面向薄壁件的激光熔覆修复工艺参数优化研究
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摘要
目的减少薄壁零件激光熔覆修复时基板的变形量,提高成形质量。方法在前期单道单因素试验的基础上,通过三因素三水平正交试验在2mm厚的45钢上熔覆Fel合金粉末,分析了激光功率、扫描速度和送粉率对薄板变形行为的影响,并根据因素效应图分析基体变形量随各因素水平的变化,找出出现这种变化的原因。通过正交试验的极差分析提出了基体变形的公式,根据公式确定各因素对基体变形影响的主次关系,并根据变形结果,最终找到使基板变形最小的最优工艺参数。通过光学显微镜(OM)、扫描电子显微镜(SEM)和显微硬度计,研究最优工艺参数下熔覆层的显微组织和硬度,并对在最优工艺参数下熔覆的试件进行成形质量评价。结果影响基板变形的因素主次顺序依次为:激光功率、扫描速度和送粉率。基板变形量最小且冶金结合良好的最佳工艺参数为:激光功率600 W,扫描速度12 mm/s,送粉率1.2 r/min。此工艺下所得熔覆层的最高硬度达到348HV,约是基体硬度的1.6倍。结论该工艺参数可以有效减少基体的变形且激光熔覆成形质量良好,基体表面得到显著强化。
The work aims to reduce the deformation of the substrate during laser cladding repair of thin-wall parts, and improve the forming quality. On the basis of previous single channel and single factor test, Fe1 alloy powder was cladded on 2 mm thick 45 steel by three factors and three level orthogonal test, and the influences of laser power, scanning speed and powder feeding rate on the deformation behavior of sheet metal were analyzed. According to the factor effect diagram, the changes of the substrate deformation along with the factors level were also investigated and the corresponding reason was found out. The formula of the deformation of the substrate was put forward by the extreme analysis of the orthogonal test. According to the formula, the main and secondary relation of the influence on the substrate deformation caused by the factors was determined, and the optimum process parameters to minimize the substrate deformation were finally found out according to the deformation results. The microstructure and hardness of the cladding layer under the optimal process parameters were studied by optical microscope(OM), scanning electron microscope(SEM) and microhardness tester, and the molding quality of the cladding layer under the optimal process parameters was evaluated. The factors affecting the substrate deformation were laser power, scanning speed and powder feeding rate in order. The optimal process parameters to minimize the substrate deformation and realize good metallurgical bonding were 600 W laser power, 12 mm/s scanning speed and 1.2 r/min powder feeding rate. The maximum hardness of the cladding layer under such process was 348HV(about 1.6 times of the substrate hardness). The process parameters can effectively reduce the substrate deformation, ensure the good laser cladding quality and strengthen the substrate surface significantly.
The work aims to reduce the deformation of the substrate during laser cladding repair of thin-wall parts, and improve the forming quality. On the basis of previous single channel and single factor test, Fe1 alloy powder was cladded on 2 mm thick 45 steel by three factors and three level orthogonal test, and the influences of laser power, scanning speed and powder feeding rate on the deformation behavior of sheet metal were analyzed. According to the factor effect diagram, the changes of the substrate deformation along with the factors level were also investigated and the corresponding reason was found out. The formula of the deformation of the substrate was put forward by the extreme analysis of the orthogonal test. According to the formula, the main and secondary relation of the influence on the substrate deformation caused by the factors was determined, and the optimum process parameters to minimize the substrate deformation were finally found out according to the deformation results. The microstructure and hardness of the cladding layer under the optimal process parameters were studied by optical microscope(OM), scanning electron microscope(SEM) and microhardness tester, and the molding quality of the cladding layer under the optimal process parameters was evaluated. The factors affecting the substrate deformation were laser power, scanning speed and powder feeding rate in order. The optimal process parameters to minimize the substrate deformation and realize good metallurgical bonding were 600 W laser power, 12 mm/s scanning speed and 1.2 r/min powder feeding rate. The maximum hardness of the cladding layer under such process was 348HV(about 1.6 times of the substrate hardness). The process parameters can effectively reduce the substrate deformation, ensure the good laser cladding quality and strengthen the substrate surface significantly.
引文
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[13]张德强,张吉庆,李金华,等.离焦量对45#钢表面激光熔覆镍基碳化钨粉的影响[J].表面技术,2015,44(12):92-97.ZHANG De-qiang,ZHANG Ji-qing,LI Jin-hua,et al.Effect of defocusing amount on laser cladding of selffluxing Ni-based WC on 45#steel surface[J].Surface technology,2015,44(12):92-97.
[14]梁荣茗.三坐标测量机的设计、使用、维修与检定[M].北京:中国质检出版社,2001.LIANG Rong-ming.Design,operation,maintenance and verification of three coordinate measuring machines[M].Beijing:China Quality Inspection Press,2001.
[15]黄金开,谢长生,许德胜.薄板模具钢脉冲Nd:YAG激光熔凝试样变形量的测量[J].中国激光,2003,30(8):750-754.HUANG Jin-kai,XIE Chang-sheng,XU De-sheng.Deformation measurement of thin plate die steel during pulsed Nd:YAG laser remelting[J].Chinese journal of lasers,2003,30(8):750-754.
[16]姜伟,胡芳友,黄旭仁.工艺参数对激光熔覆微观形貌的影响[J].表面技术,2007,36(4):57-58.JIANG Wei,HU Fang-you,HUANG Xu-ren.The influence of craft parameter on the microstructure by CO2 laser cladding[J].Surface technology,2007,36(4):57-58.
[2]王鑫龙,孙文磊,张建杰,等.激光熔覆零件破损边界提取和形状还原研究[J].激光技术,2017,41(5):675-679.WANG Xin-long,SUN Wen-lei,ZHANG Jian-jie,et al.Study on damage boundary extraction and shape reduction of laser cladding parts[J].Laser technology,2017,41(5):675-679.
[3]黄勇,孙文磊,陈影.激光熔覆再制造复杂轴类零件的轨迹规划[J].红外与激光工程,2017,46(5):45-51.HUANG Yong,SUN Wen-lei,CHEN Ying.Research on laser remanufacturing method of complex shaft parts based on NURBS interpolation[J].Infrared and laser engineering,2017,46(5):45-51.
[4]HOFMAN J T,LANGE D F,PATHIRAJ B,et al.FEMmodeling and experimental verification for dilution control in laser cladding[J].Journal of materials processing technology,2011,211:187-196.
[5]李亚敏,范福杰,韩锦玮.工艺参数对激光熔覆718合金涂层的影响[J].兰州理工大学学报,2018,44(5):7-14.LI Ya-min,FAN Fu-jie,HAN Jin-wei.Effect process parameters on laser-cladded 718 alloy coating[J].Journal of Lanzhou University of Technology,2018,44(5):7-14.
[6]钟敏霖,宁国庆,刘文今.激光熔覆快速制造金属零件研究与发展[J].激光技术,2002,26(5):388-391.ZHONG Min-lin,NING Guo-qing,LIU Wen-jin.Research and development on laser direct manufacturing metallic components[J].Laser technology,2002,26(5):388-391.
[7]郑必举,魏金宇,蒋业华,等.激光熔覆NiCoFeCrTi高熵合金涂层及其耐磨性能研究[J].激光技术,2016,40(3):432-435.ZHENG Bi-ju,WEI Jin-yu,JIANG Ye-hua,et al.Wear property of NiCoFeCrTi high entropy alloy coating by laser cladding[J].Laser technology,2016,40(3):432-435.
[8]罗奎林,郭双全,何勇,等.激光熔覆修复航空发动机风扇机匣TC4钛合金静子叶片[J].中国表面工程,2015,28(6):141-146.LUO Kui-lin,GUO Shuang-quan,HE Yong,et al.Repairing TC4 titanium stator blade of aero-engine fan casing by laser cladding[J].China surface engineering,2015,28(6):141-146.
[9]任德亮,林齐,李婷,等.冷作模具曲面激光熔覆修复工艺及路径研究[J].表面技术,2018,47(3):54-60.REN De-liang,LIN Qi,LI Ting,et al.Laser cladding repair technology and path of cold-worked dies[J].Surface technology,2018,47(3):54-60.
[10]高士友,咸士玉.激光直接沉积过程中基板变形分析[J].塑性工程学报,2007,14(5):57-61.GAO Shi-you,XIAN Shi-yu.Analysis of substrate deformation in the process of laser direct deposition[J].Journal of plasticity engineering,2007,14(5):57-61.
[11]罗明贤.316L不锈钢粉末激光熔覆工艺热-力耦合数值模拟[D].秦皇岛:燕山大学,2011:73-74.LUO Ming-xian.Numerical simulation of thermalmechanical behavior during laser cladding 316L stainless steel powder[D].Qinhuangdao:Yanshan University,2011:73-74.
[12]KRZYZANOWSKI M,BAJDA S,LIU Y J,et al.3Danalysis of thermal and stress evolution during laser cladding of bioactive glass coatings[J].Journal of the mechanical behavior of biomedical materials,2016,59:404-417.
[13]张德强,张吉庆,李金华,等.离焦量对45#钢表面激光熔覆镍基碳化钨粉的影响[J].表面技术,2015,44(12):92-97.ZHANG De-qiang,ZHANG Ji-qing,LI Jin-hua,et al.Effect of defocusing amount on laser cladding of selffluxing Ni-based WC on 45#steel surface[J].Surface technology,2015,44(12):92-97.
[14]梁荣茗.三坐标测量机的设计、使用、维修与检定[M].北京:中国质检出版社,2001.LIANG Rong-ming.Design,operation,maintenance and verification of three coordinate measuring machines[M].Beijing:China Quality Inspection Press,2001.
[15]黄金开,谢长生,许德胜.薄板模具钢脉冲Nd:YAG激光熔凝试样变形量的测量[J].中国激光,2003,30(8):750-754.HUANG Jin-kai,XIE Chang-sheng,XU De-sheng.Deformation measurement of thin plate die steel during pulsed Nd:YAG laser remelting[J].Chinese journal of lasers,2003,30(8):750-754.
[16]姜伟,胡芳友,黄旭仁.工艺参数对激光熔覆微观形貌的影响[J].表面技术,2007,36(4):57-58.JIANG Wei,HU Fang-you,HUANG Xu-ren.The influence of craft parameter on the microstructure by CO2 laser cladding[J].Surface technology,2007,36(4):57-58.