航空压气机叶片增材修复最优热输入分析

龚淼; 戴士杰; 王志平; 王立文

doi:10.12073/j.hjxb.20200602001

航空压气机叶片增材修复最优热输入分析

龚淼^{1, 2,},
戴士杰^1, ,,
王志平²,
王立文²

1.
河北工业大学，天津，300401
2.
中国民航大学，天津，300300

基金项目: 国家重点研发计划项目(2019YFB1311104)；中国民航科技重大专项(MHRD20130104).

详细信息

作者简介:
龚淼，1982年出生，博士，副研究员；主要研究方向为：航空发动机叶片增材修复；Email：mgong69@163.com.

通讯作者:
戴士杰，教授，博士研究生导师. Email：dsj7176@126.com.

中图分类号: TG 456.3
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- 文章访问数: 530
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出版历程
- 收稿日期: 2020-06-01
- 网络出版日期: 2020-10-21
- 刊出日期: 2020-11-22

Research on optimal heat input for blade repair of aero compressor

1.
Hebei University of Technology, Tianjin, 300401, China
2.
Civil Aviation University of China, Tianjin, 300300, China

摘要

摘要: 建立了压气机叶片MPAW增材修复传热模型，首先通过分析合金的热物性，计算出叶片MPAW增材修复的热输入范围，得到了不同热输入下熔池的温度分布. 之后创建了增材高度与送丝速度的数学模型，求解出不同送丝速度下的增材高度，并通过对焊缝截面温度分布的数值分析，进一步缩小热输入范围，得到试验参数. 最后通过数值分析及试验对比，揭示了合金修复区组织形貌与热输入率的演化规律，得到了最优的热输入和匹配的焊接参数.结果表明，试验结果与理论模型吻合度较好，验证了理论方法的有效性. 对于1 mm厚度的超薄压气机叶片的增材修复，采用研究得到的焊接参数，可达到最优热输入率，实现较好的增材形貌和增材修复效果.
- 增材修复 /
- 压气机叶片 /
- 热输入 /
- 传热建模 /
- 数值分析
Abstract: A heat transfer model for MPAW additive manufacturing repair of compressor blades was established. Firstly, the heat input range was calculated by analyzing the thermal properties of the alloy, and the temperature distribution of molten pool under different heat input was obtained. After that, the mathematical model of the additive manufacturing height and wire feeding speed was established, and the height under different wire feeding speed was solved. Through the numerical analysis of temperature distribution of weld cross-section, the heat input range was further reduced and the experimental parameters were obtained. Finally, with numerical analysis and experimental comparison, the evolution law of microstructure and heat input rate of the alloy repair zone was revealed, and the optimal heat input and welding parameters were obtained. The experimental results are in good agreement with the theoretical model, which verifies the effectiveness of the theoretical method. The results show that the optimal heat input rate can be achieved by using the welding parameters obtained, and the better additive manufacturing morphology and repair effect can be achieved.
- additive manufacturing repair /
- compressor blades /
- heat input /
- heat transfer modeling /
- numerical analysis

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图 1 网格划分及质量分布图

Figure 1. Finite element mesh generation quality

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图 2 MPAW增材修复后的截面形貌图

Figure 2. Cross section morphology after MPAW additive manufacturing repair

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图 3 牛顿迭代法计算步骤

Figure 3. Newton iteration calculation steps

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图 4 不同送丝速度下焊缝微截面平均温度随时间的分布

Figure 4. Temperature distribution of the micro section of the weld with the time under different wire feeding speeds. (a) 3.39 mm/s; (b) 2.54 mm/s

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图 5 焊缝区显微组织形貌(试验1)

Figure 5. Microstructure of the weld zone (Exp.1)

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图 6 焊缝区白色带状区域能谱分析

Figure 6. EDS of white banded structure in weld zone. (a) EDS 1; (b) EDS 2

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图 7 析出颗粒EDS观测结果(试验1)

Figure 7. Energy spectrum analysis of precipitates (Expt.1). (a) region of Fig.6a; (b) region of Fig.6b

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图 9 焊缝区显微组织形貌(试验3)

Figure 9. Microstructure of the weld zone (Exp.3)

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图 8 焊缝区显微组织形貌(试验2)

Figure 8. Microstructure of the weld zone (Exp.2)

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图 10 焊缝区白色带状组织能谱分析(试验3)

Figure 10. EDS of white banded structure in weld zone (Exp.3). (a) EDS 1; (b) EDS 2

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图 11 焊缝区显微组织形貌(试验4)

Figure 11. Microstructure of the weld zone (Exp.4)

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图 12 堆焊区电子背散射衍射成像(试验4)

Figure 12. EBSD imaging of the weld zone (Exp.4)

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图 13 增材区HDBS和EDS检测结果(试验4)

Figure 13. HDBSD and EDS of additive manufacturing repair zone (Expt.4)

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图 14 送丝速度为3.39 mm/s (8 in/min)的增材区截面形貌

Figure 14. Cross section morphology of additive zone with wire feeding speed of 3.39 mm/s (8 in/min)

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图 15 送丝速度为2.54 mm/s (6 in/min)的增材区截面形貌

Figure 15. Cross section morphology of additive zone with wire feeding speed of 2.54 mm/s (6 in/min)

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表 1 Inconel 718合金试片与焊丝的化学成分(质量分数，%)

Table 1 Chemical composition of Inconel 718 specimens and welding wire

材料	Al	C	Co	Cr	Cu	Fe	Mn	Mo	Nb	Ni	Si	Ti
试片	0.39	0.052	0.05	19	0.17	16.7	0.29	2.93	4.97	52.3	0.26	0.9
焊丝	0.56	0.033	0.15	18.6	0.056	18.03	0.12	2.98	4.85	53.6	0.10	0.92
平均值	0.475	0.0425	0.1	18.8	0.113	17.365	0.205	2.955	4.91	53.95	0.18	0.91

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表 2 不同增材修复高度的计算结果

Table 2 Calculation results of different weld overlay heights

$\dfrac{{{v_2}}}{{{v_1}}}$	初值	结果${r_i}$/mm	精度$\varepsilon $	迭代次数	前次误差	结果H/mm
$\dfrac{3}{3}$	1	${\rm{5}}{\rm{.52}} \times {\rm{1}}{{\rm{0}}^{ - 1}}$	$1 \times {10^{ - 10}}$	32	${\rm{9}}{\rm{.82}} \times {\rm{1}}{{\rm{0}}^{ - 11}}$	0.78
$\dfrac{6}{3}$	1	${\rm{6}}{\rm{.41}} \times {\rm{1}}{{\rm{0}}^{{\rm{ - 1}}}}$	$1 \times {10^{ - 10}}$	32	${\rm{5}}{\rm{.84}} \times {\rm{1}}{{\rm{0}}^{ - 11}}$	1.04
$\dfrac{8}{3}$	1	${\rm{7}}{\rm{.00}} \times {\rm{1}}{{\rm{0}}^{ - 1}}$	$1 \times {10^{ - 10}}$	31	${\rm{7}}{\rm{.74}} \times {\rm{1}}{{\rm{0}}^{ - 11}}$	1.19
$\dfrac{{10}}{3}$	1	${\rm{7}}{\rm{.58}} \times {\rm{1}}{{\rm{0}}^{ - 1}}$	$1 \times {10^{ - 10}}$	30	${\rm{9}}{\rm{.59}} \times {\rm{1}}{{\rm{0}}^{ - 11}}$	1.33

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表 3 试验参数

Table 3 Experimental parameters

编号	焊接电流 I/A	电弧电压 U/V	送丝速度 v₂/(mm·s⁻¹)	热源移动速度 v₃/(mm·s⁻¹)
1	25	15	3.39	1.27
2	25	15	2.54	1.27
3	28	15.4	3.39	1.27
4	28	15.4	2.54	1.27

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表 4 维氏硬度检测结果(HV0.1)

Table 4 HV test results in different areas (HV0.1)

检测区域	1	2	3	4	5	平均值	偏差率δ (%)
增材区	198.3	197.5	193.9	195.1	189.7	195.88	1.66%
母材	206.7	199.7	194.2	193,7	195.7	199.08	1.66%

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