CN211848104U - High-quality shaft part preparation device based on thermal spraying and induction cladding technology - Google Patents
High-quality shaft part preparation device based on thermal spraying and induction cladding technology Download PDFInfo
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- CN211848104U CN211848104U CN201920953836.1U CN201920953836U CN211848104U CN 211848104 U CN211848104 U CN 211848104U CN 201920953836 U CN201920953836 U CN 201920953836U CN 211848104 U CN211848104 U CN 211848104U
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Abstract
The invention relates to a high-quality shaft part preparation device based on a thermal spraying and induction cladding technology. The preparation device mainly comprises: the device comprises an induction power supply, a horizontal machine tool, a three-jaw chuck, an induction coil, a terminal collecting device, a thermal spraying device, a shaft part, an amplitude transformer, a thimble and an ultrasonic generator. Firstly, preheating a substrate by using induced eddy current and selecting different preheating temperatures according to different materials; secondly, coating the substrate by adopting a thermal spraying technology, wherein the thickness of the coating can be adjusted according to the requirement, and then treating the thermally sprayed coating by ultrasonic impact; then, cladding the coating again by using the high-frequency induction eddy current; finally, the defects such as cracks, bubbles and the like are reduced by ultrasonic impact. The invention effectively combines the hot spraying technology and the induction cladding technology, exerts the advantages of each technology, can be applied to the manufacture of new parts and the repair of the parts, and can obviously improve the comprehensive use performance of the parts.
Description
Technical Field
The invention belongs to the technical field of surface treatment, and particularly relates to a high-quality shaft part preparation device based on thermal spraying and induction cladding technologies.
Background
Wear of parts during use is one of the main forms of part failure. For example, the roller produces about 15 hundred million tons of steel every year in China, and 2 kilograms of rollers are consumed for each 1 ton of steel, the consumption is mainly reflected in the abrasion of the surface of the roller, and the method for effectively reducing the abrasion is realized by coating a layer of special material on the surface of the roller by using technologies such as surfacing, laser cladding and the like. After the parts are invalid, the parts are remanufactured, so that the smelting period can be greatly shortened, the discharge of waste gas and waste water is reduced, and the recycling of resources is realized. Based on the method, surface engineering is formed, and the surface engineering comprises an electroplating technology, a thermal spraying technology, laser cladding, induction cladding and the like.
The traditional electroplating technology has great influence on the environment, particularly the chromium electroplating technology, wherein hexavalent chromium is a recognized carcinogen, and the current new technologies for replacing the traditional electroplating mainly comprise a tungsten-based alloy electroplating technology, a thermal spraying technology, a laser surface strengthening technology, an induction cladding technology and the like.
The thermal spraying technology is a technological process that a heating device is adopted to heat a coating material to a molten or semi-molten state, and then molten drops impact the surface of a matrix at a high speed by means of flame flow or high-speed gas to deposit and form a coating. Compared with other surface treatment techniques, the advantages of thermal spraying techniques are as follows: the application range is wide, the requirement on the matrix material is low, and various coatings can be prepared; the coating can be sprayed on the local part and the whole of the matrix, and the requirement on the operating environment is low; the heat affected zone of the matrix is shallow, and the deformation is small; the coating is uniform; the thickness range is wide, the coating with the thickness ranging from tens of micrometers to millimeters can be prepared, and the operation is easy. Thermal spraying, therefore, has wide application in modern industry as a surface treatment technique.
However, thermal spray technology currently has some drawbacks, mainly expressed in: the surface of the coating has pores, the porosity is high, the coating and the substrate are mechanically combined, and the bonding strength is low.
The induction cladding technology is to transfer electric energy to a heated workpiece by utilizing an electromagnetic induction principle, and heat a coating (generally powder) coated on the surface of a substrate by a skin effect generated by induction current to enable the coating to reach a molten state, so that the substrate and the coating are metallurgically bonded, and the coating with high bonding strength, low porosity and other excellent performances is obtained. Compared with laser cladding, electron beam surface treatment and other modes, induction cladding has many advantages: the influence of skin effect in the induction cladding process is realized, and the heat affected zone of the base material is shallow; the heating speed is high, the requirement on the cladding environment is low, and the method is suitable for preparing products on a large scale; compared with the laser cladding technology, the induction cladding technology has the advantages of simple equipment and lower cost.
However, there are still some problems in the induction cladding technology, and the main disadvantages are shown in: melting between the liquid phase and the solid phase easily causes cladding layer loss, and has low compactness and poor surface quality; the use of a binder (generally water glass) in the cladding process can introduce impurity elements, and the bonding strength of the coating and the base material and the coating quality are influenced.
Disclosure of Invention
The invention aims to solve the problems and provides a high-quality shaft part preparation device based on thermal spraying and induction cladding technologies, which combines the thermal spraying technology and the induction cladding technology, effectively overcomes the defects of the respective technologies, strengthens a cladding coating by using the cavitation effect and the thermal effect of ultrasonic vibration, can realize the refinement of the microstructure of the coating, and converts coarse cellular crystals and a small amount of dendrites into equiaxial crystals and fine acicular dendrites. The defects of air holes, cracks and the like can be reduced, the surface compactness of the workpiece to be processed is improved, and the higher surface quality of the coating is obtained, so that the comprehensive performance of the part is improved.
The invention provides a high-quality shaft part preparation device based on thermal spraying and induction cladding technologies, which comprises the following steps:
(1) according to the length of the part to be processed, the three-jaw chuck is adjusted to enable the part to be processed to be in a proper position so as to clamp the part;
(2) slowly moving the clamped part to the right end of the left induction coil, and moving the right ejector pin device to the right end of the part to fix the part to be processed;
(3) starting an induction power supply on the left side, preheating a part to be processed according to the difference between a matrix and a cladding material, and generally preheating to 100-300 ℃;
(4) after preheating is finished, moving the part to a thermal spraying area, simultaneously, starting the three-jaw chuck to drive the part to rotate, coating molten drops on the substrate by adopting high-pressure airflow, adjusting the rotating speed of the three-jaw chuck to 30-40 r/min after spraying is finished, immediately starting an ultrasonic generator, reducing residual stress by utilizing ultrasonic impact, reducing porosity and improving the compactness of a coating;
(5) after ultrasonic impact treatment, moving the part to the right induction coil, and heating and cladding the part again;
(6) after heating is finished, the part continues to move rightwards, and when the induction coil is moved out, the ultrasonic generator is started to perform ultrasonic impact on the cladding layer again;
(7) and closing all the devices, taking down the parts, and selecting a corresponding cooling mode according to the material.
The invention provides a high-quality shaft part preparation device based on thermal spraying and induction cladding technology, which comprises the following steps: the device comprises an induction power supply, a horizontal machine tool, a three-jaw chuck device, an induction coil, a terminal collecting device, a thermal spraying device, a shaft part, an amplitude transformer, a thimble and an ultrasonic generator, wherein the three-jaw chuck device is connected with the horizontal machine tool, the induction coil is connected with the induction power supply, the terminal collecting device is placed on the horizontal machine tool, the left end of the shaft part is clamped and fixed by the three-jaw chuck device, the right end of the shaft part is restrained by the thimble, and the amplitude transformer is connected with the ultrasonic generator.
Further limiting, the left side induction power supply has a preheating function, the power is between 40 and 60Kw, the right side induction power supply has an induction cladding function, and the power is between 90 and 110 Kw.
Further, the three-jaw chuck device and the ejector pin on the horizontal machine tool can horizontally move on the machine tool body, and the rotating speed of the three-jaw chuck can be adjusted according to a control console of the machine tool.
Further limiting, the spraying power of the thermal spraying device is between 30 and 40Kw, and the powder feeding voltage is 8V.
Further limiting, the material of the thimble is selected to be ceramic material, so that the skin effect of the induced eddy current on the thimble is avoided.
Further limiting, the power of the ultrasonic generator is 300-500 w, and the vibration frequency of the amplitude transformer is 12-20 KHz.
The technical scheme of the invention is that firstly, the matrix is preheated by using the induced eddy current, and different preheating temperatures can be selected according to different materials; secondly, coating the substrate by adopting a thermal spraying technology to form a uniform coating on the surface of the substrate, and improving the compactness of the coating by adopting ultrasonic impact; then cladding the coating again by using the skin effect of the high-frequency induction eddy current to obtain metallurgical bonding between the coating and the substrate; finally, the defects such as cracks, bubbles and the like are reduced by ultrasonic impact.
The invention has the following advantages:
the induction eddy current is adopted to preheat the substrate, the preheating is uniform, the time is short, and the bonding strength of the thermal spraying coating and the substrate can be improved; by adopting the thermal spraying technology, various alloy materials can be mixed and used to improve the surface performance of the substrate, the surface quality of the coating can be obviously improved, and the thickness of the coating can be adjusted according to the requirement; the hot sprayed coating is treated by ultrasonic impact, so that the compactness of the coating can be improved; cladding the coating by using the induced eddy current again, converting the mechanical bonding between the substrate and the coating into metallurgical bonding, greatly improving the bonding strength between the substrate and the coating and improving the surface quality of the coating; processing the cladding coating by ultrasonic impact again to convert coarse cellular crystals and a small amount of dendrites into equiaxed crystals and fine acicular dendrites so as to realize grain refinement; the invention can be applied to the manufacture of new parts and the repair and remanufacture of the parts, and the comprehensive use performance of the parts can be obviously improved by adopting the process method.
Drawings
FIG. 1: general schematic of the invention
Description of the symbols
1. Induction power supply 2, horizontal machine tool 3, three-jaw chuck 4, induction coil 5, terminal collecting device 6, thermal spraying device 7, shaft part 8, amplitude transformer 9, thimble 10, ultrasonic generator
FIG. 2: process flow diagram of the invention
Detailed Description
As shown in fig. 1, the invention is a high-quality shaft part preparation device based on thermal spraying and induction cladding technology, comprising: the ultrasonic generator comprises an induction power supply 1, a horizontal machine tool 2, a three-jaw chuck 4, an induction coil 5, a terminal collecting device 6, a thermal spraying device 7, a shaft part 8, an amplitude transformer 9, a thimble 10 and an ultrasonic generator.
The following describes a method and an apparatus for manufacturing a high-quality shaft part by induction cladding, taking nodular cast iron widely used in a roll as a matrix and nickel-based alloy powder as a cladding material, with reference to fig. 1. Wherein the size of the shaft is phi 60 multiplied by 800 mm; the power of the left side induction power supply is 60Kw, and the power of the right side induction power supply is 110 Kw; the power of thermal spraying is 32Kw, and the voltage is 8V; the power of the ultrasonic generator is 500w, the vibration frequency of the amplitude transformer is 16KHz, the distance between the amplitude transformer and the surface of the part is 30-40 mm, and the specific implementation example is as follows:
(1) polishing the substrate to remove impurities on the surface;
(2) adjusting the left three-jaw chuck device, clamping the part on the three-jaw chuck, and moving the thimble to finish the clamping of the part;
(3) designing a controller of the horizontal machine tool through programming in advance, enabling the part to move rightwards at a moving speed of 20-30 mm/s, starting an induction power supply on the left side, and enabling the part to rotate at a rotating speed of 60-70 r/min when the part moves to a hot spraying area;
(4) after the thermal spraying is finished, adjusting the moving speed of the part to be 20-30 mm/s, and simultaneously starting an ultrasonic generator on the left side to perform ultrasonic impact on the thermally sprayed coating;
(5) when the part moves to the right induction coil, the right induction power supply is started, and the part is subjected to cladding post-treatment;
(6) after the cladding is finished, when the part moves to the ultrasonic impact region, starting the ultrasonic generator on the right side, and performing ultrasonic impact on the cladding layer again;
(7) the part was removed and placed in air to cool to room temperature.
Both the left and right are described herein with reference to fig. 1.
The above-described embodiments are merely illustrative and not restrictive, and changes and additions to the above-described embodiments may be made without departing from the spirit and scope of the invention as defined in the following claims.
Claims (2)
1. High quality axle type part preparation facilities based on hot spraying and induction cladding technique includes: induction power supply, horizontal lathe, three-jaw chuck, induction coil, terminal collection device, hot spraying device, axle part, amplitude transformer, thimble, supersonic generator, its characterized in that: the three-jaw chuck device is connected with the horizontal machine tool, the induction coil is connected with the induction power supply, the terminal collecting device is placed on the horizontal machine tool, the left end of the shaft part is clamped and fixed by the three-jaw chuck device, the right end of the shaft part is restrained by the ejector pin, and the amplitude transformer is connected with the ultrasonic generator.
2. The device for preparing high-quality shaft parts based on the thermal spraying and induction cladding technology according to claim 1, is characterized in that: two induction power supplies are respectively a medium-frequency induction power supply and a high-frequency induction power supply.
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| CN201920953836.1U CN211848104U (en) | 2019-06-24 | 2019-06-24 | High-quality shaft part preparation device based on thermal spraying and induction cladding technology |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117535664A (en) * | 2023-12-01 | 2024-02-09 | 河北钨泰固机械设备有限公司 | Double-frequency induction heating composite laser cladding method and equipment thereof |
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2019
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117535664A (en) * | 2023-12-01 | 2024-02-09 | 河北钨泰固机械设备有限公司 | Double-frequency induction heating composite laser cladding method and equipment thereof |
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