearance valve of the high-pressure turbine according to claim 4, which is characterized in that: in step 8, the bonding strength of the spray coating of the workpiece is greater than 70MPa, and the microscopic strength of the coating is greater than 700Hv.
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