齿类件激光再制造及性能提升方法研究
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摘要
再制造能够使废旧产品中蕴含的价值得到开发和利用,减小报废产品对环境的污染,延长零部件的使用寿命,是发展循环经济、构建节约型社会的重要组成部分,具有十分重要的经济和社会意义。激光熔覆技术作为先进的再制造技术之一,具有对基体损伤小、加工精度高等优点,在装备零部件的再制造中具有显著优势。
齿类件是机械系统中传递载荷和运动的重要零件,齿的失效将直接影响机械系统的正常运行。由于传统维修手段的限制,齿类件维修率较低。随着激光技术的发展使齿类件的修复有望获得新的解决途径。为此,本文以不同载荷下损伤齿类件为研究对象,采用激光技术实现了齿类件的再制造,并通过活化屏等离子体氮化复合处理实现了其性能的提升。本研究获得的主要成果如下：
针对调质钢齿类件体积损伤修复,开展了激光快速成形研究,重点研究了激光快速成形件的显微组织和力学性能,探讨了修复比例对激光再制造零件性能的影响规律。研究结果表明：激光快速成形件组织致密、具有快速凝固组织特征,力学性能较好。激光修复试样的性能由激光修复区和基体两部分决定,随着激光修复比例的增加,激光修复试样的强度增加、塑性降低。
针对灰铸铁齿面磨损激光修复,探讨了铸铁激光熔覆裂纹的形成机理及控制措施,提出了采用电刷镀/激光熔覆复合处理解决铸铁激光熔覆裂纹敏感性高的新方法。研究结果表明：电刷镀/激光熔覆复合涂层组织致密,无裂纹、气孔等冶金缺陷,该方法为铸铁齿类件的再制造提供了一条可行的技术途径。
针对高速重载渗碳齿面损伤的修复,成功设计出价格低、成形性好、具有自强化性能的中锰铁基合金熔覆材料。制备的中锰铁基合金熔覆层组织致密,涂层与基体呈冶金结合,熔覆层硬度较高、具有较好的耐磨和抗接触疲劳性能。采用热力学计算、价电子理论和冲击磨料磨损等方法研究了中锰铁基合金熔覆层的自强化机理,为其实际应用提供了理论支撑。
研究了采用激光熔覆/活化屏等离子体氮化复合处理来实现激光再制造后齿类件性能提升的方法,并探讨了激光熔覆和活化屏等离子体氮化复合涂层的设计原则。研究结果表明：经复合处理后激光熔覆层的表面硬度、耐腐蚀性、耐磨性和抗接触疲劳性能都得到了显著提高；激光熔覆/活化屏等离子体复合涂层性能提高的关键在于激光熔覆层性能与载荷的合理搭配,激光熔覆层能提供足够的支撑以保护氮化层不被破坏是复合涂层设计的基本原则。
Remanufacturing can make waste products which contain value develop and utilize, reduce the environment pollution of scrap products, and prolong the service life of the parts. Remanufacturing engineering is one of the key parts of circular economy development and economical society establishment, and it is significant to economy and society. As one of the advanced remanufacturing technologies, laser cladding technology has lots of merits which supply apparent dominance for equipment parts repairing and remanufacturing, such as weak substrate impairment, high processing accuracy and so on.
Gear failure will directly affect the normal operation of the mechanical system as it is the major part for load and movement transmission. The repair rate of gear part is very low due to the limitation of traditional maintenance method. With the development of laser technology, the new repaired gear part method is provided. In this paper, the damaged gear parts were investigated. Remanufacturing of gear parts was operated by laser technology, and then active screen plasma nitriding duplex treatment was processed to improve the performance of gear parts. The principal results are as follows:
Research on laser rapid forming is carried out to settle the problem of hardened and tempered steel gear repair. Microstructure and mechanical property of laser rapid forming sample were researched, and the influence of repair ratio to the performance of laser remanufacturing parts was discussed. The results showed that the microstructure of laser rapid forming sample is dense with a characteristic of rapid solidification, and the sample has high mechanical properties. The performance of repaired specimen depends on laser repair zone and substrate, and the strength of repaired sample increases and the plasticity reduces with the increase of the ratio of laser repaired zone.
Crack formation mechanism and control measures of laser cladding coating were discussed for laser repair the wear surface of cast gear, and a new method of brush electro-plating and laser cladding duplex treatment was presented to reduce the cast iron laser cladding crack sensitivity. The results show that the duplex treated coating is dense, without any metallurgical defects such as crack and porosity. It provides a feasible technology way for cast iron gear parts remanufacturing.
The medium manganese Fe-based alloy with low price, well formability and self-strengthening properties was designed to repair surface damage of high speed over-load carburizing gear. The microstructure of medium manganese Fe-based alloy laser cladding coating is dense, and the coating and the substrate is metallurgical bond. The cladding coating has good property of hardness, wear resistance and contact fatigue resistance. Research on self-strengthening mechanism of laser cladding coating was carried based on thermodynamics calculation, valence electron theory and impact abrasive wear methods, and the result provides theoretical support for industrial application.
The method of remanufacturing gear part property improving by laser cladding and active screen plasma nitriding duplex treatment was studied and the design principle of laser cladding and active screen plasma nitriding duplex treated coating was discussed. Results show that the surface hardness, corrosion resistance, wear resistance and contact fatigue property of laser cladding were improved apparently after duplex treatment. Reasonable collocation between laser cladding coating and load is the key for performance improvement of laser cladding and active screen plasma duplex treated coating. The basic design principle of duplex treated coating is that laser cladding can provide enough support to protect nitride layer from destroying.
齿类件是机械系统中传递载荷和运动的重要零件,齿的失效将直接影响机械系统的正常运行。由于传统维修手段的限制,齿类件维修率较低。随着激光技术的发展使齿类件的修复有望获得新的解决途径。为此,本文以不同载荷下损伤齿类件为研究对象,采用激光技术实现了齿类件的再制造,并通过活化屏等离子体氮化复合处理实现了其性能的提升。本研究获得的主要成果如下：
针对调质钢齿类件体积损伤修复,开展了激光快速成形研究,重点研究了激光快速成形件的显微组织和力学性能,探讨了修复比例对激光再制造零件性能的影响规律。研究结果表明：激光快速成形件组织致密、具有快速凝固组织特征,力学性能较好。激光修复试样的性能由激光修复区和基体两部分决定,随着激光修复比例的增加,激光修复试样的强度增加、塑性降低。
针对灰铸铁齿面磨损激光修复,探讨了铸铁激光熔覆裂纹的形成机理及控制措施,提出了采用电刷镀/激光熔覆复合处理解决铸铁激光熔覆裂纹敏感性高的新方法。研究结果表明：电刷镀/激光熔覆复合涂层组织致密,无裂纹、气孔等冶金缺陷,该方法为铸铁齿类件的再制造提供了一条可行的技术途径。
针对高速重载渗碳齿面损伤的修复,成功设计出价格低、成形性好、具有自强化性能的中锰铁基合金熔覆材料。制备的中锰铁基合金熔覆层组织致密,涂层与基体呈冶金结合,熔覆层硬度较高、具有较好的耐磨和抗接触疲劳性能。采用热力学计算、价电子理论和冲击磨料磨损等方法研究了中锰铁基合金熔覆层的自强化机理,为其实际应用提供了理论支撑。
研究了采用激光熔覆/活化屏等离子体氮化复合处理来实现激光再制造后齿类件性能提升的方法,并探讨了激光熔覆和活化屏等离子体氮化复合涂层的设计原则。研究结果表明：经复合处理后激光熔覆层的表面硬度、耐腐蚀性、耐磨性和抗接触疲劳性能都得到了显著提高；激光熔覆/活化屏等离子体复合涂层性能提高的关键在于激光熔覆层性能与载荷的合理搭配,激光熔覆层能提供足够的支撑以保护氮化层不被破坏是复合涂层设计的基本原则。
Remanufacturing can make waste products which contain value develop and utilize, reduce the environment pollution of scrap products, and prolong the service life of the parts. Remanufacturing engineering is one of the key parts of circular economy development and economical society establishment, and it is significant to economy and society. As one of the advanced remanufacturing technologies, laser cladding technology has lots of merits which supply apparent dominance for equipment parts repairing and remanufacturing, such as weak substrate impairment, high processing accuracy and so on.
Gear failure will directly affect the normal operation of the mechanical system as it is the major part for load and movement transmission. The repair rate of gear part is very low due to the limitation of traditional maintenance method. With the development of laser technology, the new repaired gear part method is provided. In this paper, the damaged gear parts were investigated. Remanufacturing of gear parts was operated by laser technology, and then active screen plasma nitriding duplex treatment was processed to improve the performance of gear parts. The principal results are as follows:
Research on laser rapid forming is carried out to settle the problem of hardened and tempered steel gear repair. Microstructure and mechanical property of laser rapid forming sample were researched, and the influence of repair ratio to the performance of laser remanufacturing parts was discussed. The results showed that the microstructure of laser rapid forming sample is dense with a characteristic of rapid solidification, and the sample has high mechanical properties. The performance of repaired specimen depends on laser repair zone and substrate, and the strength of repaired sample increases and the plasticity reduces with the increase of the ratio of laser repaired zone.
Crack formation mechanism and control measures of laser cladding coating were discussed for laser repair the wear surface of cast gear, and a new method of brush electro-plating and laser cladding duplex treatment was presented to reduce the cast iron laser cladding crack sensitivity. The results show that the duplex treated coating is dense, without any metallurgical defects such as crack and porosity. It provides a feasible technology way for cast iron gear parts remanufacturing.
The medium manganese Fe-based alloy with low price, well formability and self-strengthening properties was designed to repair surface damage of high speed over-load carburizing gear. The microstructure of medium manganese Fe-based alloy laser cladding coating is dense, and the coating and the substrate is metallurgical bond. The cladding coating has good property of hardness, wear resistance and contact fatigue resistance. Research on self-strengthening mechanism of laser cladding coating was carried based on thermodynamics calculation, valence electron theory and impact abrasive wear methods, and the result provides theoretical support for industrial application.
The method of remanufacturing gear part property improving by laser cladding and active screen plasma nitriding duplex treatment was studied and the design principle of laser cladding and active screen plasma nitriding duplex treated coating was discussed. Results show that the surface hardness, corrosion resistance, wear resistance and contact fatigue property of laser cladding were improved apparently after duplex treatment. Reasonable collocation between laser cladding coating and load is the key for performance improvement of laser cladding and active screen plasma duplex treated coating. The basic design principle of duplex treated coating is that laser cladding can provide enough support to protect nitride layer from destroying.
引文
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