CN109735843B - Process method for increasing thickness of laser cladding high-hardness alloy layer and laser cladding repaired product thereof - Google Patents
Process method for increasing thickness of laser cladding high-hardness alloy layer and laser cladding repaired product thereof Download PDFInfo
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Abstract
The invention discloses a process method for increasing the thickness of a laser cladding high-hardness alloy layer, which obtains a stress distribution state by means of finite element analysis according to technical requirements, further designs the position and the size of a cutting line in a cladding area, determines a cladding process, and carries out block cladding and cutting line cladding filling. The laser cladding process of the method can effectively increase the thickness of the alloy layer, is not easy to generate defects such as cracks and the like, does not need a heat preservation process, fundamentally improves the production efficiency and has great economic benefit. Under the condition of the same performance, the numerical ratio of the process cost/the product life can be reduced by using the process method.
Description
Technical Field
The invention belongs to the technical field of laser surface modification, and particularly relates to a process method for increasing the thickness of a laser cladding high-hardness alloy layer and a laser cladding repaired product thereof.
Background
Laser cladding is a laser surface modification technology for cladding a powder material on the surface of a part by using a laser beam with high energy density to obtain a coating with excellent mechanical properties. The liquid alloy formed by melting the powder by the laser beam generates extremely high cooling speed due to the rapid heat conduction of the matrix material and is rapidly solidified and crystallized, so that firm and good metallurgical bonding is generated, and a fine and uniform microstructure (namely, the microstructure of the coating is excellent) is obtained, so that a surface coating with very excellent mechanical property, wear resistance and corrosion resistance can be obtained.
Laser cladding can be divided into two major categories, powder feeding type laser cladding and preset type laser cladding. The powder feeding type laser cladding process has the advantages of easy realization of automatic control, high laser energy absorption rate, no internal air hole and the like, but a special laser cladding spray head, a powder feeding mechanism and a high-power laser are required, so that the equipment cost is high. Meanwhile, compared with a preset laser cladding process, the forming surface is rough, and more post-treatment processing is needed. The preset laser cladding has the advantages of no material limitation, easy cladding of composite component powder, simple process, flexible operation and the like.
The laser cladding technology is a technological method for remarkably improving the wear resistance, corrosion resistance, heat resistance, oxidation resistance, electrical characteristics and the like of the surface of a base material by placing selected coating materials on the surface of a coated base body in different filling modes, simultaneously melting a thin layer on the surface of the base body through laser irradiation, and forming a surface coating which has extremely low dilution and is metallurgically combined with the base material after rapid solidification. Because the laser is used as a heat source, the molten metal has extremely high temperature gradient during solidification, so that the alloy layer has larger internal stress and larger crack tendency after solidification, and compared with other processes for preparing the alloy layer by fusion welding, the process for preparing the same alloy layer material by using the laser cladding has larger disadvantage in thickness. In order to increase the thickness of the alloy layer, two common process methods of adopting a transition layer and preheating and heat preservation are adopted, but the two methods still have respective problems: although the thickness of the alloy layer is seemingly increased by adopting the transition layer method, the service life of the alloy layer cannot be fundamentally prolonged; the preheating and heat preservation method can increase the thickness of the alloy layer to a certain extent, improve the cost of equipment and time and reduce the production efficiency.
Through retrieval, a method which can effectively increase the thickness of the laser cladding alloy, does not increase the process steps, saves the production cost and improves the production efficiency is not found.
Disclosure of Invention
The invention solves the technical problem of overcoming the defects of the prior art and provides a process method for increasing the thickness of a laser cladding high-hardness alloy layer, and the method is a novel process thought which is innovated based on the continuous improvement of the intelligent level of equipment; determining a laser cladding process scheme according to technical requirements by taking the cladding layer number and the cladding thickness of a material to be clad as starting points, carrying out finite element analysis, and obtaining a stress distribution state by a finite element software model analysis method; further determining the area of the cladding substrate material and determining the parameters of the cutting line; determining the positions of a cladding area, a cutting line and a cladding path, dividing the cutting line, carrying out laser cladding on the cladding area, and finally filling the cutting line. The laser cladding of the method can effectively increase the thickness of the alloy layer according to the cladding process, is not easy to generate the defects of cracks and the like, does not need the heat preservation process, fundamentally improves the service life of the alloy layer, improves the production efficiency and has great economic benefit.
Another object of the present invention is to provide a cladding product repaired by a process method of increasing the thickness of a laser cladding high hardness alloy layer. Under the condition of the same performance, the ratio of the process cost to the product life can be reduced by using the process method.
The invention aims to be realized by the following technical scheme:
discloses a process method for increasing the thickness of a laser cladding high-hardness alloy layer, which comprises the following steps:
s1, determining the stress distribution state of an alloy layer by means of finite element software model analysis according to the cladding layer number and the cladding thickness of a substrate material to be clad;
s2, dividing a substrate material cladding area according to the stress distribution state, and determining the position and the size of a cutting line; forming a cladding block on the surface of the substrate material;
s3, determining a cladding process;
s4, according to the cladding process of the step S3, carrying out blocking cladding, and cladding and filling the cutting line to complete alloy layer cladding meeting the technical requirements.
Further, the finite element software model analysis was performed by thermodynamic sysswell simulation software.
Further, the cutting lines are a plurality of mutually perpendicular straight lines; the dicing lines divide the surface of the substrate material into blocks of different sizes.
Further preferably, the width of the cutting line is 2-5 mm, and the edge of the cladding block is in a Y-shaped groove shape.
Furthermore, the cladding process adopts multilayer cladding, and cutting lines of two adjacent cladding blocks do not coincide; the side length of the cutting line of the even layer is 1-3 mm longer than that of the cutting line of the odd layer.
Furthermore, the laser of the cladding process is a fiber laser, the power is 100-1000W, the diameter of a laser spot is 1-5 mm, the powder feeding amount of a powder feeder is 0-10 g/min, the laser cladding scanning speed is 8-12 mm/s, and the lap joint rate is 35-50%.
Further, the cladding material adopted by the cladding process is TC containing 10-50% by mass of WC particles4The powder has WC grains of 53-150 micron size.
Further, the finite element software model analysis comprises the following specific steps:
y1., comprehensively considering the influence of factors such as thermal physical properties, conduction, convection and latent heat of phase change of the cladding material and the substrate material, and simulating a laser cladding digital model by using sysswell simulation software;
y2., loading and moving the 3D Gaussian heat source through software, and selecting a finite element method to carry out discretization processing on the 3D Gaussian heat source;
y3., establishing a laser cladding numerical model, applying load calculation, carrying out data analysis and induction arrangement on the mechanical parameters obtained in the step Y1 to obtain systematic and comprehensive mechanical problems and optimization guidance to form a design target;
y4. according to the finite element stress analysis result, aiming at the difference requirements of different areas in the product on the mechanical performance, the temperature field of the processing process is simulated by using finite element analysis software, the heat source moving track is determined, and the laser parameters are selected.
The invention also aims to disclose a cladding product repaired by laser cladding by the process method for increasing the thickness of the laser cladding high-hardness alloy layer.
Compared with the prior art, the invention has the following beneficial effects:
the invention solves the technical problem of overcoming the defects of the prior art and provides a process method for increasing the thickness of a laser cladding high-hardness alloy layer, and the method is a novel process thought which is innovated based on the continuous improvement of the intelligent level of equipment; determining a laser cladding process scheme according to technical requirements by taking the cladding layer number and the cladding thickness of a material to be clad as starting points, carrying out finite element analysis, and obtaining a stress distribution state through modeling; further determining the area of the cladding substrate material and determining the parameters of the cutting line; determining the positions of a cladding area, a cutting line and a cladding path, dividing the cutting line, carrying out laser cladding on the cladding area, and finally filling the cutting line. The laser cladding of the method can effectively increase the thickness of the alloy layer according to the cladding process, is not easy to generate the defects of cracks and the like, does not need the heat preservation process, fundamentally improves the service life of the alloy layer, improves the production efficiency and has great economic benefit.
According to the invention, based on the problems that in the laser cladding process, the molten metal has extremely high temperature gradient during solidification, so that the alloy layer has large internal stress after solidification and the crack tendency is increased, through modeling analysis, the cladding path and the cladding area are adjusted from the crack type and the crack direction of the cladding layer with the internal stress, and the cladding sequence is adjusted by combining the characteristics of a plane product, so that the cladding requirement of laser cladding on the thickness of the high-hardness alloy layer is fundamentally solved, and the service life of the alloy layer is prolonged.
Another object of the present invention is to provide a cladding product repaired by a process method of increasing the thickness of a laser cladding high hardness alloy layer. Under the condition of the same performance, the ratio of the process cost to the product life can be reduced by using the process method.
Drawings
Fig. 1 is a schematic diagram of a substrate material to be clad according to a stress distribution state after the substrate material to be clad is divided by the process method for increasing the thickness of the laser cladding high-hardness alloy layer.
Fig. 2 is a schematic structural diagram of a cutting line and a cladding block of the process method for increasing the thickness of the laser cladding high-hardness alloy layer.
Detailed Description
The present invention will be further described with reference to the following embodiments. Wherein the showings are for the purpose of illustration only and are shown by way of illustration only and not in actual form, and are not to be construed as limiting the present patent; to better illustrate the embodiments of the present invention, some parts of the drawings may be omitted, enlarged or reduced, and do not represent the size of an actual product; it will be understood by those skilled in the art that certain well-known structures in the drawings and descriptions thereof may be omitted.
Example 1
The process method for increasing the thickness of the laser cladding high-hardness alloy layer comprises the following steps:
s1, determining the stress distribution state of an alloy layer by means of finite element software model analysis according to the cladding layer number and the cladding thickness of a substrate material to be clad;
s2, dividing a substrate material cladding area according to the stress distribution state, and determining the position and the size of a cutting line; forming a cladding block on the surface of the substrate material;
s3, determining a cladding process;
s4, according to the cladding process of the step S3, carrying out blocking cladding, and cladding and filling the cutting line to complete alloy layer cladding meeting the technical requirements.
The finite element analysis is carried out through thermodynamic sysswell simulation software, the finite element analysis is carried out through thermodynamic simulation software, and the finite element analysis comprises the following specific steps:
y1., comprehensively considering the influence of factors such as thermal physical properties, conduction, convection and latent heat of phase change of the cladding material and the substrate material, and simulating a laser cladding digital model by using sysswell simulation software; the control equation of the transient temperature field heat source model in the laser cladding process is as follows:
wherein ρ is density; c. CpIs the specific heat capacity; k coefficient of thermal conductivity;
internal heat source intensity (including laser-loaded heat and latent heat of phase change); t is the temperature; t is time. Among the above parameters, ρ, cpK will change with time.
1) Initial conditions: when t is 0, the temperature of the sample is uniform, and is generally the ambient temperature.
T＝T0 (2)
2) Boundary conditions: heat exchange of objects on the boundary with the surrounding medium:
wherein, TaIs the ambient medium temperature; t issThe surface temperature of the sample; n isx、ny、nzBoundary cosine of the outside boundary normal; β is the total heat transfer coefficient of the surface: beta is beta ═ betac+βrWherein, βcIs the convective heat transfer coefficient; beta is arIs the radiative heat transfer coefficient.
Y2., loading and moving the 3D Gaussian heat source through software, and selecting a finite element method to carry out discretization processing on the 3D Gaussian heat source;
the heat flow density expression of the 3D Gaussian heat source model is as follows:
wherein Q is the energy input rate; q (x, y, z, t) is the heat flux at the (x, y, z) position at time t; the concentration factor of the heat source; v is the cladding speed; τ is a time factor of the power supply position lag. The laser energy absorption rate of the powder ranges from 85% to 95%, and the lapping rate is usually 40%.
Y3., establishing a laser cladding numerical model, applying load calculation, carrying out data analysis and induction arrangement on the mechanical parameters obtained in the step Y1 to obtain systematic and comprehensive mechanical problems and optimization guidance to form a design target;
(1) establishing a physical model:
the TC4 titanium alloy is selected as a substrate material for laser cladding, the TC4 titanium alloy powder mixed with WC particles is selected as a cladding material for laser cladding, the chemical components of the TC4 titanium alloy in the table 1 and the physical properties of the TC4 titanium alloy in the table 2 are shown.
TABLE 1
TABLE 2
(2) Establishment of geometric model
1) The model comprises an upper part and a lower part, wherein the upper layer of the model is a powder part with the size of 200mm multiplied by 100mm multiplied by 0.8 mm; the model lower layer is a substrate portion having a size of 204mm × 104mm × 10 mm.
2) The division for the network aspect in the laser cladding simulation process takes the form: a very small network is selected near a molten pool in the thickness direction of a base material; meanwhile, a relatively sparse grid is applied at a position far away from a molten pool, the thickness of cladding powder is selected to be 0.8mm, and a method of average distribution is selected to make corresponding division.
In the process of processing laser cladding simulation, in order to enable the simulation to be consistent with actual process conditions, a living and dead unit method is adopted, and in the process of modeling, cladding layers are modeled together and are divided into grids; all cladding layer powder units are killed before solving, and in the solving process, the part of the cladding units which can be covered by the heat source is activated until the heat source leaves a cladding area.
Calculating the applied load, and carrying out data analysis, induction and arrangement on the mechanical parameters obtained in the step Y1 to obtain systematic and comprehensive mechanical problems and optimization guidance to form a design target;
y4. according to the finite element stress analysis result, aiming at the difference requirements of different areas in the product on the mechanical performance, the finite element analysis software is used for simulating the temperature field of the processing process, the heat source type Gaussian moving heat source and the laser parameters selected by the heat source moving track.
In the stress distribution state obtained by modeling, solidification shrinkage stress accounts for the most part of internal stress in the alloy layer prepared by laser cladding, the whole alloy layer is divided into cladding regions, the shrinkage stress of each block is released through the edge, and then each block is connected into a whole, so that the internal stress in the whole alloy layer is reduced, the crack tendency is reduced, and the cladding thickness of the alloy layer is increased. The scanning direction and the parallelism of the internal stress are obtained.
Performing laser cladding on the whole of the material to be clad layer by layer according to the cladding layer number and the cladding thickness of the material to be clad, wherein the cutting lines are a plurality of mutually vertical straight lines according to the crack type and the cracking direction of the cladding layer; the dicing lines divide the surface of the substrate material into blocks of different sizes.
The cladding process adopts multilayer cladding, and the cladding material is TC containing 10-50% of WC particles by mass fraction4The powder has WC grains of 53-150 micron size.
Cutting lines of two adjacent cladding blocks are not overlapped; the side length of the cutting line of the even layer is 1-3 mm longer than that of the cutting line of the odd layer. The laser of the cladding process is a fiber laser, the power is 100-1000W, the diameter of a laser spot is 1-5 mm, the powder feeding amount of a powder feeder is 0-10 g/min, the laser cladding scanning speed is 8-12 mm/s, and the lap joint rate is 35-50%.
The specific operation is as follows:
1) determining technological parameters and the thickness of the 2 layers to be clad to 2 mm;
2) determining tensile stress with the internal stress direction parallel to the scanning direction;
3) establishing an alloy layer model of 200mm x 100mm x 2mm, transversely dividing the alloy layer model into 8 uniform blocks of 25mm x 100mm x 2mm, and respectively forming a first area, a second area, … … and an eighth area;
4) the width of the cutting line is increased to be 2mm, the cutting lines 2 are longitudinally separated to form block-shaped cutting areas 1 with different sizes, and the cutting lines 2 are in groove shapes, as shown in figure 2. In the embodiment, the regions formed by cutting the odd-numbered regions are the same as the regions formed by cutting the even-numbered regions, the odd-numbered regions are divided into two blocks with the area of 1:1, and the even-numbered regions are divided into three blocks with the area of 1:2: 1; the whole divided regions are centrosymmetric; fig. 1 shows a partial region of a 200mm by 100mm by 2mm alloy layer. 8 blocks with an area of 25mm by 100mm by 2 mm; multilayer cladding is adopted, and cutting lines of two adjacent cladding blocks do not coincide; the side length of the cutting line on the even layer is 1-3 mm longer and wider than that of the cutting line on the odd layer, the preferred length of the cutting line in the embodiment is 2mm, namely the side length of the cladding of the even layer (such as two layers) is shortened inwards by 1mm, and the side length of the cutting line on the corresponding even layer (such as two layers) is expanded outwards by 1 mm.
5) Respectively generating a cladding path program of the block and the cutting line 2 by using software;
6) leading a program into a manipulator to perform two-layer block cladding according to the parameters determined in the step 1), and then performing two-layer cutting line cladding, wherein multilayer cladding is adopted, and the cutting lines of two adjacent cladding blocks do not coincide; the side length of the cutting line on the even layer is 1-3 mm longer and wider than that of the cutting line on the odd layer, the preferred length of the cutting line in the embodiment is 2mm, namely the side length of the cladding of the even layer (such as two layers) is shortened inwards by 1mm, and the side length of the cutting line on the corresponding even layer (such as two layers) is expanded outwards by 1 mm.
As shown in fig. 2, the width of the cutting line in this embodiment is 2-5 mm, preferably 2mm, and the edge of the cladding block is in a "Y-shaped" groove shape. The bevel angle of the Y-shaped groove is 60 degrees; the height of the cladding block is 2.2 mm.
Comparative example 1
The same titanium alloy (TC) as in example 2 was added4) Cladding the surface of the plate, wherein the TC with the mass fraction of 10% WC particles and the thickness of 2mm4An alloy layer, wherein the WC particles have a particle size of 53-150 μm; TC (tungsten carbide)4The plate size was 200mm 100mm 20 mm.
The specific cladding process comprises the following steps: using the same equipment, same parameters, track spacing: 0.8mm, wherein the laser is a fiber laser with the power of 500W, the diameter of a laser spot is 1-5 mm, the powder feeding amount of the powder feeder is 5-10 g/min, the laser cladding scanning speed is 12mm/s, and the lap joint rate is 35-50%. Selecting TC4The plate is a material to be clad, and the cladding material is TC containing 10-50% of WC particles by mass fraction4The powder has WC grains of 53-150 micron size. The cladding track is in sequential unidirectional linear lap joint.
The products obtained in example 1 and comparative example 1 were subjected to a performance test, and 5 regions were taken at the same positions on the clad product 1 and the clad product 2 obtained in example 1 and comparative example 1 by measurement with a vernier caliper. The experimental results are shown in Table 3.
TABLE 3
The titanium alloy base material sample is placed on a wear-resistant testing machine model MLS-225 type wet rubber wheel wear testing machine, a titanium alloy base material sample piece is manufactured, laser cladding is carried out on a 26.5mm 57mm (standard size of a sample required by equipment) surface of the sample piece, the powder is TC4 powder mixed with WC particles, and the cladding thickness is 2 mm. The cladding sample and the substrate sample were subjected to wear comparison and the data are shown in table 4 below.
TABLE 4
Experiments show that the process method for increasing the thickness of the laser cladding high-hardness alloy layer can effectively increase the thickness of the alloy layer, has uniform coating, is not easy to generate the defects of cracks and the like, does not need a heat preservation process, fundamentally improves the service life of the alloy layer, improves the production efficiency and has great economic benefit.
It will be apparent that the above examples are merely examples for clearly illustrating the technical solutions of the present invention, and are not intended to limit the embodiments of the present invention. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. Any modification, equivalent replacement, and improvement made within the spirit and principle of the present invention should be included in the protection scope of the claims of the present invention.
Claims (6)
1. A process method for increasing the thickness of a laser cladding high-hardness alloy layer is characterized by comprising the following steps:
s1, according to the cladding layer number and the cladding thickness of a substrate material to be cladded,
determining the stress distribution state of the alloy layer by means of finite element software model analysis;
s2, dividing a substrate material cladding area according to the stress distribution state, and determining the position and the size of a cutting line; forming a cladding block on the surface of the substrate material;
s3, determining a cladding process;
s4, according to the cladding process of the step S3, carrying out blocking cladding, and cladding and filling the cutting line to complete alloy layer cladding meeting the technical requirements;
the cutting lines are a plurality of mutually vertical straight lines; the cutting line divides the surface of the substrate material into blocks with different sizes; the cladding process adopts multilayer cladding, and cutting lines of two adjacent cladding blocks do not coincide; the side length of the cutting line of the even layer is 1-3 mm longer than that of the cutting line of the odd layer; the width of the cutting line is 2-5 mm, and the edge of the cladding block is in a Y-shaped groove shape.
2. The process of increasing the thickness of a laser clad high hardness alloy layer of claim 1, wherein the finite element software model analysis is performed by thermodynamic sysswell simulation software.
3. The process method for increasing the thickness of the laser cladding high-hardness alloy layer according to claim 1, wherein the laser of the cladding process is a fiber laser, the power is 100-1000W, the diameter of a laser spot is 1-5 mm, the powder feeding amount of a powder feeder is 0-10 g/min, the laser cladding scanning speed is 8-12 mm/s, and the overlapping rate is 35-50%.
4. The process method for increasing the thickness of the laser cladding high-hardness alloy layer according to claim 3, wherein the cladding material selected for the cladding process is TC4 powder containing 10-50% by mass of WC particles, and the granularity of the WC particles is 53-150 μm.
5. The process method for increasing the thickness of the laser cladding high-hardness alloy layer according to any one of claims 1 to 4, wherein the finite element software model analysis comprises the following specific steps:
y1., comprehensively considering the influence of factors such as thermal physical properties, conduction, convection and latent heat of phase change of the cladding material and the substrate material, and simulating a laser cladding digital model by using sysswell simulation software;
y2., loading and moving the 3D Gaussian heat source through software, and selecting a finite element method to carry out discretization processing on the 3D Gaussian heat source;
y3., establishing a laser cladding numerical model, applying load calculation, carrying out data analysis and induction arrangement on the mechanical parameters obtained in the step Y1 to obtain systematic and comprehensive mechanical problems and optimization guidance to form a design target;
y4. according to the finite element stress analysis result, aiming at the difference requirements of different areas in the product on the mechanical performance, the temperature field of the processing process is simulated by using finite element analysis software, the heat source moving track is determined, and the laser parameters are selected.
6. A product repaired by the process method for increasing the thickness of the laser cladding high-hardness alloy layer according to any one of claims 1-5.
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