CN116352078A - 一种激光增材修复工艺 - Google Patents
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Abstract
一种激光增材修复工艺，所述激光增材技术是激光熔覆和激光快速成型技术的结合，修复过程中以碳化铬、铜和锰作为熔覆粉末，激光熔覆粉末中，碳化铬作为主要用量，其作用在于保证熔覆层必要的硬度和耐磨性能，铜和锰则作为辅料用于调整熔覆层的热膨胀性能。根据本发明的修复工艺，可将修复层与基体材料的热膨胀系数差降低至15％以下，极大地延长了飞机发动机叶片的使用寿命。
Description
技术领域
本发明涉及激光熔覆领域，具体涉及一种激光增材修复工艺。
背景技术
在飞机的服役过程中，一些关键性金属零件因变形、磨损、腐蚀等原因会出现裂纹等缺陷，这会对飞行安全造成负面影响。针对这一问题，现有技术通常会对破损零件进行修复，其中，增材制造、激光熔覆、冷喷涂以及电弧堆焊等工艺都广泛应用于金属零件的修复领域，当两种不同的材料复合在一起时，如果热膨胀系数偏差太多，则会在温度变化时产生应力，该应力会在界面处引起裂纹和间隙。然而，现有的修复工艺一般都追求修复后材料的硬度、强度和耐腐蚀性能等，对于修复材料与原有材料的热膨胀性能差异的关注少之又少，这无疑增加了飞机零部件再次损坏的风险。
发明内容
针对现有技术存在的问题，本发明的目的在于提供一种激光增材修复工艺，该方法可以降低修复层与基体材料之间的热膨胀系数差，进而避免热裂纹的产生，延长飞机发动机叶片的使用寿命。
一种激光增材修复工艺，所述激光增材是激光熔覆和激光快速成型技术的结合，其特征在于，包括以下步骤：
选择待修复的飞机发动机叶片，对叶片待修复部位进行抛光处理；用盐酸溶液清洗叶片表面以除去氧化层；再依次用丙酮、无水乙醇和去离子水清洗叶片；
以PVA溶液作为粘结剂，使粘结剂与熔覆粉末均匀混合，然后涂覆于叶片表面待修复部位形成预置层，在氩气保护下通过激光增材工艺修复叶片，其中，熔覆粉末由52-75重量份的碳化铬、10-30重量份的铜和14-20重量份的锰组成，熔覆粉末中碳化铬的用量为52wt％-75wt％，修复过程的激光功率为850-1000W，扫描速度为300-350mm/mi n，光斑直径为3-3.5mm，搭接率为35％-40％，能量密度为360-400W/mm2。
优选地，所述发动机叶片的材质为GH4080A Cr-Ni合金。
优选地，所述抛光处理后的表面粗糙度为2-3μm。
优选地，所述盐酸溶液的浓度为15％-20％。
优选地，所述粘结剂的浓度为5wt％-8wt％。
优选地，所述熔覆粉末由52重量份的碳化铬、30重量份的铜和18重量份的锰组成。
本发明提供了一种激光增材修复工艺，激光增材技术是激光熔覆和激光快速成型技术的结合，修复过程中以碳化铬、铜和锰作为熔覆粉末，熔覆粉末中，碳化铬作为主要用料，其作用在于保证熔覆层必要的硬度和耐磨性能，铜和锰则作为辅料用于调整熔覆层的热膨胀性能。根据本发明的修复工艺，可将修复层与基体材料的热膨胀系数差降低至15％以下，进而延长了飞机发动机叶片的使用寿命。
具体实施方式
下面通过具体实施例来验证本发明的技术效果，但是本发明的实施方式不局限于此。
实施例1
选择待修复的飞机发动机叶片(叶片材质为GH4080A Cr-Ni合金)，对叶片待修复部位进行抛光处理，抛光处理后的表面粗糙度约2μm；用20％的盐酸溶液清洗叶片表面以除去氧化层；再依次用丙酮、无水乙醇和去离子水清洗叶片；
以5wt％的PVA溶液作为粘结剂，使粘结剂与熔覆粉末均匀混合，然后涂覆于叶片表面待修复部位形成预置层，在氩气保护下通过激光增材工艺修复叶片，其中，熔覆粉末由65重量份的碳化铬、21重量份的铜和14重量份的锰组成，修复过程的激光功率为850W，扫描速度为300mm/mi n，光斑直径为3mm，搭接率为35％，能量密度为360W/mm2。
实施例2
选择待修复的飞机发动机叶片(叶片材质为GH4080A Cr-Ni合金)，对叶片待修复部位进行抛光处理，抛光处理后的表面粗糙度约2μm；用20％的盐酸溶液清洗叶片表面以除去氧化层；再依次用丙酮、无水乙醇和去离子水清洗叶片；
以5wt％的PVA溶液作为粘结剂，使粘结剂与熔覆粉末均匀混合，然后涂覆于叶片表面待修复部位形成预置层，在氩气保护下通过激光增材工艺修复叶片，其中，熔覆粉末由52重量份的碳化铬、30重量份的铜和18重量份的锰组成，修复过程的激光功率为850W，扫描速度为300mm/mi n，光斑直径为3mm，搭接率为35％，能量密度为360W/mm2。
实施例3
选择待修复的飞机发动机叶片(叶片材质为GH4080A Cr-Ni合金)，对叶片待修复部位进行抛光处理，抛光处理后的表面粗糙度约2μm；用20％的盐酸溶液清洗叶片表面以除去氧化层；再依次用丙酮、无水乙醇和去离子水清洗叶片；
以5wt％的PVA溶液作为粘结剂，使粘结剂与熔覆粉末均匀混合，然后涂覆于叶片表面待修复部位形成预置层，在氩气保护下通过激光增材工艺修复叶片，其中，熔覆粉末由60重量份的碳化铬、20重量份的铜和20重量份的锰组成，修复过程的激光功率为850W，扫描速度为300mm/mi n，光斑直径为3mm，搭接率为35％，能量密度为360W/mm2。
实施例4
选择待修复的飞机发动机叶片(叶片材质为GH4080A Cr-Ni合金)，对叶片待修复部位进行抛光处理，抛光处理后的表面粗糙度约2μm；用20％的盐酸溶液清洗叶片表面以除去氧化层；再依次用丙酮、无水乙醇和去离子水清洗叶片；
以5wt％的PVA溶液作为粘结剂，使粘结剂与熔覆粉末均匀混合，然后涂覆于叶片表面待修复部位形成预置层，在氩气保护下通过激光增材工艺修复叶片，其中，熔覆粉末由70重量份的碳化铬、15重量份的铜和15重量份的锰组成，修复过程的激光功率为850W，扫描速度为300mm/mi n，光斑直径为3mm，搭接率为35％，能量密度为360W/mm2。
实施例5
选择待修复的飞机发动机叶片(叶片材质为GH4080A Cr-Ni合金)，对叶片待修复部位进行抛光处理，抛光处理后的表面粗糙度约2μm；用20％的盐酸溶液清洗叶片表面以除去氧化层；再依次用丙酮、无水乙醇和去离子水清洗叶片；
以5wt％的PVA溶液作为粘结剂，使粘结剂与熔覆粉末均匀混合，然后涂覆于叶片表面待修复部位形成预置层，在氩气保护下通过激光增材工艺修复叶片，其中，熔覆粉末由75重量份的碳化铬、10重量份的铜和15重量份的锰组成，修复过程的激光功率为850W，扫描速度为300mm/mi n，光斑直径为3mm，搭接率为35％，能量密度为360W/mm2。
对比例1
选择待修复的飞机发动机叶片(叶片材质为GH4080A Cr-Ni合金)，对叶片待修复部位进行抛光处理，抛光处理后的表面粗糙度约2μm；用20％的盐酸溶液清洗叶片表面以除去氧化层；再依次用丙酮、无水乙醇和去离子水清洗叶片；
以5wt％的PVA溶液作为粘结剂，使粘结剂与熔覆粉末均匀混合，然后涂覆于叶片表面待修复部位形成预置层，在氩气保护下通过激光增材工艺修复叶片，其中，熔覆粉末由200重量份的碳化铬、30重量份的铜和18重量份的锰组成，修复过程的激光功率为850W，扫描速度为300mm/mi n，光斑直径为3mm，搭接率为35％，能量密度为360W/mm2。
对比例2
选择待修复的飞机发动机叶片(叶片材质为GH4080A Cr-Ni合金)，对叶片待修复部位进行抛光处理，抛光处理后的表面粗糙度约2μm；用20％的盐酸溶液清洗叶片表面以除去氧化层；再依次用丙酮、无水乙醇和去离子水清洗叶片；
以5wt％的PVA溶液作为粘结剂，使粘结剂与熔覆粉末均匀混合，然后涂覆于叶片表面待修复部位形成预置层，在氩气保护下通过激光增材工艺修复叶片，其中，熔覆粉末由30重量份的碳化铬、30重量份的铜和18重量份的锰组成，修复过程的激光功率为850W，扫描速度为300mm/mi n，光斑直径为3mm，搭接率为35％，能量密度为360W/mm2。
进一步地，发明人对实施例1-5和对比例1-2的修复层的热膨胀系数进行测试，并且测试上述试验组在循环高温下的稳定性能，具体为：在50℃/mi n的升温速率下将叶片升温至600℃，保温2h后自然冷却至室温，重复该步骤并记录各试验组产生热裂纹的循环次数。
由于飞机叶片样品成本昂贵，作为替代，发明人选取GH4080A Cr-Ni合金作为实施例1-5和对比例1-2的基材，并通过人为加工获得待修复部位相似的工件进行试验并测试，除此之外，其余所有工艺流程不变。试验组的具体实验数据如表1所示，表中线膨胀系数差定义为：∣A-B∣/A；式中A＝13.8×10-6/℃(本发明选取的GH4080A Cr-Ni合金在600℃时的线膨胀系数)，B为修复层600℃时的线膨胀系数，线膨胀系数差用于衡量修复层材料与基材其他部位的热膨胀性能的差异。
表1各试验组的测试数据
熔覆粉末中，碳化铬作为主要用料，其作用在于保证熔覆层必要的硬度和耐磨性能，铜和锰则作为辅料用于调整熔覆层的热膨胀性能。从表1可以看到，当碳化铬的用量占比超过80％(对比例1)或低于40％(对比例2)时，都无法获得令人满意的效果，所以，本发明将碳化铬的用量占比确定为52wt％-75wt％。通过本发明的激光增材修复工艺，可以降低修复层与飞机叶片材料的线膨胀系数差，进而减少长时间高温工作中产生的热裂纹情况，延长发动机叶片的使用寿命。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明技术原理的前提下，还可以做出若干改进和变型，这些改进和变型也应视为本发明的保护范围。
Claims (6)
1.一种激光增材修复工艺，所述激光增材是激光熔覆和激光快速成型技术的结合，其特征在于，包括以下步骤：
选择待修复的飞机发动机叶片，对叶片待修复部位进行抛光处理；用盐酸溶液清洗叶片表面以除去氧化层；再依次用丙酮、无水乙醇和去离子水清洗叶片；
以PVA溶液作为粘结剂，使粘结剂与熔覆粉末均匀混合，然后涂覆于叶片表面待修复部位形成预置层，在氩气保护下通过激光增材工艺修复叶片，其中，熔覆粉末由52-75重量份的碳化铬、10-30重量份的铜和14-20重量份的锰组成，熔覆粉末中碳化铬的用量为52wt％-75wt％，修复过程的激光功率为850-1000W，扫描速度为300-350mm/min，光斑直径为3-3.5mm，搭接率为35％-40％，能量密度为360-400W/mm2。
2.一种如权利要求1所述的激光增材修复工艺，其特征在于，所述发动机叶片的材质为GH4080A Cr-Ni合金。
3.一种如权利要求1所述的激光增材修复工艺，其特征在于，所述抛光处理后的表面粗糙度为2-3μm。
4.一种如权利要求1所述的激光增材修复工艺，其特征在于，所述盐酸溶液的浓度为15％-20％。
5.一种如权利要求1所述的激光增材修复工艺，其特征在于，所述粘结剂的浓度为5wt％-8wt％。
6.一种如权利要求5所述的激光增材修复工艺，其特征在于，所述熔覆粉末由52重量份的碳化铬、30重量份的铜和18重量份的锰组成。
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