CN113001098A - Electric spark deposition-ultrasonic rolling composite repairing method for surface damage of metal part - Google Patents
Electric spark deposition-ultrasonic rolling composite repairing method for surface damage of metal part Download PDFInfo
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- CN113001098A CN113001098A CN202110236813.0A CN202110236813A CN113001098A CN 113001098 A CN113001098 A CN 113001098A CN 202110236813 A CN202110236813 A CN 202110236813A CN 113001098 A CN113001098 A CN 113001098A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H5/00—Combined machining
- B23H5/06—Electrochemical machining combined with mechanical working, e.g. grinding or honing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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Abstract
The invention provides a metal part surface damage electric spark deposition-ultrasonic rolling composite repairing method, which comprises the following steps: s1, finishing and purifying; s2, electric spark deposition repairing; s3, finishing the repairing layer; and S4, ultrasonic surface rolling treatment is carried out, and the repair of the metal part is completed. The invention utilizes the ultrasonic surface rolling treatment process on the basis of the electric spark deposition repair, and the reciprocating rolling and the circulating impact action of the ultrasonic rolling tool on the repair layer can cause the repair layer to generate plastic deformation, thereby improving the density of the repair layer, reducing the roughness of the surface of the repair layer, releasing the residual tensile stress of the repair layer, presetting the residual compressive stress and strengthening the performance of the repair layer.
Description
Technical Field
The invention relates to the technical field of metal part surface additive repair, in particular to a metal part surface damage electric spark deposition-ultrasonic rolling composite repair method.
Background
The metal parts are affected by corrosion, abrasion, scraping and the like in the service process, the surfaces of the metal parts lose effectiveness, internal materials are not damaged, and if the whole parts are scrapped, great resource waste is caused. The metal part additive repair is concerned more and more widely, and the common metal part additive repair methods include: electric spark deposition, laser cladding, spraying, surfacing and coating.
The electric spark deposition technology is widely applied to the fields of mechanical industry, ocean engineering, die industry, petroleum and mineral exploitation and the like due to the characteristics of portability, easy operation, good binding force between a repair layer and a parent metal and small heat input. The electric spark deposition technology utilizes heat generated by pulse discharge to melt the electrode rod and the base material, so that the electrode rod material is cladded on the surface of the base material, and the effect of part repair is achieved. Because the pulse discharge position is uncontrollable in the pulse deposition process and the deposition point material is not uniformly distributed, the surface of the deposited repairing layer is rough, and a hole defect is formed in the repairing layer. The electric spark deposition repairing is a hot working process, materials are rapidly melted and solidified, the repairing layer is subjected to the action of repeated cyclic heating influence, and the repairing layer is in a residual tensile stress state, so that cracks are easy to grow and expand in the service process. Therefore, conventional spark-erosion repair is less effective and often cannot be used to repair critical and critical parts.
Disclosure of Invention
The invention provides a composite material increase and decrease repairing method of electric spark deposition and ultrasonic rolling, aiming at the characteristics of low density, residual tensile stress state and rough surface of an electric spark deposition repairing layer. Ultrasonic rolling treatment is based on traditional rolling treatment, and an ultrasonic system is used for enabling a rolling ball or a rolling column to vibrate at high frequency, so that ultrasonic impact is applied to materials during rolling. Researches show that the ultrasonic rolling treatment can play a role in well reducing the surface roughness, improving the surface hardness and presetting the residual pressure stress. The method combining the electric spark deposition technology and the ultrasonic rolling treatment can realize good part repairing effect, and the repaired part can recover and even exceed the original performance. The invention utilizes the ultrasonic surface rolling treatment process, and the repairing layer generates plastic deformation through the reciprocating rolling and the circulating impact action of the ultrasonic rolling tool on the repairing layer, thereby improving the density of the repairing layer, reducing the roughness of the surface of the repairing layer, releasing the residual tensile stress of the repairing layer, presetting the residual compressive stress and strengthening the performance of the repairing layer.
The technical means adopted by the invention are as follows:
an electric spark deposition-ultrasonic rolling composite repairing method for surface damage of a metal part comprises the following steps:
s1, finishing and purifying:
the method comprises the steps of polishing and purifying the damaged part of the surface of the metal part, removing the material of the damaged part, cleaning and purifying the surface, enabling the damaged part to be regular in shape and smooth in surface, and enabling the damaged part to be in a plane or a cambered surface. The cleaning and purifying comprises purifying oxidation and corrosion products on the damaged surface and oil stains and dust attached to the surface. And the surface roughness of the damaged part after the polishing and purification treatment is less than or equal to Ra6.3. The finishing can be in the form of machining or manual grinding.
S2, electric spark deposition repair:
performing additive repairing on the damaged part by adopting an electric spark deposition technology to obtain a repairing layer, and reserving machining allowance according to actual working conditions; the machining allowance is larger than the removal amount in the repair layer finishing treatment hereinafter. The electric spark deposition technology comprises an electric spark deposition overlaying repair method for small-volume damaged parts and a cold welding repair method for large-volume damaged parts; the electric spark deposition overlaying repair method and the cold welding repair method both utilize high temperature generated by pulse discharge to melt an electrode and a base metal, and electrode materials are coated on a damaged part, wherein the electric spark deposition overlaying repair method is high-frequency low-power discharge, and the cold welding repair method is low-frequency high-power discharge;
s3, finishing the repair layer:
polishing the surface of the repairing layer, removing the rough surface of the repairing layer, and enabling the metal part after the polishing treatment to recover the shape and size requirements of the original part; the finishing can be in the form of machining or manual grinding.
S4, ultrasonic surface rolling treatment:
and (4) performing strengthening treatment on the polished repairing layer by adopting an ultrasonic surface rolling technology to finish the repairing of the metal part. During ultrasonic surface rolling treatment, the ultrasonic surface rolling cutter performs reciprocating vibration along the direction vertical to the surface of the repairing layer while performing reciprocating rolling motion on the surface of the repairing layer. And carrying out automatic ultrasonic surface rolling treatment by adopting a machining center or a milling machine or carrying out ultrasonic surface rolling treatment in a handheld mode. If the parts and the ultrasonic rolling tool are installed and fixed on a machine tool, the air pressure of the ultrasonic rolling tool, the feed line and the feed speed of the machine tool are set, the ultrasonic generator is started, the vibration frequency and the amplitude are adjusted, the numerical control machine is started, and the ultrasonic rolling tool is controlled to carry out ultrasonic rolling treatment on the repairing layer. And cooling and lubricating are carried out continuously during the ultrasonic rolling treatment. The cooling and lubricating mode is to inject cooling and lubricating liquid into the processing area through a filtering and circulating system, and the preferred cooling and lubricating liquid is kerosene.
Compared with the prior art, the invention has the following advantages:
1. the method can effectively prepare the repairing layer with high hardness, a compressive stress state and excellent wear resistance.
2. The density of the repairing layer can be improved through ultrasonic rolling treatment, and hole defects in the repairing layer are healed after the ultrasonic rolling treatment, so that the possibility of breakage and falling of the repairing layer is reduced.
3. The repairing layer is subjected to plastic deformation by repeated impact and reciprocating extrusion action of the rolling head on the repairing layer, so that the effect of work hardening is achieved, and the hardness of the repairing layer is improved. Meanwhile, the repairing layer is subjected to grain fiberization and fragmentation under the action of impact and extrusion, so that the grain refining effect is achieved, and the hardness of the repairing layer is further improved. The dual hardness-enhancing effect enhances the wear resistance of the repair layer.
4. The surface rolling is combined with the action of ultrasonic vibration impact, so that the repairing layer is subjected to uniform plastic deformation, the original residual tensile stress of the repairing layer is released, and uniform compressive stress is preset in the repairing layer, so that the fatigue resistance of the repairing layer is improved.
Based on the reason, the invention can be widely popularized in the fields of metal additive repair and the like.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a schematic view showing the principle of ultrasonic rolling treatment in example 2 of the present invention.
FIG. 2 is an SEM image of the internal cross section of a metal part after repair in example 1 of the present invention.
FIG. 3 is a SEM image of a surface cross section of a repaired metal part in example 1 of the present invention.
FIG. 4 is an SEM image of the internal cross section of a repaired metal part in example 2 of the present invention.
FIG. 5 is a SEM image of a surface cross section of a repaired metal part in example 2 of the present invention.
FIG. 6 is a cross-sectional microhardness distribution comparison of the metal part of example 1 after repair and the metal part of example 2 after repair.
Detailed Description
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
The relative arrangement of the components and steps, the numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present invention unless specifically stated otherwise. Meanwhile, it should be understood that the sizes of the respective portions shown in the drawings are not drawn in an actual proportional relationship for the convenience of description. Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail but are intended to be part of the specification where appropriate. Any specific values in all examples shown and discussed herein are to be construed as exemplary only and not as limiting. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, further discussion thereof is not required in subsequent figures.
In the description of the present invention, it is to be understood that the orientation or positional relationship indicated by the directional terms such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal" and "top, bottom", etc., are generally based on the orientation or positional relationship shown in the drawings, and are used for convenience of description and simplicity of description only, and in the absence of any contrary indication, these directional terms are not intended to indicate and imply that the device or element so referred to must have a particular orientation or be constructed and operated in a particular orientation, and therefore should not be considered as limiting the scope of the present invention: the terms "inner and outer" refer to the inner and outer relative to the profile of the respective component itself.
Spatially relative terms, such as "above … …," "above … …," "above … …," "above," and the like, may be used herein for ease of description to describe one device or feature's spatial relationship to another device or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is turned over, devices described as "above" or "on" other devices or configurations would then be oriented "below" or "under" the other devices or configurations. Thus, the exemplary term "above … …" can include both an orientation of "above … …" and "below … …". The device may be otherwise variously oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
It should be noted that the terms "first", "second", and the like are used to define the components, and are only used for convenience of distinguishing the corresponding components, and the terms have no special meanings unless otherwise stated, and therefore, the scope of the present invention should not be construed as being limited.
The invention discloses a metal part surface damage electric spark deposition-ultrasonic rolling composite repairing method, which comprises the following steps:
s1, finishing and purifying:
the method comprises the steps of polishing and purifying the damaged part of the surface of the metal part, removing the material of the damaged part, cleaning and purifying the surface, enabling the damaged part to be regular in shape and smooth in surface, and enabling the damaged part to be in a plane or a cambered surface. The cleaning and purifying comprises purifying oxidation and corrosion products on the damaged surface and oil stains and dust attached to the surface. And the surface roughness of the damaged part after the polishing and purification treatment is less than or equal to Ra6.3. The finishing can be in the form of machining or manual grinding.
S2, electric spark deposition repair:
performing additive repairing on the damaged part by adopting an electric spark deposition technology to obtain a repairing layer, and reserving machining allowance according to actual working conditions; the machining allowance is larger than the removal amount in the repair layer finishing treatment hereinafter. The electric spark deposition technology comprises an electric spark deposition overlaying repair method for small-volume damaged parts and a cold welding repair method for large-volume damaged parts; the electric spark deposition overlaying repair method and the cold welding repair method both utilize high temperature generated by pulse discharge to melt an electrode and a base metal, and electrode materials are coated on a damaged part, wherein the electric spark deposition overlaying repair method is high-frequency low-power discharge, and the cold welding repair method is low-frequency high-power discharge;
s3, finishing the repair layer:
polishing the surface of the repairing layer, removing the rough surface of the repairing layer, and enabling the metal part after the polishing treatment to recover the shape and size requirements of the original part; the finishing can be in the form of machining or manual grinding.
S4, ultrasonic surface rolling treatment:
and (4) performing strengthening treatment on the polished repairing layer by adopting an ultrasonic surface rolling technology to finish the repairing of the metal part. During ultrasonic surface rolling treatment, the ultrasonic surface rolling cutter performs reciprocating vibration along the direction vertical to the surface of the repairing layer while performing reciprocating rolling motion on the surface of the repairing layer. And carrying out automatic ultrasonic surface rolling treatment by adopting a machining center or a milling machine or carrying out ultrasonic surface rolling treatment in a handheld mode. If the parts and the ultrasonic rolling tool are installed and fixed on a machine tool, the air pressure of the ultrasonic rolling tool, the feed line and the feed speed of the machine tool are set, the ultrasonic generator is started, the vibration frequency and the amplitude are adjusted, the numerical control machine is started, and the ultrasonic rolling tool is controlled to carry out ultrasonic rolling treatment on the repairing layer. And cooling and lubricating are carried out continuously during the ultrasonic rolling treatment. The cooling and lubricating mode is to inject cooling and lubricating liquid into the processing area through a filtering and circulating system, and the preferred cooling and lubricating liquid is kerosene.
The metal parts and the materials to be deposited selected in the following examples are all national standard QAL9-4 aluminum bronze, and the main chemical components are Cu, Al and Fe.
The metal part is a rectangular parallelepiped block 2 cut to 20 × 20 × 5 mm.
The used electric spark deposition repairing equipment is an SZ-8100 electric spark deposition repairing machine produced by Shanghai Sheng Jiang electromechanical equipment Limited.
In order to highlight the advantages of the present invention, the following comparative experiment was conducted, example 1 being an experiment in which ultrasonic rolling treatment of the surface of the repair layer was not conducted, and example 2 being an experiment in which ultrasonic rolling treatment of the surface of the repair layer was conducted.
Example 1
As shown in fig. 2, 3 and 6, the steps of the method for repairing the metal part by electric spark deposition are as follows:
s1, finishing and purifying:
before the repair layer is prepared, the prepared metal parts are subjected to finishing and purification treatment, and the surface to be repaired is mainly treated. And (3) polishing the surface to be repaired by using 200#, 400#, 600# and 800# sandpaper in sequence to remove the surface oxide layer and make the surface smooth. After sanding, the sand paper is washed with industrial alcohol to remove impurities that may be present.
S2 repairing by electric spark deposition
The sample was fixed using a jig and the repair layer was prepared using the process parameters shown in table 1. During the deposition process, the deposition tracks are preferably coated in the same direction in each deposition layer, and the deposition tracks are perpendicular to each other between two adjacent deposition layers.
TABLE 1 EDGE DEPOSITION PROCESS PARAMETERS
S3 repair layer finishing treatment
And (5) polishing the surface of the repair layer by using 200#, 600#, 1000#, and 1200# sandpaper in sequence. After polishing, the samples were cleaned with industrial alcohol.
Example 2
As shown in fig. 1, 4-6, the present embodiment is the same as steps S1, S2 and S3 of example 1 in a method for repairing damaged surfaces of metal parts by electrospark deposition-ultrasonic rolling, with the difference that the following step S4 is added.
S4, ultrasonic rolling treatment of the surface of the repair layer:
the metal part 2 is fixed by using flat tongs 4, and in order to ensure the installation and fastening of the metal part 2, the cushion block 3 is used for auxiliary installation. And (3) controlling an ultrasonic rolling system by using a numerical control machining center to process the surface of the repairing layer, wherein the rolling tool head 1 performs feed and feed along the direction parallel to the surface of the repairing layer on one hand, and performs ultrasonic frequency micro-amplitude vibration along the direction vertical to the surface of the repairing layer on the other hand, so as to obtain the repaired metal part. The process parameters are shown in table 2.
And (3) evaluating the effect:
by analyzing fig. 2 and 4, in example 2, compared with example 1, no obvious holes are seen inside the repair layer, and the repair layer has high density.
By analyzing fig. 3 and 5, the repair layer of example 2 has finer surface grains than example 1.
Example 2 sample modificationThe maximum microhardness of the composite layer reaches 346.3Hv0.05Compared with the sample repair layer which is not subjected to ultrasonic rolling treatment in the embodiment 1, the microhardness of the sample repair layer is improved by 31 percent.
The surface of the repair layer of the sample in the embodiment 2 is in a compressive stress state, and the average stress value is-298.8 MPa; the surface of the repair layer of the sample in the example 1 is in a tensile stress state, and the average stress value is 134.8 MPa.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.
Claims (10)
1. The electric spark deposition-ultrasonic rolling composite repairing method for surface damage of the metal part is characterized by comprising the following steps of:
s1, finishing and purifying:
the method comprises the following steps of (1) carrying out polishing and purification treatment on damaged parts on the surfaces of metal parts, removing materials of the damaged parts, cleaning and purifying the surfaces, and enabling the damaged parts to be regular in shape and smooth in surface;
s2, electric spark deposition repair:
performing additive repairing on the damaged part by adopting an electric spark deposition technology to obtain a repairing layer, and reserving machining allowance according to actual working conditions;
s3, finishing the repair layer:
polishing the surface of the repairing layer, removing the rough surface of the repairing layer, and enabling the metal part after the polishing treatment to recover the shape and size requirements of the original part;
s4, ultrasonic surface rolling treatment:
and (4) performing strengthening treatment on the polished repairing layer by adopting an ultrasonic surface rolling technology to finish the repairing of the metal part.
2. The electric spark deposition-ultrasonic rolling composite repairing method for the surface damage of the metal part as claimed in claim 1, wherein in the step S2, the electric spark deposition technology comprises an electric spark deposition overlaying repair method for a small-volume damaged part and a cold welding repair method for a large-volume damaged part.
3. The electric spark deposition-ultrasonic rolling composite repairing method for the surface damage of the metal part as claimed in claim 2, wherein the electric spark deposition overlaying repairing method and the cold welding repairing method both utilize high temperature generated by pulse discharge to melt an electrode and a base metal and coat an electrode material on a damaged part, the electric spark deposition overlaying repairing method is high-frequency low-power discharge, and the cold welding repairing method is low-frequency high-power discharge.
4. The method for repairing damaged surfaces of metal parts by electrospark deposition-ultrasonic rolling composite as claimed in claim 1, wherein in step S4, during ultrasonic surface rolling, the ultrasonic surface rolling tool performs reciprocating vibration in a direction perpendicular to the surface of the repair layer while performing reciprocating rolling motion on the surface of the repair layer.
5. The method for repairing damaged surfaces of metal parts by electrospark deposition-ultrasonic rolling composite as claimed in claim 1, wherein in step S4, a machining center or a milling machine is used for performing automatic ultrasonic surface rolling treatment or a handheld manner is used for performing ultrasonic surface rolling treatment.
6. The electric spark deposition-ultrasonic rolling composite repairing method for the surface damage of the metal part as claimed in claim 1, wherein the machining allowance is larger than the removal amount of the repairing layer by polishing treatment.
7. The method for repairing damaged portions of surfaces of metal parts by electrospark deposition-ultrasonic rolling composite as claimed in claim 1, wherein in step S1, the damaged portions are made to be flat or cambered surfaces.
8. The method for repairing damaged surfaces of metal parts by electrospark deposition-ultrasonic rolling composite as claimed in claim 1, wherein in said S1, said cleaning and cleaning includes cleaning the damaged surfaces from oxidation and rust products and from oil and dust attached to the surfaces.
9. The method for repairing damaged portions of surfaces of metal parts by electrospark deposition-ultrasonic rolling composite as claimed in claim 1, wherein in S1, the surface roughness of the damaged portions after finishing and cleaning treatment is less than or equal to ra 6.3.
10. The method for repairing damaged surface of metal part by electrospark deposition-ultrasonic rolling composite as claimed in claim 1, wherein in said step S1 and said step S3, said polishing method in polishing damaged portion of surface of metal part and polishing treatment of said repairing layer comprises machining or manual grinding.
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| CN114654164A (en) * | 2022-03-28 | 2022-06-24 | 航天材料及工艺研究所 | Electric spark deposition-cold pressure welding composite repairing method |
| CN114799747A (en) * | 2022-04-14 | 2022-07-29 | 无锡智能自控工程股份有限公司 | Composite manufacturing process for strengthening high-temperature wear resistance of valve shaft for valve |
| CN114897034A (en) * | 2022-07-14 | 2022-08-12 | 深圳市信润富联数字科技有限公司 | Stamping die supervision method, device, equipment and storage medium |
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| CN114799747A (en) * | 2022-04-14 | 2022-07-29 | 无锡智能自控工程股份有限公司 | Composite manufacturing process for strengthening high-temperature wear resistance of valve shaft for valve |
| CN114897034A (en) * | 2022-07-14 | 2022-08-12 | 深圳市信润富联数字科技有限公司 | Stamping die supervision method, device, equipment and storage medium |
| CN114897034B (en) * | 2022-07-14 | 2022-10-28 | 深圳市信润富联数字科技有限公司 | Stamping die supervision method, device, equipment and storage medium |
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