The integral leaf disk is a key component of aero engine components. The tip of the blade is easy to wear during use, and the two ends of the blade root are prone to crack failure and lead to scrap. The laser additive manufacturing technology can control the deformation and achieve the traditional overlay Unreachable repair accuracy. The use of laser additive manufacturing technology can realize the direct molding of the whole leaf disc in a short time, which can save costs and improve production efficiency in a large procedure.
At present, the manufacturing method of the whole leaf disc adopts the forging method. The forging causes a high cost and a long cycle. The forging whole leaf disc also has some metallurgical defects. The direct laser forming of the aeroengine's overall disc can reduce costs and speed up the cycle. Defects such as blade tip wear and cracks are prone to occur during the use of the aero-engine overall impeller. In most cases, it is scrapped because it cannot be repaired. The direct replacement cost of the aero engine's overall disc is very expensive, and the cost of a new product is generally not less than one million. There have been successful cases of laser remanufacturing and repair of whole leaf discs in foreign countries. Due to foreign technical barriers, China has rarely successfully applied laser remanufacturing of whole leaf blades. Therefore, the development of laser remanufacturing technology for the whole leaf disk is an urgent technical problem to be solved. Laser cladding metallographic detection meets the inspection requirements, with appropriate layer thickness, good side forming, no metallurgical defects, and uniform structure.
After the mechanical properties of the sample pass the test, single-component cladding and sample cladding repair are performed. The defects are artificially made and repaired by laser melting. In order to ensure the shape after cladding, a certain thickness needs to be guaranteed, and the scanning path needs to be designed according to the shape of the blade.
Through the single-component cladding test, the feasibility of the cladding, the stability of the process, and the cladding effect of the single-component blades, including deformation and defects, were confirmed. The machining allowance and deformation were confirmed through the repair after cladding And so on.
Single element (material: titanium alloy) notch cladding effect
After cladding, no defects were inspected, and the final result reached the project acceptance standard. Sample blade (material: TC17) cladding test
Integral leaf disc (material: GH4169 nickel-based alloy) cladding effect
