基于激光再制造的三维同轴送粉工作头研究
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摘要
激光再制造是一种以激光熔覆技术为核心的新兴绿色修复技术。它可以实现对重大零件的快速修复，降低成本，为企业参与市场竞争赢得时间。同轴送粉工作头是激光再制造系统的关键部件，涉及激光与材料相互作用许多基本问题，深入开展三维同轴送粉工作头的研究具有重要的理论意义和应用价值。
本文介绍了激光再制造技术的原理，综述了国内外研究发展现状。建立了粒子受热状态、光能分配模型和粉末流场浓度模型，对光粉相互作用进行了较深入的理论分析。综合机械设计的相关理论，设计出具有三维空间工作功能、粉末流束焦点可调的新型送粉工作头。首次结合数字粒子图像测速技术(DPIV)设计了对粉末流束的速度场和浓度场的试验方案，并实际检测了在不同工作状态下的粉末流束的速度场和浓度场。开展了送粉工作头的实际应用试验研究，利用研制的三维送粉工作头对导套零件和不锈钢板进行了大面积激光再制造的初步试验研究，取得了良好的效果。分析了工艺参数对粉末利用率、熔覆层质量等方面的影响。
试验表明同轴送粉工作头具有全方向性和和其粉末流束的焦点可调节特性。其主要技术参数如下：
聚焦方式： 透镜／反射聚焦
送粉方式： 载气式／非载气式
Φ轴转角： 0°—360°
Ψ轴转角： -60°—+60°
粉末利用率： 载气式≥30％，非载气式≥60％
Laser refabrication is a kind of new green reconstruction technology that based on laser cladding. It can be used to repair important weared parts rapidly, so it may bring the reducing production cost and saving working time. 3D coaxial feeding head is the most important and key part in laser refabrication. Many problems of interactions between laser and materials were involved in. It is significant and valuable to carry through the research of 3D coaxial feeding head deeply.
In this paper, technical principles of laser refabrication were introduced. Current states of development were summarized in China and other countries. Model of the heated particles, model of division of the laser energy and concentration of powder stream were presented. Interaction between powder particles and laser was analyzed deeply. New 3D coaxial feeding head with adjustable of the powder stream focus was designed. DPIV(Digital Particle Image Velocimetry) technology was used to observe velocity fields and concentration fields of powder streams. A series of processing tests using 3D coaxial feeding head were carried out. Using 3D coaxial feeding head, large area laser refabrication was carried out in metallic sheath and stainless steel plates. The influence of the technological parameters to powder utilization ratio and quality of cladding were analyzed.
It is shown that the 3D coaxial feeding head has the characteristic of full-direction and adjustable focus of powder stream.
Major technical parameters of 3D coaxial feeding head: Focus model: lens focus/reflection focus
Feeding model: carrying gas/without gas
Rotational angle of Φ axis: 0° -360°
Rotational angle of ψ axis: -60 °--+60°
Powder utilization ratio: feeding with carry gas >30%
feeding without gas >60%
本文介绍了激光再制造技术的原理，综述了国内外研究发展现状。建立了粒子受热状态、光能分配模型和粉末流场浓度模型，对光粉相互作用进行了较深入的理论分析。综合机械设计的相关理论，设计出具有三维空间工作功能、粉末流束焦点可调的新型送粉工作头。首次结合数字粒子图像测速技术(DPIV)设计了对粉末流束的速度场和浓度场的试验方案，并实际检测了在不同工作状态下的粉末流束的速度场和浓度场。开展了送粉工作头的实际应用试验研究，利用研制的三维送粉工作头对导套零件和不锈钢板进行了大面积激光再制造的初步试验研究，取得了良好的效果。分析了工艺参数对粉末利用率、熔覆层质量等方面的影响。
试验表明同轴送粉工作头具有全方向性和和其粉末流束的焦点可调节特性。其主要技术参数如下：
聚焦方式： 透镜／反射聚焦
送粉方式： 载气式／非载气式
Φ轴转角： 0°—360°
Ψ轴转角： -60°—+60°
粉末利用率： 载气式≥30％，非载气式≥60％
Laser refabrication is a kind of new green reconstruction technology that based on laser cladding. It can be used to repair important weared parts rapidly, so it may bring the reducing production cost and saving working time. 3D coaxial feeding head is the most important and key part in laser refabrication. Many problems of interactions between laser and materials were involved in. It is significant and valuable to carry through the research of 3D coaxial feeding head deeply.
In this paper, technical principles of laser refabrication were introduced. Current states of development were summarized in China and other countries. Model of the heated particles, model of division of the laser energy and concentration of powder stream were presented. Interaction between powder particles and laser was analyzed deeply. New 3D coaxial feeding head with adjustable of the powder stream focus was designed. DPIV(Digital Particle Image Velocimetry) technology was used to observe velocity fields and concentration fields of powder streams. A series of processing tests using 3D coaxial feeding head were carried out. Using 3D coaxial feeding head, large area laser refabrication was carried out in metallic sheath and stainless steel plates. The influence of the technological parameters to powder utilization ratio and quality of cladding were analyzed.
It is shown that the 3D coaxial feeding head has the characteristic of full-direction and adjustable focus of powder stream.
Major technical parameters of 3D coaxial feeding head: Focus model: lens focus/reflection focus
Feeding model: carrying gas/without gas
Rotational angle of Φ axis: 0° -360°
Rotational angle of ψ axis: -60 °--+60°
Powder utilization ratio: feeding with carry gas >30%
feeding without gas >60%
引文
[1] 关振中主编，激光加工工艺手册，中国计量出版社，1998
[2] 居毅、郭绍义、李宗全，金属表面激光合金化及熔敷处理的研究进展，材料科学与工程，2002 Vo120．1：143-145
[3] 郭伟、徐庆鸿、田锡唐，激光熔覆的研究发展现状，宇航材料工艺，1998 (2)：33-35
[4] 张庆茂、刘喜明、关振中，激光表面熔敷的进展及智能控制，金属热处理，1999 (11)：1-3
[5] 杨洗陈，王建军，刘运武等，非载气式激光同轴送粉试验研究，中国激光, Vol．31，No．1，2004：120-124
[6] 杨洗陈，李会山，王云山，刘运武等，用于重大装备修复的激光再制造技术，激光与光电子学进展，Vpl．40，No．10，2003：53-57
[7] Yang Xi-chen(杨洗陈)et．al,"A new coaxial powder feeder without carrying gas for laser direct materials deposition", SPIE, Vol. 4915, 2002: 153-161
[8] 刘运武，杨洗陈，王云山，激光熔敷中粉末粒子流对光能吸收的研究，天津工业大学学报，2003，Vol．22，No．4：13-16
[9] 刘运武，杨洗陈，激光再制造过程中的粉末流场检测技术，激光产品世界，2003，No．11：26-30
[10] 刘振侠，黄卫东，万柏涛，送粉激光熔覆数值模型基本问题研究，中国激光，2003，Vol30．No．6
[11] 杨洗陈，激光固体加热，天津工业大学讲义，1985
[12] 杨洗陈，激光熔池动力学，天津工业大学讲义，1985
[13] E．Hoffmann 等，用CO2激光束成型中的温度检测加工过程，激光与光电子，1997 (1)：25-32
[14] Chang-Yi Liu, Jehnming Lin, Thermal processes of a powder particle in coaxial laser cladding, OPTICS & Laser Technology, 2003 (35): 81-86
[15] 薛春芳，田欣利，董世运等，激光直接烧结成形金属零件的试验研究，应用激光，2003，Vol．23,No．3：130-134
[16] Yunchang Fu, A. Loredo, A theoretical model for laser and powder particles interaction during laser cladding, Jounmal of Materials Processing Technology 2002 (128): 106-112
[17] 张庆茂，刘喜明，孙宁，关振中，送粉式激光熔覆熔池深度的分析模型及其影响因素，焊接学报，2000，Vol．21，No．4：42-45
[18] Jehnming Lin, A simple model of powder catchment in coaxial laser cladding, Optics & Laser Technology, 31 (1999): 233-238
[19] 杨扬，CO2激光束几种聚焦方案的比较，激光杂志，1999，Vol20 No．2：29-32
[20] 邱宣怀，机械设计，高等教育出版社，1997
[21] J. Lin and W. M. Steen, "Design characteristics and development of a nozzle for coaxial laser cladding", Journal of Laser Application, Vol. 10, No. 2, 1998
[22] 张魁武，国外激光熔覆设备，金属热处理，2002，Vol．27，No．7：26-32
[23] 闫毓禾，钟敏霖编著，高功率激光加工及其应用，天津科学技术出版社，1994
[24] 左铁钏，高强铝合金的激光加工，国防工业出版社，2002
[25] 王从曾等，材料性能学，北京工业大学出版社，2001
[26] 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，Vol．28，No．2：130～134
[27] 沈德久等，同轴送粉对激光熔覆组织的细化作用，应用激光，2002，Vol．22，No．3：290-292
[28] 张庆茂，钟敏霖，杨森等，送粉式激光熔覆层质量与工艺参数之间关系，焊接学报，2001，Vol．22，No．4：51～54
[29] 杨永强，宋永伦，送粉激光熔覆时激光与粉末的交互作用，中国激光，1998，Vol．25，No．3：280～283
[30] E. W. Kreutz, G. Backes, A. Gasser, Rapid prototyping with CO_2 laser radiation, Applied Surface Science, 86 (1995): 310～316
[31] Laser X Co. Ltd, Chiryu-shi, Laser-cladding process: a study using stationary and scanning CO2 laser beams, Surface and Coatings Technology, 97 (1997): 442～447
[32] 石惠娴，王勤辉，骆仲泱等，PIV应用于气固多相流动的研究现状，动力工
程，2002，Vol．22，No． 1：1589～1593
[33] M. Qian, L. C. Lim, Z. D. Chen, Parametric studies of laser cladding processes, Journal of Materials Processing Technology, 63 (1997): 590～593
[34] 王浩，曾理江，二维及三维流场的光学测量方法，光学技术，2001，Vol．27，No．2：139～142
[2] 居毅、郭绍义、李宗全，金属表面激光合金化及熔敷处理的研究进展，材料科学与工程，2002 Vo120．1：143-145
[3] 郭伟、徐庆鸿、田锡唐，激光熔覆的研究发展现状，宇航材料工艺，1998 (2)：33-35
[4] 张庆茂、刘喜明、关振中，激光表面熔敷的进展及智能控制，金属热处理，1999 (11)：1-3
[5] 杨洗陈，王建军，刘运武等，非载气式激光同轴送粉试验研究，中国激光, Vol．31，No．1，2004：120-124
[6] 杨洗陈，李会山，王云山，刘运武等，用于重大装备修复的激光再制造技术，激光与光电子学进展，Vpl．40，No．10，2003：53-57
[7] Yang Xi-chen(杨洗陈)et．al,"A new coaxial powder feeder without carrying gas for laser direct materials deposition", SPIE, Vol. 4915, 2002: 153-161
[8] 刘运武，杨洗陈，王云山，激光熔敷中粉末粒子流对光能吸收的研究，天津工业大学学报，2003，Vol．22，No．4：13-16
[9] 刘运武，杨洗陈，激光再制造过程中的粉末流场检测技术，激光产品世界，2003，No．11：26-30
[10] 刘振侠，黄卫东，万柏涛，送粉激光熔覆数值模型基本问题研究，中国激光，2003，Vol30．No．6
[11] 杨洗陈，激光固体加热，天津工业大学讲义，1985
[12] 杨洗陈，激光熔池动力学，天津工业大学讲义，1985
[13] E．Hoffmann 等，用CO2激光束成型中的温度检测加工过程，激光与光电子，1997 (1)：25-32
[14] Chang-Yi Liu, Jehnming Lin, Thermal processes of a powder particle in coaxial laser cladding, OPTICS & Laser Technology, 2003 (35): 81-86
[15] 薛春芳，田欣利，董世运等，激光直接烧结成形金属零件的试验研究，应用激光，2003，Vol．23,No．3：130-134
[16] Yunchang Fu, A. Loredo, A theoretical model for laser and powder particles interaction during laser cladding, Jounmal of Materials Processing Technology 2002 (128): 106-112
[17] 张庆茂，刘喜明，孙宁，关振中，送粉式激光熔覆熔池深度的分析模型及其影响因素，焊接学报，2000，Vol．21，No．4：42-45
[18] Jehnming Lin, A simple model of powder catchment in coaxial laser cladding, Optics & Laser Technology, 31 (1999): 233-238
[19] 杨扬，CO2激光束几种聚焦方案的比较，激光杂志，1999，Vol20 No．2：29-32
[20] 邱宣怀，机械设计，高等教育出版社，1997
[21] J. Lin and W. M. Steen, "Design characteristics and development of a nozzle for coaxial laser cladding", Journal of Laser Application, Vol. 10, No. 2, 1998
[22] 张魁武，国外激光熔覆设备，金属热处理，2002，Vol．27，No．7：26-32
[23] 闫毓禾，钟敏霖编著，高功率激光加工及其应用，天津科学技术出版社，1994
[24] 左铁钏，高强铝合金的激光加工，国防工业出版社，2002
[25] 王从曾等，材料性能学，北京工业大学出版社，2001
[26] 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，Vol．28，No．2：130～134
[27] 沈德久等，同轴送粉对激光熔覆组织的细化作用，应用激光，2002，Vol．22，No．3：290-292
[28] 张庆茂，钟敏霖，杨森等，送粉式激光熔覆层质量与工艺参数之间关系，焊接学报，2001，Vol．22，No．4：51～54
[29] 杨永强，宋永伦，送粉激光熔覆时激光与粉末的交互作用，中国激光，1998，Vol．25，No．3：280～283
[30] E. W. Kreutz, G. Backes, A. Gasser, Rapid prototyping with CO_2 laser radiation, Applied Surface Science, 86 (1995): 310～316
[31] Laser X Co. Ltd, Chiryu-shi, Laser-cladding process: a study using stationary and scanning CO2 laser beams, Surface and Coatings Technology, 97 (1997): 442～447
[32] 石惠娴，王勤辉，骆仲泱等，PIV应用于气固多相流动的研究现状，动力工
程，2002，Vol．22，No． 1：1589～1593
[33] M. Qian, L. C. Lim, Z. D. Chen, Parametric studies of laser cladding processes, Journal of Materials Processing Technology, 63 (1997): 590～593
[34] 王浩，曾理江，二维及三维流场的光学测量方法，光学技术，2001，Vol．27，No．2：139～142