曲轴维修与再制造现状与展望
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摘要
曲轴作为关键重要的传动零件,被广泛应用于汽车、煤矿、船舰、化工、石化等领域,其质量的好坏直接关系着工作系统的性能。列举分析了曲轴类零件的典型失效形式及其主要原因,归纳总结了曲轴修复和再制造常用技术手段,包括镀层技术、焊层技术、激光熔覆技术、热喷涂技术以及热喷涂层的重熔技术,并重点介绍了高速电弧喷涂技术在曲轴再制造方面的优势及应用现状。总结了目前曲轴维修与再制造存在的主要问题,并对曲轴再制造的发展方向进行了展望。
As a critical transmission part,crankshaft is widely used in automobiles,coal mines,ships,chemical,petrochemical and other fields.The quality of crankshaft directly influences the performance of the work system.Typical failure modes of crankshafts were presented and the feasible causes were analysed.Crankshaft repairing and remanufacturing technologies such as coating technique,welding technique,laser cladding technique,thermal spraying technique and remelt technique of sprayed coating layer were systematically summarized and discussed.The advantages and application status of high speed arc spraying technique in crankshaft remanufacturing were mainly introduced. The current problems of crankshaft maintenance and remanufacturing are pointed out and development trend of crankshaft remanufacturing was prospected in this paper.
As a critical transmission part,crankshaft is widely used in automobiles,coal mines,ships,chemical,petrochemical and other fields.The quality of crankshaft directly influences the performance of the work system.Typical failure modes of crankshafts were presented and the feasible causes were analysed.Crankshaft repairing and remanufacturing technologies such as coating technique,welding technique,laser cladding technique,thermal spraying technique and remelt technique of sprayed coating layer were systematically summarized and discussed.The advantages and application status of high speed arc spraying technique in crankshaft remanufacturing were mainly introduced. The current problems of crankshaft maintenance and remanufacturing are pointed out and development trend of crankshaft remanufacturing was prospected in this paper.
引文
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5 Cheng J B,Wang Z H,Xu B S.Wear and corrosion behaviors of FeCrBSiNbW amorphous/nanocrystalline coating prepared by arc spraying process[J].Journal of Thermal Spray Technology,2012,21(5):1025.
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7 Fonte M,Freitas de M.Marine main engine crankshaft failure analysis:A case study[J].Engineering Failure Analysis,2009,16:1940.
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34 Chivu O,Cicic D T,Rontescu C,et al.The influence of the reconditioning by welding processes on the hardness of crankshafts in the automotive industry[J].Metalurgija,2016,55(2):281.
35 Hatatea M,Shiotaa T,Abe N,et al.Bonding characteristics of spheroidal graphite cast iron and mild steel using electron beam welding process[J].Vacuum,2004,73(73):667.
36 Torims T.Laser cladding device for in-situ repairs of marine crankshafts[J].Advanced Materials Research,2013,712-715:709.
37 Xing H,Zhang X P.Application of carbon dioxide laser melt-castin technique in ammonia compressor bend bearing renovation[J].Science&Technology in Chemical Industry,2002,10(5):39(in Chinese).邢辉,张晓萍.二氧化碳激光熔铸技术在氨压缩机曲轴修复中的应用[J].化工科技,2002,10(5):39.
38 Torims T,Pikurs G,Ratkus A,et al.Development of technological equipment to laboratory test in-situ laser cladding for marine engine crankshaft renovation[J].Procedia Engineering,2015,100:559.
39 Feng H,Li J F,Sun J.Study on remanufacture repair of damaged crank shaft journal surface by laser cladding[J].Chinese Journal of Lasers,2014,41(8):80(in Chinese).封慧,李剑峰,孙杰.曲轴轴颈损伤表面的激光熔覆再制造修复[J].中国激光,2014,41(8):80.
40 Sampath S.Thermal spray applications in electronics and sensors:Past,present,and future[J].Journal of Thermal Spray Technology,2010,19(5):921.
41 Zhang Z Q,Wang H D,Xu B S,et al.Characterization of microstructure and rolling contact fatigue performance of NiCrBSi/WC-Ni composite coatings prepared by plasma spraying[J].Surface&Coatings Technology,2015,261:60.
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2 Xu B S,Ma S N,Liu S C,et al.Application of surface engineering and remanufacturing engineering[J].Journal of Materials Protection,2000,33(1):1(in Chinese).徐滨士,马世宁,刘世参,等.表面工程的应用和再制造工程[J].材料保护,2000,33(1):1.
3 Kathuria Y P.Metal rapid prototyping via a laser generating/selective sintering process[J].Journal of Engineering Manufacture,2000,214(1):1.
4 Xu B S.Nano surface engineering and remanufacture engineering[J].Transactions of Nanoferrous Metals Society of China,2004,14(S2):1.
5 Cheng J B,Wang Z H,Xu B S.Wear and corrosion behaviors of FeCrBSiNbW amorphous/nanocrystalline coating prepared by arc spraying process[J].Journal of Thermal Spray Technology,2012,21(5):1025.
6 Tian H L,Wei S C,Chen Y X,et al.Surface remelting treated high velocity arc sprayed FeNiCrAlBRE coating by tungsten inert gas[J].Physics Procedia,2013,50:322.
7 Fonte M,Freitas de M.Marine main engine crankshaft failure analysis:A case study[J].Engineering Failure Analysis,2009,16:1940.
8 Kakade P,Pasarkar M D.Analyzing and identifying various approaches for crankshaft failures[J].Journal of Multidisciplinary Engineering Science and Technology,2015,2(2):76.
9 Fonte M,Anes V,Duarte P,et al.Crankshaft failure analysis of a boxer diesel motor[J].Engineering Failure Analysis,2015,56:109.
10 Silva F S.An investigation into the mechanism of a crankshaft failure[J].Key Engineering Materials,2003,245-246:351.
11 Alfares M A,Falah A H,Elkholy A H.Failure analysis of a vehicle engine crankshaft[J].Journal of Failure Analysis and Prevention,2007,7:12.
12 Asi O.Failure analysis of a crankshaft made from ductile cast iron[J].Engineering Failure Analysis,2006,13:1260.
13 Xu X L,Yu Z W,Yang Z.Truck diesel engine crankshaft failure analysis[J].Journal of Failure Analysis and Prevention,2011,11:51.
14 Yang Z,Liu Y Z,Zhou L Y,et al.Investigation on surface crack of C38N2 automobile engine crankshaft[J].Advanced Materials Research,2011,311-313:1648.
15 Jiang J.Probe into repairing crankshaft of diesel locomotive engine[J].Railway Locomotive&Car,2006,26(6):58(in Chinese).蒋静.内燃机车柴油机曲轴修复的探讨[J].铁道机车车辆,2006,26(6):58.
16 Huang B G,Lu Y H,Xie D J.Study on engine crankshaft remanufacturing process[J].Equipment Manufactring Technology,2011(5):10(in Chinese).黄邦戈,陆宇衡,谢德锦.发动机曲轴再制造工艺研究[J].装备制造技术,2011(5):10.
17 Chen M H,Chen Y,Feng X L.Repair technology of off-highway truck crank shaft by friction and spray electroplating[J].Coal Mine Machinery,2008,29(9):171(in Chinese).陈名华,陈勇,冯春晓.矿用汽车曲轴的摩擦电喷镀修复[J].煤矿机械,2008,29(9):171.
18 He Y C,Pan S L,Hu Z H.Repair by laser fusion coating of cracks in crank-shaft of large reciprocating compressor[J].Petro-Chemical Equipment Technology,2007,34(5):52(in Chinese).贺运初,潘树林,胡祖汉.大型往复压缩机曲轴裂纹的激光熔覆修复[J].石油化工设备技术,2007,34(5):52.
19 Koehler H,Partes K,Seefeld T,et al.Laser reconditioning of crankshafts:From lab to application[J].Physics Procedia,2010,5:387.
20季培,钱志强,季永清.一种用于汽车发动机曲轴表面进行激光熔覆的方法:中国,103498143[P].2014-01-08.
21 Tan W F,Shi C G,Liu F,et al.Application of explosive spray coating on large-scale crankshaft repairing[J].China Petroleum Machinery,2004,32(10):39(in Chinese).谭文锋,石成刚,刘锋,等.爆炸喷涂技术在大型曲轴修复中的应用研究[J].石油机械,2004,32(10):39.
22 Gao W G,Liu J W,Yi J M,et al.Thermal spraying technology and its application in restoration of nodular cast iron crankshaft[J].Journal of Hunan Institute of Engineering,2004,14(4):27(in Chinese).高为国,刘金武,易际明,等.热喷涂技术及其在球墨铸铁曲轴修复中的应用[J].湖南工程学院学报,2004,14(4):27.
23 Sergeev V V,Spiridonov Y L,Farakhshin I I.Reconditioning crankshafts of domestic and foreign diesel engines by electric arc metallising[J].Welding International,2004,18(7):578.
24 Zhu H,Su J C.Arc spraying technology in revamping crank shaft of automobile engine[J].Tractor and Fam Transporter,2008,35(2):96(in Chinese).朱华,苏建成.发动机曲轴磨损的电弧喷涂修复工艺[J].拖拉机与农用运输车,2008,35(2):96.
25 Zhang G Q,Wang C T,Pu G Q.Fatigue life prediction of crankshaft repaired by twin arc spraying[J].Journal of Central South University,2005,34(2):324.
26张彬,付东兴,孙昊,等.一种用电弧喷涂方法制备曲轴再制造涂层用的粉芯丝材及其应用:中国,104694840[P].2015-06-10.
27 Liang X B,Chen Y X,Bai J Y,et al.An automatic high velocity arc spraying technology applied to remanufacture engine crankshaft[J].China Surface Engineering,2010,23(3):112(in Chinese).梁秀兵,陈永雄,白金元,等.自动化高速电弧喷涂技术再制造发动机曲轴[J].中国表面工程,2010,23(3):112.
28 Tian H L.Remanufacturing on heavy duty/high impact shaft and wear-resistance mechanism of spraying coatings[D].Beijing:School of Materials Science&Engineering,2014(in Chinese).田浩亮.重载、高冲击轴类件再制造工艺及涂层耐磨机理研究[D].北京:北京航空航天大学,2014.
29 Dong W Z,Jia S Z,Yan J,et al.Technological application research on remanufacturing of iron-base alloy plating iron for crankshaft[J].Diesel Engine,2011,33(2):43(in Chinese).董文仲,贾珊中,阎军,等.曲轴铁基合金镀铁再制造技术工艺应用研究[J].柴油机,2011,33(2):43.
30 Qian H F,Lei W N,Tang C S,et al.Research on pretreatment process for remanufacturing of diesel crankshaft by brushing electroplating[J].Electroplating&Pollution Control,2015,35(5):12(in Chinese).钱海峰,雷卫宁,唐从顺,等.柴油机曲轴再制造镀前处理工艺研究[J].电镀与环保,2015,35(5):12.
31 Xu Q Z,Li F Y,Ding T,et al.Experimental study on application of cold-welding technology in engine remanufacturing field[J].Advanced Materials Research,2012,482-484:2051.
32 Lyalyakin V P,Murzaev V P,Slinko D B.Advancement of the process of cold welding of cast iron[J].Metal Science and Heat Treatment[J].Advanced Materials Research,2014,56(7):420.
33 Chivu O,Rontescu C,Cicic D T,et al.The effects of reconditioning by welding of crankshafts in automotive industry[J].Metalurgija,2016,55(1):55.
34 Chivu O,Cicic D T,Rontescu C,et al.The influence of the reconditioning by welding processes on the hardness of crankshafts in the automotive industry[J].Metalurgija,2016,55(2):281.
35 Hatatea M,Shiotaa T,Abe N,et al.Bonding characteristics of spheroidal graphite cast iron and mild steel using electron beam welding process[J].Vacuum,2004,73(73):667.
36 Torims T.Laser cladding device for in-situ repairs of marine crankshafts[J].Advanced Materials Research,2013,712-715:709.
37 Xing H,Zhang X P.Application of carbon dioxide laser melt-castin technique in ammonia compressor bend bearing renovation[J].Science&Technology in Chemical Industry,2002,10(5):39(in Chinese).邢辉,张晓萍.二氧化碳激光熔铸技术在氨压缩机曲轴修复中的应用[J].化工科技,2002,10(5):39.
38 Torims T,Pikurs G,Ratkus A,et al.Development of technological equipment to laboratory test in-situ laser cladding for marine engine crankshaft renovation[J].Procedia Engineering,2015,100:559.
39 Feng H,Li J F,Sun J.Study on remanufacture repair of damaged crank shaft journal surface by laser cladding[J].Chinese Journal of Lasers,2014,41(8):80(in Chinese).封慧,李剑峰,孙杰.曲轴轴颈损伤表面的激光熔覆再制造修复[J].中国激光,2014,41(8):80.
40 Sampath S.Thermal spray applications in electronics and sensors:Past,present,and future[J].Journal of Thermal Spray Technology,2010,19(5):921.
41 Zhang Z Q,Wang H D,Xu B S,et al.Characterization of microstructure and rolling contact fatigue performance of NiCrBSi/WC-Ni composite coatings prepared by plasma spraying[J].Surface&Coatings Technology,2015,261:60.
42 Sharma S P,Dwivedi D K,Jain P K.Effect of La2O3addition on the microstructure,hardness and abrasive wear behavior of flame sprayed Ni based coatings[J].Wear,2009,267(5):853.
43 Singh L,Chawla V,Grewal J S.A review on detonation gun sprayed coatings[J].Journal of Minerals&Materials Characterization&Engineering,2012,11(3):243.
44 Chen Y X,Xu B S,Xu Y,et al.Progress in applying HVAStechnology to maintenance&remanufacture engineering[J].China Surface Engineering,2006,19(Z1):169(in Chinese).陈永雄,徐滨士,许一,等.高速电弧喷涂技术在装备维修与再制造工程领域的研究应用现状[J].中国表面工程,2006,19(Z1):169.
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