Machine part restoration method

FIELD: machine part restoration, namely restoration methods suitable for using in aircraft engines, machine engineering and other branches of technology for restoring rubbing surfaces of cylindrical parts.

SUBSTANCE: method comprises steps of mounting on surface of part prepared for restoration before surfacing, blank of additive material in the form of band; using band with thickness 0.1 - 5.0 mm and mounting it at gap no more than 0.2 mm; performing multi-layer surfacing of additive material in vacuum by means of scanning electron beam; mechanically working part after surfacing each layer of additive material.

EFFECT: simplified process of surfacing material, elimination of residual stresses and deformations in article.

11 cl, 2 dwg, 1 tbl

 

The invention relates to the repair of machine parts, in particular to methods of repair, and can be used in the aircraft engine industry, engineering and other technical fields to restore the rubbing surfaces of the cylindrical parts.

Known way to restore scallops labyrinth seals, which make welding with a pulsed supply of filler wire on the surface of the scallops surfacing rollers with prior and subsequent thermo - mechanical processing. The cladding is produced in shielding gases argon-arc welding with non-consumable electrode (see Modern technologies in the production of gas turbine engines. Edited Aghbalyan, Gkezia, Besarabia, Moscow, Mashinostroenie, 1997, p.100-101).

The disadvantages of this method: there is no exact orientation surfaced rollers relative to the axis of the restoring scallops, line fusing fusible metal substrate (product) has a sharp transition, which affects the formation surfaced rollers and the deformation of the product.

Also there is a method of electron-beam welding, according to which the welding surface of the workpiece for multiple passes mold overlapping with the formation of ridges. Detail for surfacing move relative to the beam in the longitudinal and transverse on the ravlenija (see SU 1107414, CL. 23 To 15/00, 15.06.90).

The disadvantages of this method of electron-beam welding are large axial shrinkage of molded metal and limiting the increase in diameter recreated due to the lack of application of the filler material.

Closest to the proposed method is a method of repair of the rubbing surfaces of the cylindrical machine parts, in particular the rolls, including the removal of traces of wear, a multi-layer cladding of internal donor layer of high-alloy steel and an outer wear-resistant layer made of alloy steel with the following mechanical and thermal treatment, while the total content of alloying elements donor layer exceeds the total content of alloying elements wear-resistant layer 1.97-16,7 time (see patent RU 2083342 C1, CL. 23 P 6/00, 10.07.1997, claim 1 of the formula).

The disadvantages of this method are the following. This method is difficult to use, as the filler wire must be accurately positioned relative to the axis of the sweep of the electron beam; the diameter of the filler wire and the departure of its severely limited by the difficulty in providing reliable combining it with the beam; the feed speed of the filler wire must be synchronized with the speed of welding; electron beam welding filler wire neizbeznosti significant proportion of the weld pool, which is fed filler wire and the welding filler material to the substrate, resulting in the inevitable emergence of a large residual stresses and deformation of the recovered product.

The technical result - the simplification of welding the exception of elevated residual stresses and deformation of the product as a whole.

This task is solved in that in the method of repair of machine parts, including preparation of the surface and restore the given geometrical parameters details multilayer welding filler material and its mechanical processing, according to the invention, repair parts before applying each layer of filler material mounted his billet thickness of 0.1-5.0 mm with a gap, the value of which does not exceed 0.2 mm, and the welding filler material is carried out scanning electron beam in vacuum, and the mechanical treatment is carried out after deposition of each layer of the filler material.

The choice of these ranges due to the following. The thickness of the ribbon to choose less than 0.1 mm is not recommended due to the low efficiency of the process, and greater than 5.0 mm is due to the large talovlozheny the melting of the material and, consequently, high residual stresses and deformations. The gap between mounted in the title is ovcoy and repaired the item does not exceed 0.2 mm, otherwise, to obtain defect-free welding is impossible.

The workpiece can be performed in the form of a tape which is pre-prepared for installation by rolling to form geometrical dimensions of the filler material and to save the metal.

When mounting the workpiece can be done pre-fixation relative to the repair parts are TIG welded. This is necessary for the fixation of the filler material on the part.

For the fixation of the filler material on the parts when mounting tape can be done pre-fixation relative to the repair parts are TIG welding.

Can the cladding layer of filler material to make several passes that allows you to minimize welding stress and deformation of parts.

Can welding be carried out with speed 15-60 m/h, which allows to obtain a defect-free weld.

You as the workpiece material to use alloy based on Nickel.

You can repair parts rotor gas turbine engine.

You can repair the scallops labyrinth seals of the rotor of the CCD.

1 schematically shows a longitudinal section of part of the repaired product;

figure 2 - repair the product in the deposition process.

The implementation of the method considered is the example of repair of the labyrinth seals of the compressor rotor.

The device for implementing the method comprises a cathode-ray installation with vacuum chamber (not shown). In the vacuum chamber is repaired item - rotor 1 compressor with scallops 2 labyrinth seals. Deposited layer 3, the filler material in the form of rings 4, the gap 5, the electron beam gun 6.

The method is as follows.

In this way recovered scallops labyrinth seals compressor rotor with wear more than 1.0 mm, the Rotor 1 with scallops 2 labyrinth seals are made of steel EI 961.

Prepare the surface of the scallops 2 labyrinth seals for repair as follows. Measure the diameter of the wear D IPMS., then remove method of the grooves worn part of the working surface of the scallops 2 to diameter machining D fur. arr.

Then perform the restore operation specified geometric parameters of the repair parts - scallops 2 labyrinth seal as follows. The results of measurements from an alloy based on Nickel residence permit-98 made four ring 4 of a thickness of 1.0 mm (two pieces) and 2.0 mm (two pieces) and a width equal to the width of the worn part of the scallops 2 labyrinth seal (17 mm). The ring 4 is made by rolling a strip of material in the form of a tape in the ring. The number of rings 4 op is Adelaida size nominal diameter D nom. restored scallops 2.

Made ring 4 is mounted on the ready to repair the surface.

Fused ring 4 is fixed on the ready to repair the surface of the rotor 1 by using argon-arc welding.

Welding was carried out on the installation ELU-20, equipped with a power unit PSU 60/15. Modes of electron-beam welding are presented in the table.

Table
The thickness of the ring, mmAccelerating voltage, kVThe current focusing lens, mAThe beam current, mAThe frequency of oscillation of the beam, HzThe oscillation amplitude, mmWelding speed, m/h
1,060840 stand.23104,520
  830 slave.    
2,060840 stand.30104,520
  830 slave.    

In a vacuum chamber of an electron-beam installation put the repaired product. Welding mA is emulator installation was performed by moving the electron beam gun 6 and repaired product of the rotor 1.

The cladding layer of the filler material 5 is carried out by the system control the electron beam, which provides the static deflection and dynamic scanning on the selected path with a given frequency and amplitude. The filler material is chosen alloy based on Nickel VI.

After molding of one ring 4 holds machining on a lathe to provide a gap 5 is not more than 0.2 mm weld between the treated layer 3 and mounted as a ring 4, which provides a tight seal for the inner side of the ring to the repaired surface of the rotor 1. The size of the gap 5 is measured plumbing probe.

Repeat the previous operation to obtain the desired nominal diameter D nom. required for cutting scallops labyrinth seals.

Then spend the final machining to restore the original geometric dimensions of the scallops 2 labyrinth seals.

Restored scallops labyrinth seals of the rotor is subjected to external inspection, measuring geometrical parameters of the measuring bracket, radiographic testing and metallographic control samples.

According to the obtained results judged according restored scallops 2 labyrinth seals Proc. of the ments of the drawing.

Thus, the proposed method provides complete recovery of the geometric characteristics of scallops labyrinth seals, simplifies the process of repair of the rotor allows to obtain high-quality formation of joints in the cladding zone and to exclude an increased level of residual welding stresses.

1. Method of repair of machine parts, including preparation of the surface and restore the given geometrical parameters details multilayer welding filler material and machining, characterized in that the repaired parts before applying each layer of filler material is mounted in the blanks with a thickness of 0.1 - 5.0 mm with a gap, the value of which does not exceed 0.2 mm, and the welding filler material is carried out scanning electron beam in vacuum, and the mechanical treatment is carried out after deposition of each layer of the filler material.

2. The method of repair under item 1, characterized in that the workpiece is performed in the form of a tape which is pre-prepared for installation by rolling.

3. The method of repair under item 1, characterized in that when mounting the workpiece is carried out by pre-fixing the relative repair parts are TIG welding.

4. The method of repair under item 2, wherein when mounting the tape is carried out by pre-fixing the relative repair parts are TIG welding.

5. The method of repair under item 1, characterized in that the cladding layer of filler material is carried out in several passes.

6. The method of repair under item 1, characterized in that the welding carried out with a speed of 15 to 60 m/h

7. The method of repair under item 1, characterized in that as the workpiece material used is an alloy based on Nickel.

8. The method of repair under item 2, characterized in that as the tape material used is an alloy based on Nickel.

9. The method of repair under item 1, characterized in that the repair parts rotor gas turbine engine (GTE).

10. The method of repair under item 2, characterized in that the repair parts rotor gas turbine engine.

11. The repair method according to any one of points 1 to 10, characterized in that the repair scallops labyrinth seals of the rotor of the CCD.



 

Same patents:

FIELD: restoration of cast iron rolling rolls with journals damaged at operation.

SUBSTANCE: method comprises steps of mechanically removing damaged layer and performing electric arc surfacing of rotated roll in place of damaged layer removal while feeding steel austenite wire electrode with diameter 3 - 5 mm to welding zone. Surfacing is realized at density of electric current 30 - 40 A/sq. mm and at electrode feeding speed 80 - 110 m/h. After surfacing journal is subjected to spontaneous cooling.

EFFECT: possibility for completely restoring geometry size of operational properties of damaged roll at keeping the same values of its hardness and strength.

1 tbl, 1 ex

FIELD: manufacture or restoration of worn surfaces of parts, mainly of carbon construction steels.

SUBSTANCE: method comprises steps of plotting (before deformation) curves of plastic yielding of austenite in real coordinates "stress-deformation"; setting according to curves of plastic yielding mode of hot plastic deformation; performing single heating up to temperature higher than Ac3, hot plastic deformation in selected modes and quenching. Isothermic seasoning of parts is performed before quenching for creating polygonal structure of hot-deformed austenite. Quenching is realized directly after hot plastic deformation without isothermic seasoning of hot-deformed austenite. Material is shifted due to metal reserved at stage of making parts.

EFFECT: enhanced constructional strength of parts of carbon construction steel, lowered energy and materials consumption.

4 cl, 2 ex

FIELD: reconditioning of threads of components.

SUBSTANCE: the invention is dealt with repair and recovery of threads on components. Machining is realized by two tools with electrocontact heating of a rotating component. The first tool is installed in a position located in a cavity of a standard thread and conduct finishing-strengthening machining. The second tool is positioned in the beginning of a worn thread and displaced in respect to the first. Movement of the second tool is exercised along the spiral line at the point of overlapping of coils of the threads of the first and second tools and the electrocontact reconditioning is made at the expense of plastic redistribution of the material. The machining is realized with a different force of pressing of the tools to the treated surfaces. The invention allows to restore the profile of the thread and to improve its properties on the components having a wear on a separate section along the length of the of a spiral surface.

EFFECT: the invention ensures reconditioning of the profile of the thread, improvement of its properties on the components having the worn separate sections along the length of the spiral surfaces.

1 dwg

The invention relates to a cement mechanical engineering and can be used in the repair of band rotary kiln

The invention relates to metallurgy, and more particularly to the repair of metallurgical equipment, and can be used to restore the rollers of the roller conveyor of the hot rolling mill

The invention relates to the field of metallurgy and can be used to restore banded roller winders hot rolling mills

The invention relates to the production of building materials, mining and chemical industry, in particular to the processing of the pins of the grinding pipe mills without dismantling

The invention relates to methods for repair and strengthening of worn parts by welding and can be used mainly for the restoration of the working bodies of tillage machines, mainly paws cultivators

The invention relates to the field of nanotechnology, and in particular to methods of recovery probes

The invention relates to a device for calibration of polymer compositions deposited on the worn hole body parts, and can be used to restore the Seating surfaces of rolling bearing housings, gear boxes

FIELD: machine engineering, namely apparatuses for surfacing at restoring defective or damaged parts.

SUBSTANCE: surfacing machine tool includes column with yoke, cross piece, carriage, face chuck, table with adjustable inclination angle, surfacing head having mechanism for reciprocation motion in horizontal plane, mechanism for vertically moving surfacing head, mechanism for rotating in horizontal plane surfacing head with mouthpiece. On surfacing head there are mounted: reel with surfacing wire, mechanism for feeding wire to surfacing zone through mouthpiece and mechanism for reciprocation motion of surfacing head in horizontal plane. Machine tool is provided with matching device having actuating organ and providing kinematic connection between mechanism for rotating surfacing head and mechanism for vertical motion of surfacing head. Handle and flywheel kinematically joined with toothed rack of cross piece are secured to carriage. Matching device is in the form of worm reduction gear of rotation mechanism that is kinematically joined through first cone reduction gear with face chuck and through set of gear wheels - with connection coupling. The last through spring of actuating organ in the form of electromagnet and through second and third cone reduction gears is joined with lead nut of vertical motion mechanism.

EFFECT: enhanced operating efficiency, enlarged functional possibilities of machine tool.

2 cl, 4 dwg, 1 tbl

FIELD: restoration of cast iron rolling rolls with journals damaged at operation.

SUBSTANCE: method comprises steps of mechanically removing damaged layer and performing electric arc surfacing of rotated roll in place of damaged layer removal while feeding steel austenite wire electrode with diameter 3 - 5 mm to welding zone. Surfacing is realized at density of electric current 30 - 40 A/sq. mm and at electrode feeding speed 80 - 110 m/h. After surfacing journal is subjected to spontaneous cooling.

EFFECT: possibility for completely restoring geometry size of operational properties of damaged roll at keeping the same values of its hardness and strength.

1 tbl, 1 ex

FIELD: processes for surfacing by means of lying electrode, possibly manufacture of crowns of teeth of digging machines working in condition of intensified wear.

SUBSTANCE: method comprises steps of placing electrodes with gap on part to be surfaced; using flux and additive powder material; exciting electric arc between electrode and surfaced surface; performing multi-layer surfacing alternatively on upper and lower sides of crown; using steel substrate whose width is equal to distance between lateral faces of crown and whose length is equal approximately to difference of length values of new and worn crowns along axis of lateral side; arranging steel substrate in direction of plane crossing axes of lateral faces of crown and welding it to crown along contour of wear; fixing crown with welded substrate in such a way that at first its upper side is arranged horizontally, then its lower side is arranged horizontally; placing electrodes across lengthwise axis of crown at first on substrate and then on surfaced zones until their complete restoration.

EFFECT: enhanced quality of restored surface, lowered cost and simplified technique of process.

3 cl, 5 dwg, 1 ex

FIELD: processes for surfacing with use of lying electrode, possibly restoration of worn surfaces of parts in different industry branches.

SUBSTANCE: method for surfacing bead of rollers of road building machines comprises steps of arranging roller in such a way that its axis is vertical; dividing surfaced zone of bead by technological sectors; forming electrodes of n mutually joined rods bent along arcs of sectors and arranging them on surfaced area of respective sector with gap; supplying flux and additive powder material to surfaced zone; connecting electrode and part with power source for exciting electric arc and performing surfacing; placing electrodes on sectors of bead simultaneously along the whole circle; electrically connecting front end of one electrode with bead; at surfacing narrow beads, forming electrodes of n mutually joined rods arranged one over another.

EFFECT: enlarged manufacturing possibilities of method for surfacing parts with annular worn surface, lowered cost, enhanced efficiency of process.

3 cl, 5 dwg, 1 ex

The invention relates to metallurgy, and more particularly to the repair of metallurgical equipment, and can be used to restore the rollers of the roller conveyor of the hot rolling mill

The invention relates to the field of metallurgy and can be used to restore banded roller winders hot rolling mills
The invention relates to welding and cladding and may find application in the manufacture of new parts and restoration with simultaneous hardening of worn parts like shaft, the axis of the plunger, knives for cutting and granulation of materials
Up!