AU2016101936A4 - A method for repairing a sprocket wheel - Google Patents
A method for repairing a sprocket wheel Download PDFInfo
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- 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
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C30/00—Alloys containing less than 50% by weight of each constituent
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/08—Ferrous alloys, e.g. steel alloys containing nickel
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/12—Ferrous alloys, e.g. steel alloys containing tungsten, tantalum, molybdenum, vanadium, or niobium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/32—Ferrous alloys, e.g. steel alloys containing chromium with boron
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
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Abstract
This present disclosure provides a method for repairing a sprocket wheel, which includes the following steps: establish a standard need-to-be-repaired model for a worn sprocket with the maximum abrasion loss; process each worn sprocket to make its abrasion loss reaches the maximum abrasion loss; perform cladding on the processed worn-sprocket to form the standard need-to-be-repaired model, so as to obtain the repaired sprocket wheel. This present disclosure has the advantages as follows: the cladding process is easy to accomplish and the quality of the cladding is high, and the use ratio of the resources recycling is improved effectively, and the cost is reduced, the practical function is very meaningful, and meanwhile the wear resistance of the sprocket is increased effectively. I I ' I ' I ' I Fig. 1 900 z Fig. 2
Description
1
A METHOD FOR REPAIRING A SPROCKET WHEEL TECHNIC ALFIELD
The present disclosure mainly relates to the technical field of repairing work pieces, and more particularly to a method for repairing a sprocket wheel.
BACKGROUND
The sprocket wheel is an important component of the scraper conveyor and the transfer conveyor. The drag chain of the scraper conveyor is driven by the sprocket wheel, when the sprocket wheel runs, the gear teeth of the sprocket wheel engage the chain link in turn to drive the drag chain to do a continuous motion, so as to achieve the function of conveying coals.
During the using process in the pit, the sprocket wheel of the mining scraper conveyor suffers the alternating stress from the chain, thus it is easy to form fatigue pitting on the surface of the sprocket. In addition, because of the bad lubricating condition between the sprocket wheel and the chain, it causes the abrasion before the pitting formed, which leads to the short service life of the sprocket wheel, so that it cannot meet the production requirement far and away. It is definitely a huge waste if not repair the worn part of the sprocket wheel but replace it with a new one, and rises the cost invested in. For this reason, how to repair the worn sprocket wheel to make the entire mechanics performance level of the repaired sprocket wheel could reach or even exceed the standard of a new production is a technical problem worth to further research.
SUMMARY
This present disclosure accordingly provides a method for repairing a sprocket wheel.
In order to achieve the aim as above-mentioned, this present disclosure provides a solution as follows: A method for repairing a sprocket wheel includes the following steps: 2016101936 02 Nov 2016 2 step 1: establish a standard need-to-be-repaired model for a worn sprocket with the maximum abrasion loss; step 2: process each worn sprocket to make its abrasion loss reaches the maximum abrasion loss; 5 step 3: perform cladding on the processed worn-sprocket to form the standard need-to-be-repaired model, so as to obtain the repaired sprocket wheel.
In the above-mentioned method for repairing a sprocket wheel, before step 1, further includes: perform pretreatment process on the worn sprocket wheel, wherein the pretreatment process may include that: clean the entire surface of the sprocket 10 wheel to remove the surface greasy dirty and the rust, polish the worn sprocket to make it show the metallic luster.
Further, in step 1, the step of establishing a standard need-to-be-repaired model for a worn sprocket with the maximum abrasion loss may include as follows: 1) measure the abrasion loss of each worn sprocket to identify the sprocket with 15 the maximum abrasion loss; 2) obtain three-dimension data of the worn sprocket with the maximum abrasion loss by using three-dimensional laser scanning; 3) obtain three-dimension data of a standard sprocket by using three-dimensional laser scanning; 20 4) input two groups of three-dimension data obtained from step 2) and step 3) into a control system to establish the standard need-to-be-repaired model for the worn sprocket with the maximum abrasion loss and generate numerical control codes.
Further, the step of generating method of the numerical control code may include: the control system performs hierarchical processing on the standard 25 need-to-be-repaired model, and a hierarchical slice thickness is 0.3-0.6mm; and the control system records the initial point and the ending point of the hierarchical slice, and generates numerical control codes. 2016101936 02 Nov 2016 3
Further in step 3, performing cladding on the processed worn-sprocket to form the standard need-to-be-repaired model, so as to obtain the repaired sprocket wheel may include: 1) set a to-be-repaired surface of the worn sprocket right to face a laser head, 5 connect the laser to the control system; 2) identify an original starting point of the to-be-repaired surface by red laser emitted from the laser, and the original starting point is same with an initial point of the hierarchical slice; 3) under the guiding of the numerical control code, perform cladding from the 10 initial point to the ending point, slice by slice, according to the proportion of that the model size: the practical size = 1:1; 4) perform cladding by the laser with Alloy Powder One on the base-body surface of the worn sprocket, slice by slice, to form a transition cladding layer; 5) perform cladding by the laser with Alloy Powder Two on the surface of the 15 transition cladding layer to form a top cladding layer, until obtain the standard need-to-be-repaired model by cladding.
Further, the overall thickness of the transition cladding layer is 0.3-1.8mm; the transition cladding layer and the top cladding layer are cladded by means of multi-laps, and the overlap rate is 30%-50%. 20 Further, the laser is a fiber laser, an optical fiber coupling laser or a semiconductor laser, the shielding gas flow of the laser is 270-300m3/h, the pressure of the shielding gas is 0.3-0.5MPa, the cutter lifting speed is 2000-3000mm/min, the linear speed is 600-1800mm/min, the negative defocusing amount is 3-8mm, and the powder feeding speed is 10-20g/min; during the cladding for the transition cladding 25 layer, the power of the laser is 1200-1500W; during the cladding for the top cladding layer, the power of the laser is 600-800W.
Further, the components of the Alloy Powder One include as follows:
Cr: 15-20 portions, Mn: 0.6-1.2 portions, Si: 0.5-1 portion, Ni: 26-35 portions, Mo: 2016101936 02 Nov 2016 4 1.5-3.5 portions, and Fe: 39.1-56.2 portions.
There are high contents of Ni and Cr in the Alloy Powder One, the friendly user interface of the cladding layer is promoted by the element of Ni with well wettability, and the corrosion resistance of the cladding layer is improved by using quite a high 5 proportion of Cr with a low price. Additionally, the cladding layer has good ductility and toughness simultaneously because of using a certain amount of Mo.
Further, the components of the Alloy Powder Two include as follows: C: 1-1.4 portions, Cr: 4.5-6 portions, Mn: 0.5-1.1 portions, Si: 0.2-0.5 portion, Ni: 9-13 portions, Mo: 3.3-5.6 portions, V: 1.5-2.4 portions, W: 5.5-6.0 portions and Fe: 10 63.8-73.9 portions.
The elements of Ni, Mn and Mo in the Alloy Powder Two can form a stable austenite, have hardening capacity. And the elements of W and V are strong carbide forming elements which can form fine and dispersive carbide, so as to make the top cladding layer have well strength. The elements of Cr and Si can enhance the top 15 cladding layer’s inoxidizability and the resistance to high temperature corrosive gases.
Further, the components of the Alloy Powder Two include as follows: C: 0.8-1.2 portions, Cr: 3.0-5.0 portions, Mn: 3.5-4.5 portions, Si: 1.3-1.8 portions, Ni: 0.5-2.0 portions, B: 0.1-1.2 portions, V: 1.0-2.0 portions, W: 8.2-10.5 portions, and Fe: 71.6-80.6 portions. 20 The elements of Si and B in the Alloy Powder Two have strong deoxidation and slaggability, and they can preferentially react with oxygen of the transition cladding layer and the oxide of the surface of the base body to generate floating materials such as borosilicate with low melting point which floats on the surface of the furnace hearth, so as to reduce the oxygen contain and the slag inclusion of the top cladding layer, 25 and enhance the wettability and the processability of the base body and the transition cladding layer. The elements of Cr, W, V and B can form stereoplasm particle phrase to improve the whole abrasive resistance of the top cladding layer.
This present disclosure has these advantages as below: 2016101936 02 Nov 2016 5 1. In this present disclosure, through obtaining the 3D data of the worn sprocket with the maximum abrasion loss, establish the standard need-to-be-repaired model, so as to repair the worn sprocket wheel, which can increase the recycling rate of resources effectively. 5 2. In this present disclosure, process each worn sprocket to make its abrasion loss reaches the maximum abrasion loss, thus it can accomplish the repairing for the whole worn sprocket through establishing one standard need-to-be-repaired model, which makes the working efficient quite high and makes the cladding processing quite easy. 10 3. In this present disclosure, the Alloy Powder One is used in coordination with the
Alloy Powder Two, the Alloy Powder One is used for cladding the transition cladding layer which can form metallurgical bonding with the base-body surface of the worn sprocket, and the transition cladding layer has well corrosion resistance and strong toughness. The Alloy Powder Two is used for cladding the top cladding layer which 15 can improve the wear resistance of the sprocket because of the top cladding layer’s inoxidizability and the resistance to high temperature corrosive gases and well wear-resistance, etc. 4. In this present disclosure, the power parameters of the laser are optimized, which contributes to the firm bonding between the Alloy Powder One and base body 20 during the cladding process of the transition cladding layer, and prevent the dilution rate of the top cladding layer being too much during the cladding process of the top cladding layer, and also contributes to the heat dissipation generated in the process of cladding, and can improve the quality of the cladding. 5. In this present disclosure, the Alloy Powder One is used in coordination with 25 different Alloy Powder Two, which can improve the wear resistance of the sprocket effectively, and the cost of the Alloy Powder One is low, which can reduce the cost and has strongly practical function, etc. 2016101936 02 Nov 2016 6
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a graph of the hardness gradient of Sample One of the present disclosure;
Fig. 2 is a graph of the hardness gradient of Sample Two of the present 5 disclosure.
Herein, in Fig. 1 and Fig. 2, the horizontal coordinate represents the height of the detected point with the unit of mm, and the longitudinal coordinate represents micro hardness value.
10 DETAILED DESCRIPTION
In order to make the skilled in this art understand the present disclosurebetter, the technical solution of the present disclosure will now be described more clearly and fully hereinafter together with embodiments of the present disclosure, which are not all of the embodiments of thepresent disclosure. According to the exemplary embodiments 15 of thisdisclosure, all other similar embodiments obtained by those skilled in this art without any creative work belong to the protection scope of the present disclosure.
Embodiment One: A method for repairing a sprocket wheel includes the following steps: 20 Step 1: perform pretreatment process on the worn sprocket wheel, the pretreatment process includes that: clean the entire surface of the sprocket wheel to remove the surface greasy dirty and the rust, polish the worn sprocket to make it show the metallic luster.
Step 2: measure the abrasion loss of each worn sprocket to identify the sprocket 25 with the maximum abrasion loss, obtain the three-dimension (3D) data of the worn sprocket with the maximum abrasion loss by using REVscan three-dimensional laser scanner. It can achieve noncontact measurement by the technology of the 3D scanning, and obtain the 3D data of the standard sprocket by using REVscan 3D laser scanner, and input those two groups of 3D data into the control system to establish a 2016101936 02 Nov 2016 7 standard need-to-be-repaired model for the worn sprocket with the maximum abrasion loss.
The control system performs hierarchical processing on the standard need-to-be-repaired model, and the slice thickness is 0.3-0.6mm. The control system 5 records the initial point and the ending point of the hierarchical slice, and generates numerical control codes.
The control system is configured with Geomagic Qualify software, and the control system can read the STL file, display it in two-dimension three-dimension with color, analyze the STL model and achieve to rotate, resize and shift the model. The control 10 system also can hierarchically slice the model according to the design requirement, and the slice thickness, the initial point and the ending point of the hierarchical slice can be controlled. The control system can fill up the slice contour, and the filled pattern includes a checkerboard pattern, a strip pattern, an overall pattern and an off-set pattern, etc. 15 Step 3: process each worn sprocket to make its abrasion loss reaches the maximum abrasion loss.
Step 4: perform cladding on the processed worn-sprocket to form the standard need-to-be-repaired model, so as to obtain the repaired sprocket wheel, and the specific processing is described as below: 20 1) Set the to-be-repaired surface of the worn sprocket right to face the laser head, connect the laser to the control system. 2) Identify the original starting point of the to-be-repaired surface by red laser emitted from the laser, and the original starting point is same with the initial point of the hierarchical slice. 25 3) Linder the guiding of the numerical control code, according to the proportion of that the size of the model : the practical size=1:1, perform the cladding from the initial point to the ending point slice by slice. 4) The laser performs cladding with Alloy Powder One on the base surface of the 2016101936 02 Nov 2016 8 worn sprocket, slice by slice, to form a transition cladding layer. 5) The laser performs cladding with Alloy Powder Two on the surface of the transition cladding layer to form a top cladding layer until obtain the standard need-to-be-repaired model by cladding. 5 Step 5: perform surface cleaning and polishing on the surface of the repaired sprocket wheel, and then put it in storage.
The transition cladding layer and the top cladding layer are cladded in the manner of multi-laps, the overlap rate is 30%, and the laser is a fiber laser. The shielding gas flow of the laser is 270m3/h, the pressure of the shielding gas is 0.3MPa, the cutter 10 lifting speed is 2000mm/min, the linear speed is 600mm/min, the negative defocusing amount of the laser is 3mm, and the powder feeding speed is 10g/min. During the cladding for the transition cladding layer, the power of the laser is 1200W; during the cladding for the top cladding layer, the power of the laser is 600W.
In this embodiment, the material of the sprocket wheel is 42CrMo. The overall 15 thickness of the standard need-to-be-repaired model is 9.0mm, the thickness of the hierarchical slice is 0.3mm, and the overall thickness of the transition cladding layer is 0.3mm.
The components of the Alloy Powder One include as follows: Cr: 15 portions, Mn: 0.6 portion, Si: 0.5 portion, Ni: 26 portions, Mo: 1.5 portions, and Fe: 56 portions. 20 The components of the Alloy Powder Two include as follows: C: 1 portion, Cr: 4.5 portions, Mn: 0.5 portion, Si: 0.2 portion, Ni: 9 portions, Mo: 3.3 portions, V: 1.5 portions, W: 5.5 portions and Fe: 73.9 portions.
Embodiment Two:
Herein, the parts which are same with Embodiment One are no longer repeated, 25 which are different from Embodiment One include as below:
The overlap rate of the transition cladding layer and the top cladding layer is 30%, and the laser is a fiber laser. The shielding gas flow of the laser is 270m3/h, the pressure of the shielding gas is 0.3MPa, the cutter lifting speed is 2000mm/min, the 2016101936 02 Nov 2016 9 linear speed is 600mm/min, the negative defocusing amount is 3mm, and the powder feeding speed is 10g/min. During the cladding for the transition cladding layer, the power of the laser is 1200W; during the cladding for the top cladding layer, the power of the laser is 600W. 5 In this embodiment, the overall thickness of the standard need-to-be-repaired model is 9.6mm, the thickness of the hierarchical slice is 0.3mm, and the overall thickness of the transition cladding layer is 1.5mm.
The components of the Alloy Powder One include as follows: Cr: 15 portions, Mn: 0.6 portion, Si: 0.5 portion, Ni: 26 portions, Mo: 1.5 portions, and Fe: 56.2 portions. 10 The components of the Alloy Powder Two include as follows: C: 0.8 portion, Cr: 3.0 portions, Mn: 3.5 portions, Si: 1.3 portions, Ni: 0.5 portion, B: 0.1 portion, V: 1.0 portion, W: 8.2 portions, and Fe: 80.6 portions.
Embodiment Three:
Herein, the parts which are same with Embodiment One are no longer repeated, 15 which are different from Embodiment One include as below:
The overlap rate of the transition cladding layer and the top cladding layer is 38%, and the laser is an optical fiber coupling laser. The shielding gas flow of the laser is 280m3/h, the pressure of the shielding gas is 0.4MPa, the cutter lifting speed is 2500mm/min, the linear speed is 1200mm/min, the negative defocusing amount is 20 5.5mm, and the powder feeding speed is 15g/min. During the cladding for the transition cladding layer, the power of the laser is 1350W; during the cladding for the top cladding layer, the power of the laser is 700W.
In this embodiment, the overall thickness of the standard need-to-be-repaired model is 9.45mm, the thickness of the hierarchical slice is 0.45mm, and the overall 25 thickness of the transition cladding layer is 0.45mm.
The components of the Alloy Powder One include as follows: Cr: 17 portions, Mn: 0.9 portion, Si: 0.7 portion, Ni: 31 portions, Mo: 2.5 portions, and Fe: 47.8 portions.
The components of the Alloy Powder Two include as follows: C: 1.2 portions, Cr: 2016101936 02 Nov 2016 10 5.2 portions, Μη: 0.8 portion, Si: 0.4 portion, Ni: 12 portion, Mo: 4.4 portions, V: 1.9 portions, W: 5.7 portions, and Fe: 67 portions.
Embodiment Four:
Herein, the parts which are same with Embodiment One are no longer repeated, 5 which are different from Embodiment One include as below:
The overlap rate of the transition cladding layer and the top cladding layer is 42%, and the laser is an optical fiber coupling laser. The shielding gas flow of the laser is 280m3/h, the pressure of the shielding gas is 0.45MPa, the cutter lifting speed is 2600mm/min, the linear speed is 1300mm/min, the negative defocusing amount is 10 6mm, and the powder feeding speed is 16g/min. During the cladding for the transition cladding layer, the power of the laser is 1290W; during the cladding for the top cladding layer, the power of the laser is 680W.
In this embodiment, the overall thickness of the standard need-to-be-repaired model is 9.45mm, the thickness of the hierarchical slice is 0.45mm, and the overall 15 thickness of the transition cladding layer is 0.9mm.
The components of the Alloy Powder One include as follows: Cr: 18 portions, Mn: 0.8 portion, Si: 0.8 portion, Ni: 30 portions, Mo: 2.3 portions, and Fe: 47.5 portions.
The components of the Alloy Powder Two include as follows: C: 0.9 portion, Cr: 4.3 portions, Mn: 3.9 portions, Si: 1.6 portions, Ni: 1.4 portions, B: 0.6 portion, V: 1.7 20 portions, W: 9.3 portions, and Fe: 75.3 portions.
Embodiment Five:
Herein, the parts which are same with Embodiment One are no longer repeated, which are different from Embodiment One include as below:
The overlap rate of the transition cladding layer and the top cladding layer is 25 48%, and the laser is a semiconductor laser. The shielding gas flow of the laser is 290m3/h, the pressure of the shielding gas is 0.45MPa, the cutter lifting speed is 2800mm/min, the linear speed is 1600mm/min, the negative defocusing amount is 6mm, and the powder feeding speed is 17g/min. During the cladding for the 2016101936 02 Nov 2016 11 transition cladding layer, the power of the laser is 1400W; during the cladding for the top cladding layer, the power of the laser is 750W.
In this embodiment, the overall thickness of the standard need-to-be-repaired model is 9.6mm, the thickness of the hierarchical slice is 0.6mm, and the overall 5 thickness of the transition cladding layer is 0.6mm.
The components of the Alloy Powder One include as follows: Cr: 18 portions, Mn: 1.2 portions, Si: 0.9 portion, Ni: 33 portions, Mo: 3.4 portions, and Fe: 43.3 portions.
The components of the Alloy Powder Two include as follows: C: 1.4 portions, Cr: 10 6 portions, Mn: 1.1 portions, Si: 0.5 portion, Ni: 13 portions, Mo: 5.6 portions, V: 2.4 portions, W: 6 portions, and Fe: 63.8 portions.
Embodiment Six:
Herein, the parts which are same with Embodiment One are no longer repeated, which are different from Embodiment One include as below: 15 The overlap rate of the transition cladding layer and the top cladding layer is 50%, and the laser is a semiconductor laser. The shielding gas flow of the laser is 300m3/h, the pressure of the shielding gas is 0.5MPa, the cutter lifting speed is 3000mm/min, the linear speed is 1800mm/min, the negative defocusing amount is 8mm, and the powder feeding speed is 20g/min. During the cladding for the 20 transition cladding layer, the power of the laser is 1500W; during the cladding for the top cladding layer, the power of the laser is 800W.
In this embodiment, the overall thickness of the standard need-to-be-repaired model is 9.6mm, the thickness of the hierarchical slice is 0.6mm, and the overall thickness of the transition cladding layer is 1.8mm. 25 The components of the Alloy Powder One include as follows: Cr: 20 portions,
Mn: 1.2 portions, Si: 1 portion, Ni: 35 portions, Mo: 3.5 portions, and Fe: 39.1 portions.
The components of the Alloy Powder Two include as follows: C: 1.2 portions, Cr: 5.0 portions, Mn: 4.5 portions, Si: 1.8 portions, Ni: 2.0 portions, B: 1.2 portions, V: 2.0 2016101936 02 Nov 2016 12 portions, W: 10.5 portions, and Fe: 71.6 portions.
Contrast Testing One:
Take samples from the repaired sprocket wheels obtained from Embodiment Five and Embodiment Six of this present disclosure, the cladding samples are taken from 5 the repaired part by using wire-electrode cutting, the size of the samples is 10mmx10mmx10mm, and the samples are respectively marked as Sample One and Sample Two.
Perform sanding and polishing on Sample One and Sample Two, and perform the hardness testing on their section by using an HVS-1000A digital display 10 micro-hardness tester, taking testing points from the base body, the transition cladding layer and the top cladding layer successively, and the testing points are taken at an interval of 0.1 mm in the identical testing zone, the testing points are taken at an interval of 0.5 mm in the steady area of the hardness. The hardness gradient graph of Sample One is shown in Fig. 1 and the hardness gradient graph of Sample Two is 15 shown in Fig. 2.
As shown in Fig. 1, the average hardness of the top cladding layer of Sample One is 660FIV, the average hardness of its transition cladding layer is 350HV, and the average hardness of its base body of the sprocket is 275HV. The hardness of the top cladding layer and the transition cladding layer are comparatively stable, and the 20 hardness of the top cladding layer and the transition cladding layer are higher than the hardness of the base body of the sprocket, so as to enhance the wear resistance of the sprocket wheel effectively.
As shown in Fig. 2, the average hardness of the top cladding layer of Sample Two is 900FIV, the average hardness of its transition cladding layer is 345FIV, and the 25 average hardness of its base body of the sprocket is 275FIV. The hardness of the top cladding layer and the transition cladding layer are comparatively stable, and the hardness of the top cladding layer and the transition cladding layer are higher than the hardness of the base body of the sprocket, so as to enhance the wear resistance of the sprocket wheel effectively. 2016101936 02 Nov 2016 13
Thus it can be seen that: the same transition cladding layer bonding with different top cladding layers can improve the wear resistance of the sprocket wheel effectively, and the thickness of the transition cladding layer has quite a little influence on its average hardness. 5 Contrast Testing Two:
Obtain Sample One and Sample Two from Contrast Testing One, and take a base body of 42CrMo with same size as Sample Three. Clean and dry Sample One, Sample Two and Sample Three, and then weigh them respectively as the pre-experimental weights. Perform Grinding operations on the three samples against 10 45-steel, the grinding time is controlled to be 1.5h, and then clean and dry those three samples and then weigh them respectively as the post-experimental weights. Calculate the weight losses by grinding. The above operations are repeated, by three times, to obtain the experimental data shown in table 1.
Table 1
Samples Weight loss by the first grinding/g Weight loss by the second qrinding /g Weight loss by the third grinding /g Sample One 0.0039 0.0028 0.0041 Sample Two 0.0025 0.0016 0.0028 Sample Three 0.0325 0.0398 0.0428 15 The above experiments are performed in the laboratory of Shandong Energy
Heavy Equipment Group, Dazu Remanufacturing Co., Ltd.
According to analysis of the above experimental data, the grinding weight losses of the three times of each sample are close, which illustrates that Sample One, Sample Two and Sample Three are of higher stability. 20 In the three times of grinding, the grinding weight losses of Sample One and
Sample Two are comparatively close, which illustrates that the sprocket wheels repaired by Alloy Powder One combining with different Alloy Powder Two have close abrasion resistance.
In the three times of grinding, the grinding weight losses of Sample One and 2016101936 02 Nov 2016 14
Sample Two are both obviously lower than the grinding weight loss of Sample Three, which illustrates that the sprocket wheels repaired by the cladding methods according to the present disclosure have higher abrasion resistance than the base body of the sprocket wheel. 5 Additionally, it should be understood that even though this specification is described as exemplary embodiments, each embodiment include not only one method solution, which is considered to make this specification clear. The specification should be deem as a whole by those ordinary skilled in this art, the method solution of every embodiment can be can be properly devised to form other embodiments 10 understood by those skilled in this art.
Claims (5)
1. A method for repairing a sprocket wheel, comprising: step 1: establishing a standard need-to-be-repaired model for a worn sprocket with the maximum abrasion loss; step 2: processing each worn sprocket to make its abrasion loss reaches the maximum abrasion loss; and step 3: performing cladding on the processed worn-sprocket to form the standard need-to-be-repaired model, so as to obtain the repaired sprocket wheel.
2. The method for repairing a sprocket wheel according to Claim 1, further comprising: before step 1, performing pretreatment process on the worn sprocket wheel, wherein the pretreatment process comprises that: clean the entire surface of the sprocket wheel to remove the surface greasy dirty and the rust, polish the worn sprocket to make it show the metallic luster; and/or, wherein in step 1, establishing a standard need-to-be-repaired model for a worn sprocket with the maximum abrasion loss comprises as follows: 1) measure the abrasion loss of each worn sprocket to identify the sprocket with the maximum abrasion loss; 2) obtain three-dimension data of the worn sprocket with the maximum abrasion loss by using three-dimensional laser scanning; 3) obtain three-dimension data of a standard sprocket by using three-dimensional laser scanning; 4) input two groups of three-dimension data obtained from step 2) and step 3) into a control system, so as to establish the standard need-to-be-repaired model for the worn sprocket with the maximum abrasion loss and generate numerical control codes.
3. The method for repairing a sprocket wheel according to Claim 2, wherein: generating method of the numerical control code comprises: the control system performs hierarchical processing on the standard need-to-be-repaired model, and a hierarchical slice thickness is 0.3-0.6mm; and the control system records the initial point and the ending point of the hierarchical slice, and generates numerical control codes.
4. The method for repairing a sprocket wheel according to Claim 3, wherein, in step 3, performing cladding on the processed worn-sprocket to form the standard need-to-be-repaired model, so as to obtain the repaired sprocket wheel comprises: 1) set a to-be-repaired surface of the worn sprocket right to face a laser head, connect the laser to the control system; 2) identify an original starting point of the to-be-repaired surface by red laser emitted from the laser, and the original starting point is same with an initial point of the hierarchical slice; 3) under the guiding of the numerical control code, perform cladding from the initial point to the ending point, slice by slice, according to the proportion of that the model size: the practical size=1:1; 4) perform cladding by the laser with Alloy Powder One on the base-body surface of the worn sprocket, slice by slice, to form a transition cladding layer; 5) perform cladding by the laser with Alloy Powder Two on the surface of the transition cladding layer to form a top cladding layer, until obtain the standard need-to-be-repaired model by cladding.
5. The method for repairing a sprocket wheel according to Claim 4, wherein: the overall thickness of the transition cladding layer is 0.3-1.8mm; the transition cladding layer and the top cladding layer are cladded by means of multi-laps, and the overlap rate is 30%-50%; and /or, the laser is a fiber laser, an optical fiber coupling laser or a semiconductor laser, the shielding gas flow of the laser is 270-300m3/h, the pressure of the shielding gas is 0.3-0.5MPa, the cutter lifting speed is 2000-3000mm/min, the linear speed is 600-1800mm/min, the negative defocusing amount of the laser is 3-8mm, and the powder feeding speed is 10-20g/min; during the cladding for the transition cladding layer, the power of the laser is 1200-1500W; during the cladding for the top cladding layer, the power of the laser is 600-800W; and /or, the components of the Alloy Powder One include as follows: Cr: 15-20 portions, Mn: 0.6-1.2 portions, Si: 0.5-1 portion, Ni: 26-35 portions, Mo: 1.5-3.5 portions, and Fe: 39.1-56.2 portions; the components of the Alloy Powder Two include as follows: C: 1 -1.4 portions, Cr: 4.5-6 portions, Mn: 0.5-1.1 portions, Si: 0.2-0.5 portion, Ni: 9-13 portions, Mo: 3.3-5.6 portions, V: 1.5-2.4 portions, W: 5.5-6.0 portions and Fe: 63.8-73.9 portions; or, the components of the Alloy Powder Two include as follows: C: 0.8-1.2 portions, Cr: 3.0-5.0 portions, Mn: 3.5-4.5 portions, Si: 1.3-1.8 portions, Ni: 0.5-2.0 portions, B: 0.1-1.2 portions, V: 1.0-2.0 portions, W: 8.2-10.5 portions, and Fe: 71.6-80.6 portions.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201610157161.0A CN105734559B (en) | 2016-03-18 | 2016-03-18 | A kind of sprocket wheel restorative procedure |
| CN201610157161.0 | 2016-03-18 |
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| AU2016101936A4 true AU2016101936A4 (en) | 2016-12-01 |
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| US8597724B2 (en) * | 2007-07-06 | 2013-12-03 | United Technologies Corporation | Corrosion protective coating through cold spray |
| CN100557082C (en) * | 2007-08-03 | 2009-11-04 | 中国人民解放军装甲兵工程学院 | Carburization-like overloading tooth component tooth surface laser cladding powdered material and restorative procedure |
| CN105154870B (en) * | 2015-09-01 | 2018-01-23 | 广东工业大学 | A kind of metal parts Stress Control 3D printing reproducing method |
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| CN105734559B (en) | 2018-05-01 |
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