小模数齿轮激光熔覆修复工艺试验研究
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摘要
本文研究了激光熔覆技术在小模数斜齿轮修复中的应用。小模数齿轮激光熔覆易产生齿面干涉、齿面裂纹、齿顶塌陷等现象。试验结果表明,合理选择光斑尺寸、扫描位置、扫描方法、工艺参数和熔覆顺序有助于获得平整光滑、齿面无裂纹、齿槽无凹陷、齿顶无塌陷的熔覆层。
针对齿面熔覆时易出现裂纹的问题,设计了几种不同的熔覆方案,进行了几种不同方案的熔覆试验,最后确定了齿面熔覆的合理的工艺方法和工艺参数。齿面熔覆时对激光束与齿面的相对位置要求较高,否则易造成干涉,试验中通过合理的位置设计及选择适当的光斑大小解决了此问题。
针对齿顶熔覆时易发生塌陷的问题,试验了多种不同的方案。提出了采用激光预置粉末的方法,即通过使用较低的激光能量密度预先扫描,使小部分粉末能熔化或呈微熔状态,依靠这部分粉末使大量的粉末粘结成团附着在齿顶表面,然后进行正式的激光熔覆,试验发现此工艺能解决齿顶塌陷问题。
在进行整个轮齿及完整齿轮的熔覆中,面临的主要问题是热量的积累及热量的分布不均匀。在连续扫描过程中,热量的积累会造成后续熔覆时熔池保存时间长,从而造成熔体的流动,即材料的转移;热量分布的不均匀,会造成整个齿轮发生不均匀的变形。通过采用合理的扫描顺序及分齿方法等解决了遇到的热量积累及热量分布问题。
It has been researched that laser cladding is appied to the repairing of a close-toothed helical gear in this paper. Laser cladding for a close-toothed gear often meets such problems as the interference between the laser beam and the adjacent tooth flank, the crackings produced on the tooth flank coating,the caved tooth slot and the collapsed tooth tip. The experimental study shows that the smooth, non-cracking,non-caving,non-collapsing coating on the gear tooth can be obtained by the intelligent selection of the beam size, the beam positioning,the scanning technique,the technological parameters and the cladding procedure.
For the cracking problem on the tooth flank coating, various coating methods are designed and experienced. Finally reseanable process method and parameter are confirmed. When cladding the tooth flank, the relative position between the laser spot and tooth flank is demanded severely, otherwise it is easy that the interference occurs, in the experiment the problem above is resolved through designing the rational relative position and selecting the appropriate spot size.
For collapsing problem on the tooth tip coating, various experiment methods have been carried on. The method of depositing the powder in advance through the laser is proposed, that is, scanning in advance through the lower energy density laser enables the small partial powder to melt or to melt slightly, so that relying on the partial melting a large amounts of powder are felt and joined together into a mass attaching to the surface of tooth tip, then the formal cladding is carried on. Experiment indicates that the collapsing problem can be solved by the process above.
During cladding the whole tooth and entire gear, the main problems faced with are the accumulation of heat and the uneven distribution of heat. In continuous scanning process, the thermal accumulation will cause the cladding pool preserve long time during the subsequent scanning, thereby causing the melt flowing, that is, the material is transferred. Uneven distribution of the heat will cause the entire gear uneven deformation. Through utilizing the reasonable scanning sequence and interval number of tooth, the problems of the thermal accumulation and distribution are solved.
针对齿面熔覆时易出现裂纹的问题,设计了几种不同的熔覆方案,进行了几种不同方案的熔覆试验,最后确定了齿面熔覆的合理的工艺方法和工艺参数。齿面熔覆时对激光束与齿面的相对位置要求较高,否则易造成干涉,试验中通过合理的位置设计及选择适当的光斑大小解决了此问题。
针对齿顶熔覆时易发生塌陷的问题,试验了多种不同的方案。提出了采用激光预置粉末的方法,即通过使用较低的激光能量密度预先扫描,使小部分粉末能熔化或呈微熔状态,依靠这部分粉末使大量的粉末粘结成团附着在齿顶表面,然后进行正式的激光熔覆,试验发现此工艺能解决齿顶塌陷问题。
在进行整个轮齿及完整齿轮的熔覆中,面临的主要问题是热量的积累及热量的分布不均匀。在连续扫描过程中,热量的积累会造成后续熔覆时熔池保存时间长,从而造成熔体的流动,即材料的转移;热量分布的不均匀,会造成整个齿轮发生不均匀的变形。通过采用合理的扫描顺序及分齿方法等解决了遇到的热量积累及热量分布问题。
It has been researched that laser cladding is appied to the repairing of a close-toothed helical gear in this paper. Laser cladding for a close-toothed gear often meets such problems as the interference between the laser beam and the adjacent tooth flank, the crackings produced on the tooth flank coating,the caved tooth slot and the collapsed tooth tip. The experimental study shows that the smooth, non-cracking,non-caving,non-collapsing coating on the gear tooth can be obtained by the intelligent selection of the beam size, the beam positioning,the scanning technique,the technological parameters and the cladding procedure.
For the cracking problem on the tooth flank coating, various coating methods are designed and experienced. Finally reseanable process method and parameter are confirmed. When cladding the tooth flank, the relative position between the laser spot and tooth flank is demanded severely, otherwise it is easy that the interference occurs, in the experiment the problem above is resolved through designing the rational relative position and selecting the appropriate spot size.
For collapsing problem on the tooth tip coating, various experiment methods have been carried on. The method of depositing the powder in advance through the laser is proposed, that is, scanning in advance through the lower energy density laser enables the small partial powder to melt or to melt slightly, so that relying on the partial melting a large amounts of powder are felt and joined together into a mass attaching to the surface of tooth tip, then the formal cladding is carried on. Experiment indicates that the collapsing problem can be solved by the process above.
During cladding the whole tooth and entire gear, the main problems faced with are the accumulation of heat and the uneven distribution of heat. In continuous scanning process, the thermal accumulation will cause the cladding pool preserve long time during the subsequent scanning, thereby causing the melt flowing, that is, the material is transferred. Uneven distribution of the heat will cause the entire gear uneven deformation. Through utilizing the reasonable scanning sequence and interval number of tooth, the problems of the thermal accumulation and distribution are solved.
引文
[1]徐积仁.光与高科技.激光学会会刊,1999,1(4);9～11
[2]江海河.激光加工技术应用的发展及展望.光电子技术与信息,2001,14(4);1～12
[3]Wolfgang Schulz,Reinhart Poprawe.Manufacturing with novel high power diode lasers.IEEEjournal of selected topics in quantum electronics,2000,4(6);696～705
[4]冯志刚.激光熔覆层质量控制研究.激光杂志,1995,16(3);118
[5]张永康.激光加工技术.2004,第一版;193
[6]郎娟,邢志华,朱起云.激光表面改性技术在工业中的应用.中国设备工程,2003(8);17～18
[7]张永康.激光加工技术.北京;化学工业出版社,2004
[8]孙晓辉.激光熔覆技术在零件修复上的应用.机械工人(热加工),2003(11);30～31
[9]Steen W M,Laser Surface Cladding.Laser Surface Treatment of Metals,1988;369～387
[10]张魁武.激光加工技术担重任.世界制造技术与装备市场,1993(3);15～18
[11]张国顺.现代激光制造技术.北京;化学工业出版社,2006
[12]曾人文,谢长生.激光熔覆温度场和流场数值模拟研究现状和发展趋势.材料科学与工程,1997,15(4);1
[13]张庆茂,刘喜明.送粉激光熔覆覆盖率的理论分析.钢铁研究学报,2002,23(3);50～53
[14]杨洗陈,李延民,黄卫东等.激光表面熔凝温度场计算.材料科学与工程,1999,17(1);21
[15]曾大文,谢长生.激光熔覆熔池二维准稳态流场及温度场的数值模拟.金属学报,1999,35(6);604
[16]Gitzofer F.Advanced in Thermal Sprazing.11th Int.Thermal Spraying Conf.Montreal,Pergamon,Torronto,1986;269～275
[17]张永康.激光加工技术.2004,第一版;201～203
[18]Pelletier J M,Hidouci A.Microstructure and mechanical properties of MnSi_2 coatings produced by laser processing.Materials Science & Engineering,1998,252(1);17～26
[19]刘喜明,关振中.送粉式激光熔覆获得最佳熔覆层的必要条件及其影响因素.中国激光,1999,26(5);470～476.
[20]张庆茂,钟敏霖,杨森,等.宽带送粉激光熔覆稀释率的控制.金属热处理,2001,26(8);20～23.
[21]Sircar S,Chattopadhyay K,Mazumder J.Metall.Trans.A.1992(23A);2419～2429
[22]张亚平等.材料工程,1993(2);30～31
[23]裴宇韬等.激光熔覆Zr02/Ni合金复合涂层的凝固组织与分层机制.中国激光,1996(3);265
[24]Haude R.Development of laser cladding using paste bonded coatings.ECALEO,1993;875
[25]Abboud J H.Functionally graded Ni-A1 and Fe-A1 coatings producted via laser cladding.Mater.Sci.,1995(30);5931
[26]沈以赴,余百运,冯钟潮等.稀土材料在激光熔履中的分布及其对耐蚀性能的影响[J].材料研究学报,1998,12(5).
[27]石世宏,傅戈雁.不锈钢表面激光熔覆层耐磨蚀性能研究[J].金属热处理,1999(3);14～16
[28]石世宏,王新林.激光熔覆化工阀门密封面的实验研究[J].激光技术,1998,22(6)
[29]裴宇韬.激光熔覆TiCp/Ni合金自生梯度涂层及其自生机[J].金属学报,1998,34(9)
[30]张亚平,高家成,文静.钛合金表面激光熔覆一步制备复合生物陶瓷涂层[[J].材料研究学报,1998,12(4)
[31]邓琦林,胡德金.激光熔覆快速成型致密金属零件的试验研究.金属热处理,2003,28(2);32～37
[32]张三川.激光熔覆进展与熔覆合金设计[J].激光技术,2002,2(3);205～207
[33]石世宏.激光涂层组织在低应力多冲载荷下的演变[J]
[34]宋光明,吴钢,黄婉娟.单向送粉双向扫描激光熔覆工艺防止裂纹的试验研究.金属热处理,2005,30(5);26～28
[35]张国顺.现代激光制造技术.北京;化学工业出版社,2006;184
[36]张永康.激光加工技术.2004,第一版;199
[37]张鲁松.冶金重载齿轮的修复技术[J].湖南冶金,2004,32(1);42
[38]Hidouci A,Pelletier J M.Microstructure and mechanical properties of MnSi2 coatings produced by laser processing.Materials Science & Engineering,1998,252(1);17～26
[39]张庆茂,钟敏霖,杨森,等.宽带送粉激光熔覆稀释率的控制.金属热处理,2001,26(8);20～23.
[40]宋光明,戴忠森.齿轮激光淬火轴向扫描分齿工艺.上海海运学院学报,1993(4);38～47
[41]朱晓东,莫之民,韩睿师等.激光表面涂覆进展.金属热处理,1994(6);6～8
[42]钟敏霖,刘文今.45kW高功率CO_2激光熔覆过程中裂纹行为的实验研究.应用激光,1999(10);193～200
[43]Hu C,Xin H,Baker T M.Formation of continuous surface A1-SiCp,metal matrix composite by overlapping laser tracks on AA6061 alloy.Materials Science and Technology,1996(12);227～232
[44]Shi G,Liu J,Ding Pet al.Microstructure and hardness distribution of laser surface overlap coating layer.Materials Science and Technology,1998(14);80～84
[45]翁铸,伍丽峰,陆文雄.激光熔覆与合金化层的缺陷产生及其防止.激光与光电子学进展,2003,40(10);58～59
[46]曾晓雁,朱蓓蒂,陶曾毅,等.激光工艺参数对熔覆层宏观质量的影响.金属热处理,1993(7);23～28
[47]张光均.激光热处理的现状及发展.金属热处理,2000(1);6～11
[48]Wu Yunjian,Patchett B M,Bicknell C.Interfacial microstructure of weld overlay of corrosion resistant alloys.Scripts Metallurgica et Materialia,1994,30(9);1133～1138
[2]江海河.激光加工技术应用的发展及展望.光电子技术与信息,2001,14(4);1～12
[3]Wolfgang Schulz,Reinhart Poprawe.Manufacturing with novel high power diode lasers.IEEEjournal of selected topics in quantum electronics,2000,4(6);696～705
[4]冯志刚.激光熔覆层质量控制研究.激光杂志,1995,16(3);118
[5]张永康.激光加工技术.2004,第一版;193
[6]郎娟,邢志华,朱起云.激光表面改性技术在工业中的应用.中国设备工程,2003(8);17～18
[7]张永康.激光加工技术.北京;化学工业出版社,2004
[8]孙晓辉.激光熔覆技术在零件修复上的应用.机械工人(热加工),2003(11);30～31
[9]Steen W M,Laser Surface Cladding.Laser Surface Treatment of Metals,1988;369～387
[10]张魁武.激光加工技术担重任.世界制造技术与装备市场,1993(3);15～18
[11]张国顺.现代激光制造技术.北京;化学工业出版社,2006
[12]曾人文,谢长生.激光熔覆温度场和流场数值模拟研究现状和发展趋势.材料科学与工程,1997,15(4);1
[13]张庆茂,刘喜明.送粉激光熔覆覆盖率的理论分析.钢铁研究学报,2002,23(3);50～53
[14]杨洗陈,李延民,黄卫东等.激光表面熔凝温度场计算.材料科学与工程,1999,17(1);21
[15]曾大文,谢长生.激光熔覆熔池二维准稳态流场及温度场的数值模拟.金属学报,1999,35(6);604
[16]Gitzofer F.Advanced in Thermal Sprazing.11th Int.Thermal Spraying Conf.Montreal,Pergamon,Torronto,1986;269～275
[17]张永康.激光加工技术.2004,第一版;201～203
[18]Pelletier J M,Hidouci A.Microstructure and mechanical properties of MnSi_2 coatings produced by laser processing.Materials Science & Engineering,1998,252(1);17～26
[19]刘喜明,关振中.送粉式激光熔覆获得最佳熔覆层的必要条件及其影响因素.中国激光,1999,26(5);470～476.
[20]张庆茂,钟敏霖,杨森,等.宽带送粉激光熔覆稀释率的控制.金属热处理,2001,26(8);20～23.
[21]Sircar S,Chattopadhyay K,Mazumder J.Metall.Trans.A.1992(23A);2419～2429
[22]张亚平等.材料工程,1993(2);30～31
[23]裴宇韬等.激光熔覆Zr02/Ni合金复合涂层的凝固组织与分层机制.中国激光,1996(3);265
[24]Haude R.Development of laser cladding using paste bonded coatings.ECALEO,1993;875
[25]Abboud J H.Functionally graded Ni-A1 and Fe-A1 coatings producted via laser cladding.Mater.Sci.,1995(30);5931
[26]沈以赴,余百运,冯钟潮等.稀土材料在激光熔履中的分布及其对耐蚀性能的影响[J].材料研究学报,1998,12(5).
[27]石世宏,傅戈雁.不锈钢表面激光熔覆层耐磨蚀性能研究[J].金属热处理,1999(3);14～16
[28]石世宏,王新林.激光熔覆化工阀门密封面的实验研究[J].激光技术,1998,22(6)
[29]裴宇韬.激光熔覆TiCp/Ni合金自生梯度涂层及其自生机[J].金属学报,1998,34(9)
[30]张亚平,高家成,文静.钛合金表面激光熔覆一步制备复合生物陶瓷涂层[[J].材料研究学报,1998,12(4)
[31]邓琦林,胡德金.激光熔覆快速成型致密金属零件的试验研究.金属热处理,2003,28(2);32～37
[32]张三川.激光熔覆进展与熔覆合金设计[J].激光技术,2002,2(3);205～207
[33]石世宏.激光涂层组织在低应力多冲载荷下的演变[J]
[34]宋光明,吴钢,黄婉娟.单向送粉双向扫描激光熔覆工艺防止裂纹的试验研究.金属热处理,2005,30(5);26～28
[35]张国顺.现代激光制造技术.北京;化学工业出版社,2006;184
[36]张永康.激光加工技术.2004,第一版;199
[37]张鲁松.冶金重载齿轮的修复技术[J].湖南冶金,2004,32(1);42
[38]Hidouci A,Pelletier J M.Microstructure and mechanical properties of MnSi2 coatings produced by laser processing.Materials Science & Engineering,1998,252(1);17～26
[39]张庆茂,钟敏霖,杨森,等.宽带送粉激光熔覆稀释率的控制.金属热处理,2001,26(8);20～23.
[40]宋光明,戴忠森.齿轮激光淬火轴向扫描分齿工艺.上海海运学院学报,1993(4);38～47
[41]朱晓东,莫之民,韩睿师等.激光表面涂覆进展.金属热处理,1994(6);6～8
[42]钟敏霖,刘文今.45kW高功率CO_2激光熔覆过程中裂纹行为的实验研究.应用激光,1999(10);193～200
[43]Hu C,Xin H,Baker T M.Formation of continuous surface A1-SiCp,metal matrix composite by overlapping laser tracks on AA6061 alloy.Materials Science and Technology,1996(12);227～232
[44]Shi G,Liu J,Ding Pet al.Microstructure and hardness distribution of laser surface overlap coating layer.Materials Science and Technology,1998(14);80～84
[45]翁铸,伍丽峰,陆文雄.激光熔覆与合金化层的缺陷产生及其防止.激光与光电子学进展,2003,40(10);58～59
[46]曾晓雁,朱蓓蒂,陶曾毅,等.激光工艺参数对熔覆层宏观质量的影响.金属热处理,1993(7);23～28
[47]张光均.激光热处理的现状及发展.金属热处理,2000(1);6～11
[48]Wu Yunjian,Patchett B M,Bicknell C.Interfacial microstructure of weld overlay of corrosion resistant alloys.Scripts Metallurgica et Materialia,1994,30(9);1133～1138