WO2022179205A1 - 超薄结构增材制造修复的方法 - Google Patents
超薄结构增材制造修复的方法 Download PDFInfo
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- WO2022179205A1 WO2022179205A1 PCT/CN2021/131426 CN2021131426W WO2022179205A1 WO 2022179205 A1 WO2022179205 A1 WO 2022179205A1 CN 2021131426 W CN2021131426 W CN 2021131426W WO 2022179205 A1 WO2022179205 A1 WO 2022179205A1
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- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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- B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
- B23P6/007—Repairing turbine components, e.g. moving or stationary blades, rotors using only additive methods, e.g. build-up welding
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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Definitions
- the invention relates to the technical field of additive manufacturing, in particular to a method for additive manufacturing and repairing of ultra-thin structures.
- the ultra-thin structure is widely used in the field of aero-engine blades.
- the integration of engine blisks and blades has become the mainstream development trend.
- Different from the conventional split blisks if the integral blisks are damaged, the damaged parts cannot be replaced, and the entire blisks need to be replaced, which will greatly increase the cost of the engine. It is of great significance to reduce the use cost of the engine to repair the blisk damaged in the processing or service process by using the relevant repair technology to restore its service performance and avoid the scrapping of the blisk.
- Laser Melting Deposition (LMD) technology is a common additive manufacturing technology.
- the technology uses a high-energy laser beam to melt synchronously conveyed powder and part of the matrix to form a moving unsteady molten pool, and it is Rapid solidification under temperature gradient, point-by-point deposition, line-by-line scanning, layer-by-layer accumulation, and finally form solid parts.
- traditional repair technologies such as arc welding
- the energy density of the high-energy laser beam in this technology is concentrated, the impact on the substrate during the forming process is small, and the forming path is highly flexible, so it is especially suitable for rapid repair of high value-added parts, such as aviation Parts such as section system, rear section platform, integral blisk, turbine blades, etc. are installed in the engine.
- the repair of parts with ultra-thin structures such as blade tips, leading and The diameter of the laser spot is larger than 1mm, which is very easy to cause laser light leakage, resulting in damage to the surface of the structure.
- the air heat transfer rate is slow, and the heat accumulation is serious, which is easy to cause the collapse, ablation and deformation of the area due to overheating.
- the repair of ultra-thin structures with high-energy beams mainly adopts the following two schemes: (1) high-energy beam equipment with ultra-small spot and high forming accuracy is used, and (2) thickened tooling is used, such as customized profiling and thickening tooling.
- the first solution requires a special repair head.
- the equipment requirements are high, and the conventional equipment is difficult to meet the requirements.
- the repair process uses small light spots throughout the process, and the repair rate is low.
- the processing of the profiling tooling takes a long time, and because the tooling and the sample are partially metallurgically combined, the tool vibration is likely to be caused during the machining and removal process after the repair is completed, which will cause machining errors and even lead to the direct occurrence of ultra-thin structures. deformation, which makes the dimensional accuracy after repair difficult to meet the design requirements.
- One object of the present invention is to provide a method for additive manufacturing and repairing of ultra-thin structures, which can solve the problems existing in the prior art, and can repair ultra-thin structures without ultra-small spot high-energy beam equipment or thickened tooling.
- the method for additive manufacturing and repairing of ultra-thin structures of the present invention can achieve the following beneficial technical effects: ultra-thin structures can be repaired without requiring ultra-small spot high-energy beam equipment or thickened tooling.
- the present invention proposes a method for repairing an ultra-thin structure by additive manufacturing.
- the repair process of the method is simple and convenient, has strong operability, is suitable for difficult-to-repair ultra-thin structures, and successfully realizes short-process repair.
- blade repair it is estimated that the repair time is reduced from the original 75h (tooling design 20h + tooling processing 30h + tooling clamping 1h + tooling removal 24h) to 12h, which greatly saves material and time costs and achieves low-cost and rapid repair.
- the method further includes step (g): after step (f), heat treatment is performed on the repaired ultra-thin structure to remove stress or adjust the microstructure.
- the method for additive manufacturing and repairing of an ultra-thin structure of the present invention can achieve the following beneficial technical effects: it can effectively remove the stress in the repaired ultra-thin structure or regulate the microstructure.
- the method further comprises step (h): after step (g), grinding or machining the repaired area so that the size of the repaired area can meet the final use requirements.
- the method for additive manufacturing and repairing of an ultra-thin structure of the present invention can achieve the following beneficial technical effects: the size of the repaired area can meet the final use requirements.
- step (e) the same high-energy beam device is used in step (e) and step (f), or other high-energy beam device different from step (f) is used in step (e).
- the method for additive manufacturing and repairing of ultra-thin structures of the present invention can achieve the following beneficial technical effects: combining flexible tooling design and additive manufacturing technology, there is no need to refit equipment or purchase new equipment, greatly reducing equipment costs , effectively expand the scope of equipment use.
- the 3D model in step (b) is obtained by modeling or 3D scanning the original part with modeling software.
- the method for additive manufacturing and repairing of an ultra-thin structure of the present invention can achieve the following beneficial technical effects: the three-dimensional model of the area to be repaired can be better obtained.
- step (c) includes: margin addition processing, hierarchical slicing processing and path planning processing.
- the method for additive manufacturing and repairing of ultra-thin structures of the present invention can achieve the following beneficial technical effects: the three-dimensional model of the area to be repaired can be preferably processed for subsequent repair operations.
- the flexible tooling in step (e) is constructed of metallic or non-metallic materials and fixed to the ultra-thin structure.
- the method for additive manufacturing and repairing of ultra-thin structures of the present invention can achieve the following beneficial technical effects: constructing a powder-carrying device with suitable materials and at suitable positions, so as to subsequently fill powder, and form adaptive flexibility after sintering Tooling.
- the repairing is performed by using the laser melting deposition technology of synchronous powder feeding, the selective laser melting deposition technology of powder spreading, or other high-energy beam additive manufacturing technology.
- the method for additive manufacturing and repairing of an ultra-thin structure of the present invention can achieve the following beneficial technical effects: repair the area to be repaired with a suitable additive manufacturing technology to ensure a better repair effect.
- Figure 1A is a schematic illustration of a compressor blade tip damage area.
- FIG. 1B is a schematic diagram of the area to be repaired at the tip of a compressor blade.
- FIG. 2 is a schematic diagram of a compressor blade tip damage flexible clamping according to the first embodiment of the present invention.
- FIG. 3 is a schematic diagram of a flexible clamping device for damage to the leading and trailing edges of a compressor blade according to a second embodiment of the present invention.
- ultra-thin structure refers to a structure with a thickness of less than 1 mm.
- air means: the technical restoration of damaged parts.
- laser fusion deposition refers to the use of lasers to melt materials into layers to create solid parts.
- additive manufacturing refers to the use of high-energy beams to melt and accumulate material layer by layer to create a solid part.
- flexible means: following the shape of the area to be repaired.
- toolsing refers to: tools or fixtures used in the repair process.
- FIG. 1A is a schematic illustration of a compressor blade tip damage area.
- FIG. 1B is a schematic diagram of the area to be repaired at the tip of a compressor blade.
- FIG. 2 is a schematic diagram of a compressor blade tip damage flexible clamping according to the first embodiment of the present invention.
- 3 is a schematic diagram of a flexible clamping device for damage to the leading and trailing edges of a compressor blade according to a second embodiment of the present invention.
- the method for additive manufacturing and repairing of ultra-thin structures of the present invention includes the following steps:
- the method for additive manufacturing and repairing of ultra-thin structures of the present invention can achieve the following beneficial technical effects: ultra-thin structures can be repaired without requiring ultra-small spot high-energy beam equipment or thickened tooling.
- the present invention proposes a method for repairing an ultra-thin structure by additive manufacturing.
- the repair process of the method is simple and convenient, has strong operability, is suitable for difficult-to-repair ultra-thin structures, and successfully realizes short-process repair.
- blade repair it is estimated that the repair time is reduced from the original 75h (tooling design 20h + tooling processing 30h + tooling clamping 1h + tooling removal 24h) to 12h, which greatly saves material and time costs and achieves low-cost rapid repair.
- the present invention adopts powder adaptive flexible tooling design, which eliminates the need to design and manufacture profiling and thickening tooling, and reduces time and cost. At the same time, it can avoid the metallurgical defects caused by the gap of the tooling and the deformation caused by the removal of the tooling, which can effectively improve the repair quality and improve the dimensional accuracy of ultra-thin structural parts after repair;
- the present invention combines flexible tooling design and additive manufacturing technology, without the need to modify the equipment or purchase new equipment, greatly reduce equipment costs, and effectively expand the scope of equipment use;
- the repairing process of the present invention is simple and convenient, has strong operability, and is suitable for difficult-to-repair ultra-thin structures.
- the method for additive manufacturing and repairing of an ultra-thin structure of the present invention further comprises step (g): after step (f), heat treatment is performed on the repaired ultra-thin structure to remove stress or adjust the microstructure.
- the method for repairing an ultra-thin structure by additive manufacturing of the present invention further comprises step (h): after step (g), grinding or machining the repaired area so that the size of the repaired area can meet the final use requirements.
- the laser parameters in step (e) are: laser power 300-400W, scanning rate 800-1000mm/min, and spot diameter 1mm.
- the powder around the bottom contour of the area to be repaired can be preferably sintered, thereby forming an adaptive flexible tool, which can effectively support the subsequent fusion deposition repair.
- the laser parameters in step (f) are: laser power 300-500W, scanning rate 400-500mm/min, spot diameter 1mm, and powder feeding rate 10-12g/min.
- the area to be repaired can be better repaired.
- step (e) the same laser high-energy beam equipment is used in step (e) and step (f).
- step (e) may also employ other high-energy beam (electron beam, ion beam, etc.) equipment different from step (f).
- the three-dimensional model in step (b) is obtained through modeling software modeling or three-dimensional scanning of the original part (the original part is an ultra-thin structure without damage), so that the area to be repaired can be better obtained. 3D model.
- step (c) includes: margin addition processing, layered slicing processing and path planning processing, so that the three-dimensional model of the area to be repaired can be preferably processed for subsequent repair operations.
- the flexible tooling in step (e) is constructed of metal or non-metal material, and is fixed to the ultra-thin structure.
- the powder-carrying device is constructed with suitable materials and in suitable positions for subsequent powder filling, and an adaptive flexible tooling is formed after sintering.
- the repairing is performed by using the laser melting deposition technology of synchronous powder feeding, the selective laser melting deposition technology of powder spreading, or other high-energy beam additive manufacturing technology. Repair the area to be repaired with appropriate additive manufacturing technology to ensure a better repair effect.
- the heat treatment parameters in step (g) are: a heat treatment temperature of 550° C. and a heat treatment time of 4 hours. With suitable heat treatment parameters, the stress in the repaired ultra-thin structure can be better removed.
- 3D modeling of the area to be repaired 3D modeling of the area to be repaired by modeling software such as UG and CAD.
- Model processing The three-dimensional model of the area to be repaired is processed by adding margin (0.5mm), layered slice processing, and path planning processing.
- the powder-carrying devices 21 are flexibly constructed on both sides of the bottom of the area to be repaired using soft metal materials such as aluminum foil, and fixed to the compressor blade with high temperature resistant tape 22, as shown in Figure 2.
- Flexible tooling manufacturing locate the bottom of the area to be repaired, obtain the bottom contour of the area to be repaired according to the model, set the laser parameters, make the laser scan one week along the contour of the bottom of the area to be repaired, and sinter the metal powder around the contour to form an adaptive Flexible tooling, forming effective support for subsequent fusion deposition repair.
- Specific parameters laser power 300-400W, scanning rate 800-1000mm/min, spot diameter 1mm.
- Additive manufacturing in the repair area After the flexible tooling is completed, according to the planned path obtained from the model processing, the repair area is additively manufactured by the synchronous powder feeding laser melting deposition technology (that is, the area to be repaired is repaired, and after the repair is completed, the area to be repaired is repaired. become the repair area). Specific parameters: laser power 300-500W, scanning rate 400-500mm/min, spot diameter 1mm, powder feeding rate 10-12g/min.
- Heat treatment Select an appropriate heat treatment system to perform stress relief treatment on the repaired ultra-thin metal structure. Heat treatment parameters are: heat treatment temperature 550 °C, heat treatment time 4h.
- Machining of front and rear edge damage Machining to remove the front and rear edge damage areas on the basis of the principle of minimum damage to form regular trapezoidal grooves.
- 3D modeling of the area to be repaired 3D modeling of the area to be repaired by modeling software such as UG and CAD.
- Model processing The three-dimensional model of the area to be repaired is subjected to margin addition processing (0.5-1mm), layered slice processing, and path planning processing.
- the powder-carrying devices 21 are flexibly constructed on both sides of the bottom of the area to be repaired by using soft metal materials such as aluminum foil, and fixed to the compressor blade with high temperature resistant tape 22, as shown in Figure 3.
- Flexible tooling manufacturing locate the bottom of the area to be repaired, obtain the bottom contour of the area to be repaired according to the model, set the laser parameters, make the laser scan one week along the contour of the bottom of the area to be repaired, and sinter the metal powder around the contour to form an adaptive Flexible tooling, forming effective support for subsequent fusion deposition repair.
- Specific parameters laser power 300-400W, scanning rate 800-1000mm/min, spot diameter 1mm.
- Additive manufacturing in the repair area After the flexible tooling is completed, according to the planned path obtained from the model processing, the repair area is additively manufactured using the synchronous powder feeding laser melting deposition technology (that is, the area to be repaired is repaired, and after the repair is completed, the area to be repaired is repaired. become the repair area). Specific parameters: laser power 300-500W, scanning rate 400-500mm/min, spot diameter 1mm, powder feeding rate 10-12g/min.
- Heat treatment Select an appropriate heat treatment system to perform vacuum stress relief treatment on the repaired ultra-thin metal structure. Heat treatment parameters are: heat treatment temperature 550 °C, heat treatment time 4h.
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Abstract
Description
Claims (8)
- 一种超薄结构增材制造修复的方法,其特征在于,所述方法包括以下步骤:(a)将所述超薄结构的损伤区域机加工去除;(b)获取所述超薄结构的待修复区域的三维模型;(c)对所述待修复区域的三维模型进行处理;(d)在所述待修复区域的底部四周构建载粉装置,使载粉装置中的粉末填充至与所述待修复区域的底部表面齐平或相切;(e)通过高能束或辅助加热装置使所述超薄结构的外轮廓周围载粉装置内粉末熔化、烧结或固化,并与所述超薄结构的外轮廓结合在一起,形成外轮廓加厚结构,成为柔性工装,起到支撑后续修复及避免烧蚀的作用;(f)根据模型处理所得规划路径,通过增材制造技术对所述待修复区域进行修复。
- 如权利要求1所述的超薄结构增材制造修复的方法,其特征在于,所述方法还包括步骤(g):在步骤(f)之后,对修复后的超薄结构进行热处理,以去除应力或者调控显微组织。
- 如权利要求2所述的超薄结构增材制造修复的方法,其特征在于,所述方法还包括步骤(h):在步骤(g)之后,对修复区域进行打磨或机加工,以使修复区域尺寸达到最终使用要求。
- 如权利要求1所述的超薄结构增材制造修复的方法,其特征在于,步骤(e)和步骤(f)中采用同一高能束设备,或步骤(e)中采用区别于步骤(f)中的其他高能束设备。
- 如权利要求1所述的超薄结构增材制造修复的方法,其特征在于,步骤 (b)中的三维模型是通过建模软件建模或三维扫描原始零件来获取的。
- 如权利要求1所述的超薄结构增材制造修复的方法,其特征在于,步骤(c)包括:余量添加处理、分层切片处理和路径规划处理。
- 如权利要求1所述的超薄结构增材制造修复的方法,其特征在于,步骤(e)中的柔性工装由金属或非金属材料来构建,且固定至所述超薄结构。
- 如权利要求1所述的超薄结构增材制造修复的方法,其特征在于,步骤(f)采用同步送粉的激光熔化沉积技术、铺粉的选区激光熔化沉积技术或其他类型增材制造技术进行修复。
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