CN112692293A - 汽轮机叶片手持式增材修复工艺方法 - Google Patents

汽轮机叶片手持式增材修复工艺方法 Download PDF

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CN112692293A
CN112692293A CN202011458815.6A CN202011458815A CN112692293A CN 112692293 A CN112692293 A CN 112692293A CN 202011458815 A CN202011458815 A CN 202011458815A CN 112692293 A CN112692293 A CN 112692293A
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handheld
laser
turbine blade
wire feeding
repair
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姚建华
陈思远
王梁
李波
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Zhejiang University of Technology ZJUT
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture 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
    • B22F7/06Manufacture 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
    • B22F7/062Manufacture 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/003Apparatus, e.g. furnaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00Processes of additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00Apparatus for additive manufacturing; Details thereof or accessories therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00Auxiliary operations or equipment, e.g. for material handling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture 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
    • B22F7/06Manufacture 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
    • B22F7/062Manufacture 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
    • B22F2007/068Manufacture 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

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Laser Beam Processing (AREA)

Abstract

一种汽轮机叶片手持式增材修复工艺方法,包括如下步骤:对待修复的汽轮机叶片进行固定,调试安装好手持激光设备和超声送丝设备,手持激光设备与超声送丝设备手动同步操作,调整保持送丝速度与手持激光扫描速度一致,启动手持激光设备的激光光源,激光脉冲能量作用于待修复叶片表面产生局部高温,使激光聚焦产生的激光光斑内的焊丝与局部修复区域液化形成熔池,而后凝固对损伤区进行无缺陷修复;本发明为一种现场修复的方法,该方式与返厂修复相比,其耗时少、成本低、修复效果好且具有广泛的应用前景。

Description

汽轮机叶片手持式增材修复工艺方法
技术领域
本发明属于激光加工性能评估技术领域,具体涉及一种汽轮机叶片手持式增材修复工艺方法。
背景技术
汽轮机末级叶片在实际服役过程中,长期受到含有水滴与微颗粒的湿蒸汽的汽蚀。汽流中夹带着二次水滴高速冲击运行中的末级叶片,会导致叶片的边缘出现蜂窝状的缺陷组织,尤其是叶片的进汽边顶部和出汽边根部,进而形成大量微小的裂纹,导致叶片抗疲劳性能降低,从而改变叶片的振动特性,削弱叶片强度,使叶片的汽动性能恶化。这种恶化体现在缩小叶片局部截面面积,改变原有的动力学线型,增加表面粗糙度,严重降低末级叶片的运行效率。汽轮机末级叶片的动能转化占据整体机组的很大比例,是机组运行热经济性的关键部位。一旦发生叶片失效,严重时会引起汽轮机发电机组强烈振动等巨大事故。传统修复方式需将叶片运输至特定场所进行修复,因叶片体积大、质量重,在运送途中带来诸如磕碰、安全性和运输成本等问题。
有鉴于此,汽轮机叶片手持式增材修复工艺方法对汽轮机叶片修复意义重大,有必要对汽轮机叶片手持式增材修复工艺方法进行针对性地研究,从而评估机组运行的安全性与可靠性。目前,现有的汽轮机叶片修复方式,例如中国专利文献公开:“一种用于汽轮机末级叶片损伤件的振动熔覆修复工艺”(公开号:CN108505035A,公开日:2008年09月08日)、“一种汽轮机叶片水蚀损坏再制造方法(超音速火焰喷涂)”(公开号:CN109653803A,公开日:2019年04月19日)、汽轮机汽蚀叶片的激光原位修复方法(公开号:CN101073858A,公开日:2007年11月21日)等以上修复方式需要多台设备综合调控,其体积和重量限制使得现场修复很难成为现实。而将汽轮机叶片送到实验室修复会因叶片体积大、质量重,在运送途中带来诸如磕碰、安全性和运输成本等问题。
发明内容
针对汽轮机叶片的局部缺损,克服现有修复手段的上述缺点,本发明开发一套包括手持激光设备,送丝***的手持式激光叶片修复方法。
本发明的技术方案如下:
一种汽轮机叶片手持式增材修复工艺方法,所述方法包括如下步骤:
(1)对待修复的汽轮机叶片进行固定,调试安装好手持激光设备和超声送丝设备;
所述汽轮机叶片的材质例如为17-4PH;
(2)手持激光设备与超声送丝设备手动同步操作,调整保持送丝速度与手持激光扫描速度一致为1~3mm/s,激光功率选为1000~1200w,采用脉冲形式,脉宽20ns,脉冲波长为1070±10nm;
优选熔覆送丝材料为钴基合金;
优选手持激光设备为光纤激光器;
(3)启动手持激光设备的激光光源,激光脉冲能量作用于待修复叶片表面产生局部高温,使激光聚焦产生的激光光斑内的焊丝与局部修复区域液化形成熔池,填充轨迹每一层交叉60°角抵消应力,而后凝固对损伤区进行无缺陷修复。
本发明实施汽轮机叶片手持式增材修复工艺方法的装置包括:超声送丝设备、手持激光设备,所述超声送丝设备包括送丝头,且送丝头上固定连接有振动装置。
本发明的有益效果主要表现在:
本发明为解决汽轮机叶片缺损问题,结合手持激光和自动送丝装置提出一种现场修复的方法,该方式与返厂修复相比,其耗时少、成本低、修复效果好且具有广泛的应用前景,是一项蕴藏着巨大经济效益和社会效益的叶片损伤修复方法。
附图说明
图1是本发明装置示意图;
1-超声送丝设备、2-手持激光设备、3-超声送丝设备送丝头、4-振动装置、5-待修复叶片。
具体实施方式
下面结合附图通过具体实施例对本发明作进一步描述,但本发明的保护范围并不仅限于此。
本发明实施汽轮机叶片手持式增材修复工艺方法的装置包括:超声送丝设备1、手持激光设备2,所述超声送丝设备1包括送丝头3,且送丝头3上固定连接有振动装置4。
实施例1
一种手持式激光叶片修复方法,包括如下步骤:
(1)对所需修复的叶片5进行固定,调试安装好手持激光2和超声送丝3设备。
(2)调整保持送丝速度与手持激光扫描速度一致为1mm/s~3mm/s,激光功率选为1000w~1200w。采用脉冲形式,脉宽20ns,脉冲波长为1070±10nm。
选用的熔覆材料为钴基合金。
选用的手持激光设备为光纤激光器。
(3)启动手持激光2设备的激光光源和振动装置4的开关,激光脉冲能量作用于待修复叶片表面,从而产生局部高温,使所述激光聚焦产生的激光光斑内的焊丝与局部修复区域液化,形成熔池,填充轨迹每一层交叉60°角而抵消应力而后凝固对损伤区进行无缺陷修复。
实施本发明方法的设备包括振动***、送丝***、激光***。
所述振动装置4与送丝头3固定连接,手持振动装置对送丝头进行振动,提高激光加工效果。
所述手持激光2与送丝头3之间的手动同步操作,保证加工的高效与效果。
本说明书实施例所述的内容仅仅是对发明构思的实现形式的列举,本发明的保护范围不应当被视为仅限于实施例所陈述的具体形式,本发明的保护范围也包括本领域技术人员根据本发明构思所能够想到的等同技术手段。

Claims (5)

1.一种汽轮机叶片手持式增材修复工艺方法,其特征在于,所述方法包括如下步骤:
(1)对待修复的汽轮机叶片进行固定,调试安装好手持激光设备和超声送丝设备;
(2)手持激光设备与超声送丝设备手动同步操作,调整保持送丝速度与手持激光扫描速度一致为1~3mm/s,激光功率选为1000~1200w,采用脉冲形式,脉宽20ns,脉冲波长为1070±10nm;
(3)启动手持激光设备的激光光源,激光脉冲能量作用于待修复叶片表面产生局部高温,使激光聚焦产生的激光光斑内的焊丝与局部修复区域液化形成熔池,填充轨迹每一层交叉60°角抵消应力,而后凝固对损伤区进行无缺陷修复。
2.如权利要求1所述汽轮机叶片手持式增材修复工艺方法,其特征在于,步骤(1)中,所述汽轮机叶片的材质为17-4PH。
3.如权利要求1所述汽轮机叶片手持式增材修复工艺方法,其特征在于,步骤(2)中,熔覆送丝材料为钴基合金。
4.如权利要求1所述汽轮机叶片手持式增材修复工艺方法,其特征在于,步骤(2)中,手持激光设备为光纤激光器。
5.实施如权利要求1所述汽轮机叶片手持式增材修复工艺方法的装置,其特征在于,所述装置包括:超声送丝设备、手持激光设备,所述超声送丝设备包括送丝头,且送丝头上固定连接有振动装置。
CN202011458815.6A 2020-12-11 2020-12-11 汽轮机叶片手持式增材修复工艺方法 Pending CN112692293A (zh)

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Application publication date: 20210423