WO2023159477A1 - 一种回转体构件偏心超高速激光复合制造方法 - Google Patents

一种回转体构件偏心超高速激光复合制造方法 Download PDF

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WO2023159477A1
WO2023159477A1 PCT/CN2022/077959 CN2022077959W WO2023159477A1 WO 2023159477 A1 WO2023159477 A1 WO 2023159477A1 CN 2022077959 W CN2022077959 W CN 2022077959W WO 2023159477 A1 WO2023159477 A1 WO 2023159477A1
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ultra
speed laser
speed
laser
deposition processing
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French (fr)
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鲁金忠
徐祥
罗开玉
杜家龙
卜星宇
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Jiangsu University
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Jiangsu University
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/31—Calibration of process steps or apparatus settings, e.g. before or during manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/364—Process control of energy beam parameters for post-heating, e.g. remelting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/366—Scanning parameters, e.g. hatch distance or scanning strategy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—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
    • 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
    • B22F7/08—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 with one or more parts not made from powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/10—Pre-treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • 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
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • 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
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
    • C23C24/106—Coating with metal alloys or metal elements only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—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
    • 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
    • B22F2007/068—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 repairing articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • 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
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention relates to an ultra-high-speed laser deposition composite ultra-high-speed laser surface secondary melting technology, which belongs to the field of extreme additive manufacturing driven by ultra-high kinetic energy, and particularly refers to an eccentric ultra-high-speed laser composite manufacturing method for a rotary component.
  • the high-speed laser cladding technology uses a high-energy-density beam to simultaneously melt the added material and the surface of the substrate material moving at a high speed through synchronous powder feeding, and quickly solidifies to form a cladding with a very low dilution rate and a metallurgical bond with the substrate.
  • layer which greatly increases the cladding rate and significantly improves the process characteristics of the surface of the base material such as wear resistance, corrosion resistance, heat resistance, and oxidation resistance. It is especially suitable for repairing and remanufacturing of shaft parts, and can also be processed on plane and complex curved surfaces. It has broad application prospects in engineering machinery, aerospace industry, and metallurgy fields, and becomes a green remanufacturing that can replace traditional electroplating technology. craft.
  • Rotary parts such as hydraulic supports in the coal mine industry, rolls in the metallurgical industry, and offshore platform pipes and columns, have performance requirements such as wear resistance and corrosion resistance on the outer surface, which is a major application field in the surface manufacturing industry.
  • there are still several problems in the current ultra-high-speed laser deposition process First, in the long-term ultra-high-speed laser deposition manufacturing process on the surface of a rotating body with a long length and a large diameter, due to the long-term reflection of the laser , which greatly shortens the service life of its core components (mainly the laser processing head); secondly, the molten pool formed on the surface will leave the top of the rotary member with the high-speed rotating substrate, and is affected by gravity.
  • the solidification time is too late to fully combine with the substrate; in addition, in the large-area ultra-high-speed laser deposition manufacturing process of large-scale engineering rotary components, manufacturing defects such as cladding layer cracks and pores, as well as semi-melting and Problems such as the adhesion of unmelted particles make the surface rougher, which increases the workload of subsequent secondary processing and seriously increases the production cost of the enterprise.
  • the purpose of the present invention is to solve the loss of core components in ultra-high-speed laser deposition processing, the short interaction time between the molten pool and the substrate during processing, and the quality problems of large-scale manufacturing of large-scale engineering rotary components, and to provide a rotary
  • the component eccentric ultra-high-speed laser composite manufacturing method can not only protect the core components during the ultra-high-speed laser deposition process, but also increase the interaction time between the molten pool and the substrate.
  • the ultra-high-speed laser composite manufacturing method can further improve the compactness and comprehensive performance of the deposited layer .
  • the method comprises the steps of:
  • Step 1 Perform pretreatment on the rotary member to be processed, and then clamp it on the ultra-high-speed laser deposition processing machine tool;
  • Step 2 According to the diameter of the revolving member to be processed and the diameter of the light outlet of the ultra-high-speed laser deposition processing head, use the manipulator to adjust and control the relative eccentric position of the light outlet of the ultra-high-speed laser deposition processing head and the revolving member;
  • Step 3 Turn on the ultra-high-speed laser deposition processing system and the special powder feeding system for ultra-high-speed laser deposition processing.
  • select the appropriate process parameters and special powder for ultra-high-speed laser deposition processing and adjust The focal plane of the laser spot coincides with the focal plane of the powder sink, and according to the dilution rate of the molten pool on the surface of the rotary component, it is located within a certain distance directly above the rotary component to be processed in a positive defocusing manner;
  • Step 4 Edit the processing program on the CNC operation panel of the ultra-high-speed laser deposition processing system, perform ultra-high-speed laser deposition processing, prepare a deposition layer that meets the thickness requirements on the surface of the rotary component, and complete the processing of the first deposition layer After that, the ultra-high-speed laser deposition processing head automatically returns to the initial position of step 4;
  • Step 5 Taking the processed surface of the deposited layer as a benchmark, adjust the relative position of the light outlet of the ultra-high-speed laser deposition processing head and the processed surface of the deposited layer in the vertical direction;
  • Step 6 Turn on the ultra-high-speed laser deposition processing system again, do not turn on the special powder feeding system for ultra-high-speed laser deposition processing, and select appropriate process parameters to perform ultra-high-speed laser surface secondary melting treatment on the processed deposition layer;
  • Step 7 Repeat steps 4, 5 and 6 according to the overall thickness requirements of the surface repair of the revolving member or the strengthening layer in the actual engineering application, and prepare a deposition layer with excellent performance on the surface of the revolving member.
  • the ultra-high-speed laser deposition processing machine tool is a five-axis linkage CNC machine tool, the maximum working stroke of the X-axis is 5000mm, and the moving speed is 0-10000mm/min; the maximum working stroke of the Y-axis is 350mm, The moving speed is 0-10000mm/min, the maximum working stroke of the Z axis is 600mm, the spindle servo speed is 0-300r/min, and the diameter of the three-jaw chuck is ⁇ 640mm.
  • the pretreatment of the revolving member to be processed includes two forms: for the revolving member with a certain damage depth and surface repair requirements, the outer circular surface is rough-turned until the entire damaged part is removed; For surface-strengthened rotary components, directly polish the surface to be smooth, clean it with alcohol, and then blow it dry.
  • the relative eccentric position between the light outlet of the ultra-high-speed laser deposition processing head and the rotary body member is the distance between the mid-perpendicular line of the ultra-high-speed laser deposition processing head and the mid-perpendicular line of the rotary body component to be processed l (shown in Figure 1(a)).
  • the diameter of the light exit of the ultra-high-speed laser deposition processing head is d h
  • the height between the center of the light exit of the ultra-high-speed laser deposition processing head and the rotating body member to be processed is h
  • the diameter of the rotating body member to be processed is D
  • the incident direction of the laser beam is related to
  • ⁇ defined as: (Attachment 1(b)); (Supplementary Figure 1(d)). Therefore, the adjustment range of l complies with ⁇ 1 ⁇ ⁇ ⁇ 2 (Fig. 1(c)), then the adjustment interval of the relative eccentric position between the light outlet of the ultra-high-speed laser deposition processing head and the rotary member is set as
  • the process parameters for ultra-high-speed laser deposition processing include laser power of 2000W-10000W, laser spot diameter of 1.5-3mm, laser scanning line speed of 333-2000mm/s, deposition layer overlapping rate is 70-85%, and the protective gas flow rate is 5-20L/min;
  • the special powder feeding system for ultra-high-speed laser deposition processing mainly includes a double-barreled synchronous powder feeder, a stirring system, a heating system, a large gas flow regulating device and Anti-static pipeline, in which the single-tube powder feeder has a capacity of up to 5L, a powder feeding rate of 2-150g/min, and a powder feeding accuracy of ⁇ 2g/min, which can realize long-distance transportation of 300-600 mesh powder; ultra-high speed During the laser deposition process, the dilution rate of the molten pool on the surface of the rotary component is generally ⁇ 8%. Therefore, the coincident plane of the focal plane of the laser spot and the focal plane of the powder sink is located within a double-barre
  • the relative position between the light outlet of the ultra-high-speed laser deposition processing head and the surface of the processed deposition layer is based on the thickness d of the deposition layer and the change ⁇ d of the thickness of the deposition layer after the secondary melting treatment of the ultra-high-speed laser surface Adjustment (shown in Fig. 2 ), that is, the vertical upward lifting distance of the ultra-high-speed laser deposition processing head on the basis of step 4 is d- ⁇ d.
  • the process parameters involved in the secondary melting treatment of the ultra-high-speed laser surface mainly include laser power and scanning speed, which are regulated based on the energy absorption value of the deposited layer, that is Among them, Q is the effective laser energy absorbed by the deposition layer, P is the laser power, ⁇ is the absorption rate of the deposition layer material to the laser beam, d is the laser spot diameter, and L is the melting point formed by the secondary melting of the ultra-high-speed laser surface on the deposition layer surface Pool effective length; ⁇ can be expressed as: where R dz is the resistivity of the deposited layer, ⁇ is the laser wavelength; L can be expressed as Among them, d o is the actual diameter of the laser beam on the surface of the deposited layer, v is the laser scanning speed, and t is the solidification time of the molten pool.
  • the invention provides an eccentric ultra-high-speed laser composite manufacturing method for a rotary member.
  • the positioning method of the ultra-high-speed laser deposition processing head with a certain eccentric distance it can not only effectively reduce the damage of reflected light to the processing head and prolong its service life, but also It can also change the conventional melt pool shape of ultra-high-speed laser deposition, that is, the "falling" form caused by high-speed motion and gravity is transformed into a "climbing" form, and the full contact between the melt pool and the surface of the rotating body is improved during the ultra-high-speed laser deposition process. Time to form a good bonding performance.
  • ultra-high-speed laser deposition combined with ultra-high-speed laser surface secondary melting treatment can not only effectively improve the surface quality and overall compactness of the deposited layer, but also promote the homogenization of the deposited layer structure, and significantly improve the repair or strengthening of the deposited layer. Comprehensive performance.
  • Fig. 1 is a schematic diagram of the adjustment range of the relative eccentric position l of the light outlet of the ultra-high-speed laser processing head and the rotary member of the present invention.
  • (a) is the interference position of laser beam reflection
  • (b) is the minimum eccentricity position
  • (c) is the effective eccentricity position
  • (d) is the maximum eccentricity position.
  • Fig. 2 is a schematic diagram of the thickness variation of the deposition layer prepared by an eccentric ultra-high-speed laser composite manufacturing method for a revolving member according to the present invention, wherein 1 is the revolving member, 2 is the ultra-high-speed laser deposition layer obtained in step 4, and 3 is step 6 The secondary melting layer on the surface of the ultrahigh-speed laser is obtained.
  • Fig. 3 is a schematic cross-sectional view of a single-layer and multi-layer stainless steel deposition layer prepared by an eccentric ultra-high-speed laser composite manufacturing method for a revolving member according to the present invention.
  • Fig. 4 is an eccentric ultra-high-speed laser composite manufacturing diagram of a 27SiMn hydraulic piston rod in a coal mining machine in an embodiment of the present invention.
  • (a) is the substrate installation and equipment debugging
  • (b) is the processing process.
  • Table 1 shows the tensile performance test results of ultra-high-speed laser deposition layers prepared under different eccentric conditions.
  • an enhanced deposition layer is prepared on the surface as an example (shown in Figure 4).
  • the diameter of the substrate is 102mm and the length is 2m.
  • the powder for ultra-high-speed laser deposition is a special 17Cr4Ni2MoSi iron-based stainless steel powder with a particle size of 25-53 ⁇ m and a chemical composition of: 0.12%C, 17.25%Cr, 1.73%Mo, 4.39% Ni, 0.41% Mn, 1.00% Si, the balance being Fe.
  • the specific manufacturing steps are:
  • Step 1 The surface of the hydraulic piston rod to be strengthened is polished with 600# sandpaper to remove impurities such as surface scale, then cleaned with alcohol, dried and clamped on an ultra-high-speed laser deposition processing machine tool, and clamped with a three-jaw chuck Tightly fixed (shown in Figure 3(a)), using a radial dynamic balancer to level the hydraulic piston rod, the radial runout error is less than 5 ⁇ m when rotating at 200 rpm;
  • Step 2 Use the manipulator to adjust and determine the relative position l of the light outlet of the ultra-high-speed laser deposition processing head and the hydraulic piston rod.
  • the diameter d h of the light exit of the ultra-high-speed laser deposition processing head is 8 mm
  • the height h between the center of the light exit of the ultra-high-speed laser deposition processing head and the hydraulic column rod is 18 mm
  • ⁇ 1 12.53°
  • ⁇ 2 25.06°
  • the adjustment range of l follows 12.53° ⁇ 25.06°
  • the adjustment interval of the relative eccentric position between the light outlet of the ultra-high-speed laser deposition processing head and the hydraulic piston rod is l ⁇ (11.06,21.60mm]
  • Step 3 Turn on the ultra-high-speed laser deposition system, set the laser spot diameter to 2mm, the laser power to 3800W, the scanning speed to 1333mm/s, the overlapping rate of the deposition layer to 75%, and the protective gas flow rate to 6.5L/min; the 17Cr4Ni2MoSi iron
  • the base powder is dried at 100°C for 2 hours, and then loaded into the double cylinders of the powder feeding system.
  • the dilution rate of the surface is less than 5%, and the focal plane of the laser spot is adjusted to coincide with the focal plane of the powder sink, and the coincident focal plane is located 6mm directly above the eccentric position of the hydraulic piston rod;
  • Step 4 Edit the processing program on the CNC operation panel of the ultra-high-speed laser deposition processing system according to the size of the hydraulic piston rod and the processing parameters in step 3, start the laser and the ultra-high-speed laser deposition processing machine tool, and prepare a layer of thickness on the surface of the hydraulic piston For a deposition layer of about 126 ⁇ m (shown in Figure 3(a)), after the first deposition layer is processed, the ultra-high-speed laser deposition processing head automatically returns to the initial position of step 4;
  • Step 5 Based on the processed surface of the deposited layer, adjust the relative position of the light outlet of the ultra-high-speed laser deposition processing head and the processed surface of the deposited layer in the vertical direction, according to the process parameter conditions at the same laser power and scanning speed.
  • the composite processing test results repeated several times below show that after the secondary melting treatment on the surface of the ultra-high-speed laser, the thickness of the ultra-high-speed laser deposition layer decreases by 9-12 ⁇ m, so on the basis of step 4, the ultra-high-speed laser processing head is lifted vertically by 114 -117 ⁇ m;
  • Step 6 Based on the existing research basis, the absorption rate of iron-based stainless steel to the laser beam is about 0.35, then Q can be expressed as It is further measured that the actual diameter of the laser beam on the surface of the deposited layer is 3.6mm, but the scanning speed of ultra-high-speed laser deposition can reach more than 1000mm/s, so L can be approximately expressed as vt, and Q can be further expressed as: 128.56P ⁇ e - vt , that is, the effective laser energy absorbed by the deposited layer is proportional to the laser power and inversely proportional to the scanning speed.
  • Step 7 Repeat steps 4, 5 and 6 according to the overall thickness requirements of the reinforced layer on the surface of the rotating body component used in engineering practice, and prepare a deposition layer with excellent performance on the surface of the rotating body component.
  • the application of the technical solution provided by the present invention can not only effectively reduce the damage of reflected light to the processing head and prolong its service life, but also can significantly eliminate the problems of adhesion of molten powder particles on the surface of the ultra-high-speed laser deposition layer and defects such as internal cracks and pores.

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Abstract

本发明涉及一种回转体构件偏心超高速激光复合制造方法。通过一定偏心距离的超高速激光沉积加工头的定位方法，不仅能够有效地减少反射光对加工头的损伤，延长其使用寿命，而且也能够改变超高速激光沉积的常规熔池形态，即由高速运动和重力引起的"下坠"形态转变为"爬升"形态，在超高速激光沉积加工过程中提高熔池与回转体构件表面充分接触的时间，形成良好的结合性能；其次，采用超高速激光沉积复合超高速激光表面二次熔融处理，不仅可以有效地改善沉积层的表面质量和整体致密性，还可以促进沉积层组织的均匀化，显著提高修复或者强化沉积层的综合性能。

Description

一种回转体构件偏心超高速激光复合制造方法 技术领域
本发明涉及到超高速激光沉积复合超高速激光表面二次熔融技术，属于超高动能驱使条件下的极端增材制造领域，特指一种回转体构件偏心超高速激光复合制造方法。
背景技术
高速激光熔覆技术是通过同步送粉方式，利用高能密度的束流使添加材料与高速率运动的基体材料表面同时熔化，并快速凝固后形成稀释率极低，与基体呈现冶金结合的熔覆层，极大提高熔覆速率，显著改善基体材料表面的耐磨、耐蚀、耐热、抗氧化等工艺特性的工艺方法。特别适合在轴类零件进行修复再制造，也能在平面和复杂曲面上进行加工，在工程机械、航空航天行业、冶金领域具有广泛的应用前景，成为可替代传统电镀技术的一种绿色再制造工艺。
回转类零件例如煤矿行业中液压支架、冶金行业的轧辊以及海洋平台管道和立柱等，对外表面有耐磨耐蚀等性能要求，是表面制造行业中的一个主要应用领域。但是在目前超高速激光沉积加工过程中仍然存在几个问题：首先，在较长长度和较大直径的回转体构件表面进行长时间的超高速激光沉积制造过程中，由于激光长时间的反射作用，极大缩短了其核心部件(主要是激光加工头)的使用寿命；其次，表面形成的熔池将随着高速旋转的基材离开回转体构件的顶部，并且受到重力的影响，在极短的凝固时间内来不及与基材充分结合；此外，在大型工程回转体构件大面积超高速激光沉积制造过程中还不可避免的出现熔覆层裂纹、气孔等制造缺陷以及涂层表面出现半熔化和未熔化颗粒附着等问题，使得表面粗糙度较大，由此增加了后续二次加工的工作量，严重增加企业的生产成本。
发明内容
针对上述问题，本发明的目的在于能够解决超高速激光沉积加工核心部件损耗，加工过程中熔池与基材作用时间短以及在大型工程回转体构件大面积制造的质量问题，提供一种回转体构件偏心超高速激光复合制造方法，在超高速激光沉积过程中不仅能够保护核心部件，提高熔池与基材作用时间，同时采用超高速激光复合制造方法能够进一步提高沉积层的致密性和综合性能。
所述方法包括以下步骤：
步骤一、对待加工回转体构件进行预处理，然后装夹到超高速激光沉积加工机床上面；
步骤二、根据待加工回转体构件的直径与超高速激光沉积加工头的出光口直径，利用机械手调整和控制超高速激光沉积加工头出光口与回转体构件的相对偏心位置；
步骤三、开启超高速激光沉积加工系统和超高速激光沉积加工专用送粉系统，根据回转体构件的修复或者表面强化的要求，选择合适的超高速激光沉积加工用的工艺参数和专用粉末，调整激光光斑焦平面与粉末汇聚焦平面重合，根据熔池在回转体构件表面的稀释率，采取正离焦的方式位于待加工回转体构件的正上方一定距离内；
步骤四、在超高速激光沉积加工系统的数控操作面板上面编辑加工程序，进行超高速激光沉积加工，在回转体构件的表面制备一层符合厚度要求的沉积层，在第一道沉积层加工完毕后，超高速激光沉积加工头自动返回步骤四的初始位置；
步骤五、以加工好的沉积层表面为基准，在竖直方向上调整超高速激光沉积加工头出光口与加工好的沉积层表面的相对位置；
步骤六、再次开启超高速激光沉积加工系统，不打开超高速激光沉积加工专用送粉系统，选择合适的工艺参数对加工好的沉积层进行超高速激光表面二次熔融处理；
步骤七、根据工程实际应用的回转体构件表面修复或者强化层的整体厚度需求，重复步骤四、五和六，在回转体构件表面进行优异性能的沉积层制备。
优选的，所述步骤一中，超高速激光沉积加工机床为五轴联动的数控机床，X轴的最大工作行程为5000mm，移动速度为0-10000mm/min；Y轴的最大工作行程为350mm，移动速度为0-10000mm/min，Z轴的最大工作行程为600mm，主轴伺服转速0-300r/min，三爪卡盘直径为Ф640mm。
优选的，所述步骤一中，对待加工回转体构件的预处理包括两种形式：对于具有一定损伤深度的表面修复要求的回转体构件，先进行粗车加工外圆面直至去除整个损伤部位；对于表面强化的回转体构件，直接将表面打磨光滑，并用酒精清洗干净后吹干。
[根据细则26改正 20.04.2022]
优选的，所述步骤二中，超高速激光沉积加工头出光口与回转体构件的相对偏心位置，即为超高速激光沉积加工头的中垂线与待加工回转体构件的中垂线的 距离l(附图1(a)所示)。其中超高速激光沉积加工头出光口的直径为d h、超高速激光沉积加工头出光口中心与待加工回转体构件高度为h、待加工回转体构件的直径为D以及激光束的入射方向与反射方向的夹角为α，定义：
Figure PCTCN2022077959-appb-000001
(附图1(b))；
Figure WO-DOC-FIGURE-2
(附图1(d))。因此，l调节范围遵循α 1＜α≤α 2(附图1(c))，则设置超高速激光沉积加工头出光口与回转体构件的相对偏心位置的调节区间为
Figure PCTCN2022077959-appb-000003
优选的，所述步骤三中，超高速激光沉积加工用的工艺参数包括激光功率为2000W-10000W，激光光斑直径为1.5-3mm，激光扫描线速度为333-2000mm/s,沉积层搭接率为70-85％，保护气流量为5-20L/min；所述的超高速激光沉积加工专用送粉系统主要包括双筒同步送粉器、搅拌系统、加温系统、大气体流量调节装置和防静电管路，其中单筒送粉器的容量可达5L，送粉速率为2-150g/min，送粉精度为±2g/min，可以实现300-600目粉末的长距离输送；超高速激光沉积过程中熔池在回转体构件表面的稀释率一般＜8％，因此，激光光斑焦平面与粉末汇聚焦平面的重合面位于待加工回转体构件偏心位置正上方3-10mm的距离内。
优选的，所述步骤五中，超高速激光沉积加工头出光口与加工好的沉积层表面的相对位置，基于沉积层的厚度d与超高速激光表面二次熔融处理后沉积层厚度变化Δd进行调整(附图2所示)，即超高速激光沉积加工头在步骤四的基础上竖直向上抬升的距离为d-Δd。
优选的，所述步骤六中，超高速激光表面二次熔融处理涉及到的工艺参数主要包括激光功率和扫描速度，基于沉积层的能量吸收值进行调控，即
Figure PCTCN2022077959-appb-000004
其中Q为沉积层吸收的有效激光能量，P为激光功率，η为沉积层材料对激光束的吸收率，d为激光光斑直径，L为超高速激光表面二次熔融在沉积层表面形成的熔池有效长度；η可以表示为：
Figure PCTCN2022077959-appb-000005
其中R dz为沉积层的电阻率，λ为激光波长；L可以表示为
Figure PCTCN2022077959-appb-000006
其中，d o为激光光束 在沉积层表面的实际直径，v为激光扫描速度，t为熔池凝固时间。
本发明提供一种回转体构件偏心超高速激光复合制造方法，通过一定偏心距离的超高速激光沉积加工头的定位方法，不仅能够有效地减少反射光对加工头的损伤，延长其使用寿命，而且也能够改变超高速激光沉积的常规熔池形态，即由高速运动和重力引起的“下坠”形态转变为“爬升”形态，在超高速激光沉积加工过程中提高熔池与回转体构件表面充分接触的时间，形成良好的结合性能。其次，采用超高速激光沉积复合超高速激光表面二次熔融处理，不仅可以有效地改善沉积层的表面质量和整体致密性，还可以促进沉积层组织的均匀化，显著提高修复或者强化沉积层的综合性能。
附图说明
图1为本发明超高速激光加工头出光口与回转体构件相对偏心位置l调节范围示意图。(a)为激光光束反射的干涉位置，(b)为最小偏心位置，(c)为有效偏心位置，(d)为最大偏心位置。
图2为本发明所述一种回转体构件偏心超高速激光复合制造方法制备的沉积层厚度变化示意图，其中1为回转体构件，2为步骤四中得到超高速激光沉积层，3为步骤六中得到的超高速激光表面二次熔融层。
图3为应用本发明所述一种回转体构件偏心超高速激光复合制造方法制备的单层和多层不锈钢沉积层截面示意图。(a)单层超高速激光沉积层，(b)单层超高速激光复合沉积层，(c)多层超高速激光复合沉积层。
图4为本发明实施例中一种煤矿机械中的27SiMn液压活塞杆偏心超高速激光复合制造图。(a)为基材安装及设备调试，(b)为加工过程。
表1为不同偏心条件下制备的超高速激光沉积层拉伸性能测试结果。
具体实施方式
为了更清楚地说明本发明所述的技术方案，下面结合实例及附图对本发明具体实施作进一步详述，但本发明不仅限于实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
以一种煤矿机械中的27SiMn液压活塞杆为基材，在表面制备强化沉积层为例(附图4所示)。基材的直径为102mm，长度为2m，超高速激光沉积用的粉末为专用的17Cr4Ni2MoSi铁基不锈钢粉末，粉末粒度为25-53μm，化学成分为： 0.12％C，17.25％Cr，1.73％Mo，4.39％Ni，0.41％Mn，1.00％Si，余量为Fe。具体制造步骤为：
步骤一、对待强化的液压活塞杆表面采用600#砂纸进行打磨去除表面氧化皮等杂质，然后用酒精清洗干净后吹干并装夹到超高速激光沉积加工机床上，采用三爪卡盘进行夹紧固定(附图3(a)所示)，采用径向动平衡仪对液压活塞杆进行调平，在200rpm旋转的情况下的径向跳动误差小于5μm；
步骤二、利用机械手调节并确定超高速激光沉积加工头出光口与液压活塞杆的相对位置l。在本实施例中，超高速激光沉积加工头出光口的直径d h为8mm，超高速激光沉积加工头出光口中心与液压立柱杆的高度h为18mm，则α 1＝12.53°，α 2＝25.06°，因此l调节范围遵循12.53°＜α≤25.06°，得到超高速激光沉积加工头出光口与液压活塞杆的相对偏心位置的调节区间为l∈(11.06,21.60mm]，本实施例中确定三组l的值分别为12、16和20mm；
步骤三、打开超高速激光沉积系统，设置激光光斑直径为2mm，激光功率为3800W，扫描速度为1333mm/s，沉积层搭接率为75％，保护气流量为6.5L/min；将17Cr4Ni2MoSi铁基粉末进行100℃下2小时烘干处理，然后装入送粉系统的双筒中，调节双筒的送粉速率均为15g/min，同时开启双筒送粉；为了保证熔池在回转体构件表面的稀释率小于5％，调整激光光斑焦平面与粉末汇聚焦平面重合，重合的焦平面位于液压活塞杆偏心位置正上方6mm处；
步骤四、在超高速激光沉积加工系统的数控操作面板上面根据液压活塞杆的尺寸和步骤三中的加工参数编辑加工程序，启动激光器和超高速激光沉积加工机床，在液压活塞表面制备一层厚度约为126μm的沉积层(附图3(a)所示)，在第一道沉积层加工完毕后，超高速激光沉积加工头自动返回步骤四的初始位置；
步骤五、以加工好的沉积层表面为基准，在竖直方向上面调整超高速激光沉积加工头出光口与加工好的沉积层表面的相对位置，根据在同等激光功率和扫描速度的工艺参数条件下重复多次的复合加工试验结果，超高速激光表面二次熔融处理后，超高速激光沉积层的厚度下降9-12μm，因此在步骤四的基础上，超高速激光加工头竖直向上抬升114-117μm；
步骤六、基于已有的研究基础，铁基不锈钢对激光束的吸收率约为0.35，则Q可以表示为
Figure PCTCN2022077959-appb-000007
进一步测得激光光束在沉积层表面的实际直径为3.6mm，但是超高速激光沉积的扫描速度可达1000mm/s以上，因此L可以 近似表示为vt，Q可以进一步表示为：128.56P×e -vt，即沉积层吸收的有效激光能量与激光功率成正比例关系，与扫描速度成反比关系。在本实施例中，步骤四制备的单层超高速激光沉积层内部无明显的裂纹和较大的孔洞出现，而是在表面附着大量的未熔或者半熔化的粉末颗粒，因此设置的超高速激光表面二次熔融处理的工艺参数主要作用在超高速激光沉积层的近表面区域即可。因此，在超高速激光沉积加工专用送粉系统关闭情况下，打开超高速激光沉积系统，设置激光功率为2850W，扫描速度为1333mm/s，其他工艺参数保持不变，对步骤四加工好的沉积层进行超高速激光表面二次熔融处理，得到单层复合制造沉积层(附图3(b)所示)。
步骤七、根据工程实际应用的回转体构件表面强化层的整体厚度需求，重复步骤四、五和六，在回转体构件表面进行优异性能的沉积层制备。
本实施例一共制备三层复合制造沉积层(附图3(c)所示)，整个沉积层无明显的气孔、裂纹等缺陷出现。
附图3为沉积层横截面显微图，其中超高速激光复合沉积层的表面粗糙度降60％，致密性可达99.8％。表1显示了本发明提供的技术方法制备的沉积层与无偏心条件下制备的沉积层的力学性能的测试对比结果，表明本发明提供的技术方法能够将超高速激光沉积层的层间结合强度提升22％左右。此外，在无偏心条件的情况下，超高速激光沉积加工头在连续工作1h后，由于反射光的干涉影响，需要进行空冷和用钢刷清除出光口处附着的熔融粉末，不仅极大的降低生产效率，而且缩短了设备的使用寿命。因此，应用本发明提供的技术方案不仅能够有效地减少反射光对加工头的损伤，延长其使用寿命，还能够明显消除超高速激光沉积层表面熔融粉末颗粒附着和内部裂纹、气孔等缺陷问题。
表1
Figure PCTCN2022077959-appb-000008
需要说明的是，对于本领域技术人员而言，显然本发明不限于上述示范性实 施例的细节，而且在不背离本发明的精神或基本特征的情况下，能够以其他的具体形式实现本发明。因此，无论从哪一点来看，均应将实施例看作是示范性的，而且是非限制性的，本发明的范围由所附权利要求而不是上述说明限定，因此旨在将落在权利要求的等同要件的含义和范围内的所有变化囊括在本发明内，不应将权利要求中的任何附图标记视为限制所涉及的权利要求。

Claims (7)

  1. 一种回转体构件偏心超高速激光复合制造方法，其特征在于，包括以下步骤：
    步骤一：对待加工回转体构件进行预处理，然后装夹到超高速激光沉积加工机床上面；
    步骤二：根据待加工回转体构件的直径与超高速激光沉积加工头的出光口直径，利用机械手调整和控制超高速激光沉积加工头出光口与回转体构件的相对偏心位置；
    步骤三：开启超高速激光沉积加工系统和超高速激光沉积加工专用送粉系统，根据回转体构件的修复或者表面强化的要求，选择合适的超高速激光沉积加工用的工艺参数和专用粉末，调整激光光斑焦平面与粉末汇聚焦平面重合，根据熔池在回转体构件表面的稀释率，采取正离焦的方式位于待加工回转体构件的正上方一定距离内；
    步骤四：在超高速激光沉积加工系统的数控操作面板上面编辑加工程序，进行超高速激光沉积加工，在回转体构件的表面制备一层符合厚度要求的沉积层，在第一道沉积层加工完毕后，超高速激光沉积加工头自动返回步骤四的初始位置；
    步骤五：以加工好的沉积层表面为基准，在竖直方向上调整超高速激光沉积加工头出光口与加工好的沉积层表面的相对位置；
    步骤六：再次开启超高速激光沉积加工系统，不打开超高速激光沉积加工专用送粉系统，选择合适的工艺参数对加工好的沉积层进行超高速激光表面二次熔融处理；
    步骤七：根据工程实际应用的回转体构件表面修复或者强化层的整体厚度需求，重复步骤四、五和六，在回转体构件表面进行优异性能的沉积层制备。
  2. 根据权利1要求所述的一种回转体构件偏心超高速激光复合制造方法，其特征在于：步骤一中，所述超高速激光沉积加工机床为五轴联动的数控机床，X轴的最大工作行程为5000mm，移动速度为0-10000mm/min；Y轴的最大工作行程为350mm，移动速度为0-10000mm/min，Z轴的最大工作行程为600mm，主轴伺服转速0-300r/min，三爪卡盘直径为Ф640mm。。
  3. 根据权利1要求所述的一种回转体构件偏心超高速激光复合制造方法，其特征在于：步骤一中，对待加工回转体构件的预处理包括两种形式：对于具有一 定损伤深度的表面修复要求的回转体构件，先进行粗车加工外圆面直至去除整个损伤部位；对于表面强化的回转体构件，直接将表面打磨光滑，并用酒精清洗干净后吹干。
  4. 根据权利1要求所述的一种回转体构件偏心超高速激光复合制造方法，其特征在于：步骤二中，超高速激光沉积加工头出光口与回转体构件的相对偏心位置，即为超高速激光沉积加工头的中垂线与待加工回转体构件的中垂线的距离l；其中超高速激光沉积加工头出光口的直径为d h、超高速激光沉积加工头出光口中心与待加工回转体构件高度为h、待加工回转体构件的直径为D以及激光束的入射方向与反射方向的夹角为α，定义：
    Figure PCTCN2022077959-appb-100001
    l调节范围遵循α 1＜α≤α 2，则设置超高速激光沉积加工头出光口与回转体构件的相对偏心位置的调节区间为
    Figure PCTCN2022077959-appb-100002
  5. 根据权利1要求所述的一种回转体构件偏心超高速激光复合制造方法，其特征在于：步骤三中，超高速激光沉积加工用的工艺参数包括激光功率为2000W-10000W，激光光斑直径为1.5-3mm，激光扫描线速度为333-2000mm/s,沉积层搭接率为70-85％，保护气流量为5-20L/min；所述的超高速激光沉积加工专用送粉系统主要包括双筒同步送粉器、搅拌系统、加温系统、大气体流量调节装置和防静电管路，其中单筒送粉器的容量可达5L，送粉速率为2-150g/min，送粉精度为±2g/min，可以实现300-600目粉末的长距离输送；激光光斑焦平面与粉末汇聚焦平面的重合面位于待加工回转体构件偏心位置正上方3-10mm的距离内。
  6. 根据权利1要求所述的一种回转体构件偏心超高速激光复合制造方法，其特征在于：步骤五中，所述超高速激光沉积加工头出光口与加工好的沉积层表面的相对位置，基于沉积层的厚度d与超高速激光表面二次熔融处理后沉积层厚度变化Δd进行调整，即超高速激光沉积加工头在步骤四的基础上竖直向上抬升的距离为d-Δd。
  7. 根据权利1要求所述的一种回转体构件偏心超高速激光复合制造方法，其特征在于：步骤六中，超高速激光表面二次熔融处理涉及到的工艺参数主要包括 激光功率和扫描速度，基于沉积层的能量吸收值进行调控，即
    Figure PCTCN2022077959-appb-100003
    其中Q为沉积层吸收的有效激光能量，P为激光功率，η为沉积层材料对激光束的吸收率，d为激光光斑直径，L为超高速激光表面二次熔融在沉积层表面形成的熔池有效长度；η可以表示为：
    Figure PCTCN2022077959-appb-100004
    其中R dz为沉积层的电阻率，λ为激光波长；L可以表示为
    Figure PCTCN2022077959-appb-100005
    其中，d o为激光光束在沉积层表面的实际直径，v为激光扫描速度，t为熔池凝固时间。
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