Method and unit for welding of at least two components by laser beam

FIELD: process engineering.

SUBSTANCE: invention relates to welding of at least two components 102, 104 of super alloys. In compliance with this process, mail weld 110 if made with the use of the first filler metal arranged between said components 102, 104 and weld surface 112 with the use of second filler metal made over the main weld. Spacer 506 is fitted between said components provided with optional flute 105 made along the surface 114 of weld 102, 104. Filler wire 504 is fed over preset surface 114 or inside said optional flute 105. Two lasers 700, 702 or laser 600 with connected beam splitter 604 produce first and second laser beams 508, 510. Said beams are directed at focus points 5122, 514 spaced apart through preset spacing (509), for example, 0.05-1.5 cm. First laser beam 508 is used for making of the main weld 110 with the help of fist filler metal between components 102, 104. Second laser beam 510 is used for making of the surface weld 112 with the use of second filler metal on the surface of the main weld 110.

EFFECT: perfected method.

9 cl, 8 dwg

 

Described in this document, the invention relates to welding by a laser beam, and more particularly, to a modified system and method of welding with a laser beam designed to join materials made of alloys or clad materials, such as used in gas turbines.

The LEVEL of TECHNOLOGY

Funds for the production of electricity and associated plants, including gas turbine engines, jet engines, wind turbines and associated platform or masts are often subjected to dynamic conditions. Possible loads in such conditions, in particular under conditions of high temperature and pressure, require the use of plant components for the production of electricity having a high strength and wear resistance. One exemplary type of materials developed for use in these conditions, include superalloys.

Superalloys are alloys containing about 50% or more by mass of the base metal, including Nickel, cobalt and iron, to which is added alloying elements to improve the mechanical and physical properties of these alloys. One specific example of a superalloy suitable for gas turbine components of aircraft and industrial gas turbines, and other �ADAC, is the alloy Rene N5, which is an alloy based on Nickel with the single-crystal rhenium. Materials from superalloys have not only good strength, but also creep resistance, fracture toughness and other mechanical properties at elevated temperatures for extended periods of time.

Welded connection material of superalloys is relatively difficult, requiring a very specific welding conditions. For example, when using such methods of welding with low input heat, such as a laser or electron beam welding, welded joints are performed in a very narrow range of welding conditions. One disadvantage of these methods is a directional grain growth of the metal in the melting zone, which creates a pronounced dendritic border in the center of the weld zone. This type of grain structure reduces the stability of the connection to cracking on the Central line, resulting in a very low fatigue strength, which, in turn, can lead to sudden failure of the welded joint by a gas turbine.

To fix the cracking problem on the Central line has developed several alternative methods of welding of superalloys from which to improve fatigue life of the connection ISP�lesuuda method of electron-beam welding with wire feed, autogenous laser welding, arc welding with tungsten electrode in inert gas or electron beam or laser welding with pre-laid gasket. In the simple method of welding with wire feed add plastic filler metal of the superalloy using an automatic wire feeder with electronic beam welding of two metal parts. However, this method is limited by the thickness of the welded connection. In addition, by increasing the thickness of the connection more than 0.25 cm often there is lack of fusion. Welding with laser without filler metal (i.e., autogenous welding) can lead to very low ductility, and weld may crack during solidification or after it. Large heat input used in arc welding, can cause relatively large distortion of the aerodynamic surfaces and increase the risk of incomplete fusion defects in the weld, which, therefore, prevents the use of welding in an inert gas as the primary method of welding of complex structures with aerodynamic surfaces. The addition of a previously laid strip between two welded components increase the thickness of the connection, as well as the ductility of the weld metal to reduce cracking of the metal of St�rnogo seam. However, if plasticity is not high enough, may cause cracking.

In the art are continuously searching for improved systems and methods of welding of superalloys and other materials to improve the performance of welded components and the empowerment of repair when using such components.

Disclosure of the INVENTION

Aspects and advantages of this invention partially set out in the following description, or may be obvious from the description, or may be specified by the invention.

In General, illustrative embodiments of the present invention relate to methods for laser beam welding at least two adjacent components by essentially simultaneous generate the primary of the weld using a first filler material located between these components, and the surface of the weld using a filler metal formed on top of the base weld.

One illustrative method of the present invention relates to a method for laser beam welding at least two adjacent metal components. The first filler metal is placed within the connection created between at least first and second components. The second filler metal� served on top of a connection, created between said at least first and second components. The first and second laser beams to induce respective first and second focal points located at a predetermined distance from each other. The first laser beam is used to generate the primary of the weld using a first filler material located between said at least first and second components. The second laser beam is used to create the surface of the weld using the second filler metal on the top of the main weld. Basic weld surface and the weld create in one pass of the first and second laser beams on the connection created between said at least first and second components.

Another illustrative embodiment of the present invention relates to apparatus for laser beam welding at least two components made of superalloys containing a first filler metal, the second filler metal, the energy source and the controller. The first filler metal is located within the connection created between at least first and second components from superalloys. The second filler metal is fed over a connection created between said at least first and second component�Tami from superalloys. The energy source generates first and second laser beams in respective first and second focal points. The energy source is connected to the controller, which is designed to control the power and position of the first and second laser beams so that the first laser beam creates the main weld with a first filler metal between said at least first and second components from superalloys and the second laser beam creates a surface weld bead using the second filler metal on the top of the main weld in one pass of the mentioned first and second laser beams on the connection created between said at least first and second components from superalloys.

These and other features, aspects and advantages of this invention will become more apparent from the following description and the attached claims of the invention. The accompanying drawings, which are incorporated herein and constitute a part of it, illustrate embodiments of this invention and together with the description serve to explain the principles of the invention.

BRIEF description of the DRAWINGS

The following is a full and sufficient description of the present invention, including preferred options for implementation, designed for the special�sheet in the art, with reference to the accompanying drawings, in which:

Fig. 1 is a view in perspective of the structure of the two components and the laying of the first filler metal before welding;

Fig. 2 is a view in perspective of the structure of the two components with the laying of the first filler metal and the surface of the welded seam from the second filler metal, is made along the upper surface after welding;

Fig. 3 is a view in perspective of the structure of the two components containing surface groove, and strip from the first filler metal before welding;

Fig. 4 is a view in perspective of the structure of the two components with the laying of the first filler metal and the surface of the welded seam from the second filler material located in the surface groove after welding;

Fig. 5 is a schematic view in perspective of an illustrative hardware components used in the formation of the weld in accordance with aspects of the present invention;

Fig. 6 is a diagram of a first illustrative embodiment of a power source intended for use in the illustrative method of welding in accordance with the present invention;

Fig. 7 shows the scheme of the second Illustrator.�operational embodiment of an energy source, intended to be used in the illustrative method of welding in accordance with the present invention; and

Fig. 8 is a block diagram of illustrative steps of a method of welding in accordance with one aspect of the present invention.

The IMPLEMENTATION of the INVENTION

Hereinafter described in detail embodiments of the invention, one or more examples of which are shown in the drawings. Each example is given to explain the invention and not limitations. In addition, specialists in the art it is obvious that the present invention can be performed modifications and changes without departing from the scope or the spirit of the invention. For example, features illustrated or described as part of one embodiment can be used with another variant of execution to receive a second embodiment. Thus, it is understood that the present invention includes such modifications and changes within the scope of the points of the attached claims and their equivalents.

Fig. 1-4 show views in perspective of two illustrative prefabricated structures before and after the application of the proposed methods of welding. These drawings and the related description examines the connection by welding of the first and second components together, but should pony�AMB, in accordance with the proposed ways you can join by welding more components and/or multiple connections between the first, second and other components.

As shown in Fig. 1, is provided first and second overall metal components 102 and 104. In one particular embodiment, the 6 components 102 and 104 are components made of one or more relevant material from superalloys. Proposed in this paper methods are particularly suitable for welding materials of superalloys, such as single-crystal superalloys based on Nickel, such as Rene N5, as well as other alloys of the same family of alloys Rene, which are used in gas turbines, etc., In another embodiment, the components 102, 104 may correspond to other examples of alloys, including superalloys based on Nickel, cobalt and iron. Specific examples of superalloys Nickel-based superalloys include Nickel-based, hardened primary gamma Prime, made in the form of either rolled or cast material (e.g. equiaxed casting with directional solidification or single crystal casting), including GTD-222, GTD-111 and materials Rene N5. A specific example based superalloy is an alloy of iron A. A specific example based superalloy cobalt is�tsya alloy A.

As shown in Fig. 1, the connection between the two components 102, 104 is inserted a metal gasket 106. In the example shown in Fig. 1, the gasket 106 and the first and second components 102, 104 near the strip 106 and a corresponding connection between the first and second components 102, 104 having substantially the same height 108. Despite the lack of illustrations, it should be understood that in some embodiments, the spacer 106 may pass above or below the height of the first and second components. In addition, it should be understood that between the spacer 106 and related components 102, 104 can be one or more small gaps (for example, corresponding to a gap width of about 0-0,025 cm between the gasket and the surface of the adjacent component).

Spacer 106 is made of a first filler metal, which can match the variety of suitable materials. In one example, the first filler metal may contain material of high strength superalloy, including superalloy strengthened primary gamma Prime content of the primary gamma-phase 10%-60%. Specific examples may include including dispersion-hardened hromonikelemolibdenovyh alloy with addition of molybdenum for solid solution hardening (for example, the alloy NIMONIC-263), and superalloys based on Nickel, hardened first�: Gama-phase (for example, alloys GTD-222, GTD-11 and materials from the family of Rene). Additional examples of high-strength superalloys for use as a first filler material including super alloys, hardened double primary gamma Prime, such as alloy 718 (nikelehromovaya alloy), an alloy 706 (nikelehromovaya alloy) and alloy-725 (nikelehromovaya alloy). In another example, the first filler metal may contain material from more ductile superalloy, including nikelerafinirovochnogo superalloy with a hardened solid solution, such as alloy INCONEL-617 (IN617), nikelehromovaya superalloy, such as INCONEL alloy-625 (IN625) or nikelehromovaya superalloy such as HAYNES alloy-230 (NA).

Fig. 2 shows the assembled construction shown in Fig. 1, after the application of the proposed methods of welding. As shown in Fig. 2, the main weld 110 is made by heating the strip 106 sufficient for penetration to the full depth of the strip between the first and second components. On the top of the main weld 110 by heating the second filler metal (for example, filler wire, placed on the upper part of the connection between the first and second components 102, 104) during the same pass of the weld is complete the surface of the weld seam 112. In vari�NTE execution shown in Fig. 2, surface weld 112 substantially implemented along the upper surface 114 formed by the first and second components 102, 104. It should be understood that some parts of the second filler metal used for the surface of the weld 112, can also pass down to the main weld seam, for example in areas any gaps between the gasket 106 and related components parts 102, 104. It should also be understood that the surface of the weld seam 112 may be formed as a continuous weld, as shown in Fig. 2, or in another embodiment may be performed as an intermittent weld is only required in places. For example, the surface of weld seam 112 may correspond to a spot welded seam, which forms spaced apart from each other separate parts of the surface of the seam or surface areas of the seam thickness.

The second filler metal used in the weld surface 112 may include any of the above examples of materials for the first filler metal mainly weld seam 110, and other materials. In specific examples for second filler metal can be an effective use of high-strength superalloy for a first filler metal and one of the more plastic� superalloys including alloy IN617, IN625 or NA, for the second filler material. In other specific examples, the ductility of the second filler metal may be higher plasticity of the first filler metal. For example, the first filler metal may have an elongation (as determined in accordance with the ASTM E8 Standard test methods of metallic materials in tension") about 10-30%, and the second filler metal may have an elongation of about 50-75%.

In the variant embodiment shown in Fig. 1 and 2, the first filler metal between the components 102, 104 is not a separate strip, and is lakirovannym metal, applied as a coating on one or more surfaces of one or both of the components 102, 104. In this case, the proposed methods of welding can be used to connect themselves clad metals. That is the main metal that is already plated, attached to such base material with the cladding. Deeply proveryai first laser main beam creates a weld between the two materials, and the second laser beam causes the plating material on the upper part. Thus, the two clad metal parts can be joined in a single operation.

Another embodiment of a prefabricated structure in accordance with the USA�AI with the proposed welding methods shown in Fig. 3 and 4. The same reference position indicate similar parts. For example, the first and second components 102 and 104 in Fig. 3 and 4 are similar to the first and second components 102 and 104 shown in Fig.1 and 2, except that the embodiment shown in Fig. 3 and 4, involves performing groove along the upper surface of these components, and the surface of the weld within this groove and not along the upper surface.

As shown in Fig. 3, the first and second components 102 and 104 is made with a groove 105 along a predetermined surface (e.g., top surface 114). The groove 105 essentially corresponds to a channel extending longitudinally essentially along the entire length of the connection between the first and second components 102, 104. As shown, the groove 105 may be configured to limit the channel having a generally U-shaped cross-section, but may use other forms, including a V-shaped or rectangular cross section. By performing the groove 105 at the junction between the first and second components 102, 104 is provided by a directional position to enter into contact with the strip 106 and generate the primary weld 110. Moreover, the region of formation of the surface of the weld 112 is designed so that the surface of the suture 112 is formed at least partially �between the first and second components 102, 104, not only along the upper surface of these components. This design, having a greater volume of the weld 112 than in Fig. 2, may further increase the durability of the weld and reduce the cracking.

In one illustrative embodiment, shown in Fig. 3 and 4, the height of the strip 107 106 is greater than the height 109 of the groove 105 and, accordingly, the height of the base weld 110 is greater than the height of the surface of the weld 112. In one specific example, the height of the first and second components 102, 104 corresponds to the height 108, as shown in Fig. 3. The height of the strip 106, which corresponds to the height 107 of the first and second components 102, 104 near the junction between the first and second components corresponds to approximately 60-80% of the height 108. Height 109, corresponding to the maximum depth of the groove 105, thus, corresponds to the difference between the heights 108 and 107, which, typically, may be about 20-40% of the height 108.

Fig. 5 schematically shows an illustrative installation to perform the welded connection of the components shown in Fig. 2 and 4. As shown in Fig. 5, above the assembled structure to be welded, provided the source is 500 energy. The prefabricated structure may be located on the top plate 502 and, more specifically, includes first and second components 102, 104 between which is inserted� strip 106 from the first filler metal. Filler wire 504 from the second filler metal is fed from a source of filler material 506, such as a winding drum, to the area above the strip 106. When between the first and second components 102, 104 is made a groove 105, as shown in Fig. 5, the end of the filler wire 504 may be located within the groove 105.

With outputs of 500 source of energy first and second laser beams 508 and 510 are sent to respective first and second focal points 512 and 514 along the modular structure shown in Fig. 5. The first focal point 512 is generally consistent with the area along the strip 106 to form the primary of the weld 110 and provalivaet first and second components 102, 104. The second focal point 514 is generally consistent with the land along the filler wire 504 or near its end to create a surface weld 112 on the top of the main seam 110. It should be understood that the actual focal point of the laser can focus in on areas that are above or below the respective surfaces of the strip and filler wire.

The distance 509 explode rays between the first and second focal points 512, 514 (or between points in parallel to the first and second laser beams 508, 510) may be sufficiently small so that the laser beams could separately create the main seam surface 110 and the suture 112,�however, in this surface seam 112 is formed immediately on top of the base weld 110, before the main seam 110 has time to cool and to harden. In one example, the distance of 509 separation of the beams is chosen in the range from approximately 0.5 to approximately 1.5 cm, This distance can be measured directly between the first and second focal points. In another embodiment, the distance 509 explode rays corresponding to the illustrative range of approximately 0.5 to 2.0 cm, can be split to explode distance horizontally and explode distance vertically. The use of the first and second focal points at different sites provides horizontal formation of the weld before the formation of the surface of the weld. The use of the first and second focal points at different sections along the vertical also provides deeper penetration of the first laser beam in the main seam, and the second laser beam enables the formation of surface seam a little higher on the vertical. In one example, the separation distance of the first and second focal points horizontally is approximately 0.5-2.0 cm, and the distance they explode vertically approximately 0.1 to 1.0 cm

It is shown schematically in Fig. 5 way double welding with a laser beam allows the connection of the first and second components 102 and 104 of the first laser beam 508 and plavini� plastic surface of the suture 112 to the cooling of the main weld 110. The fulfillment of the main suture 110 and the surface of the seam 112 may be implemented by using first and second laser beams in one step of welding, for example by essentially simultaneous targeting of the first and second laser beams on the respective first and second filler metals. The execution of the main suture 110 and the surface of the seam 112 for single pass welding leaves no time for curing and cracking of the main suture 110 before the formation of the plastic surface of the seam 112. As a result the entire weld seam (formed as the main seam 110, and surface seam) hardens evenly, thereby significantly decreases the likelihood of cracking during curing.

The execution of the main suture 110 and the surface of the seam 112 in a single pass weld is achieved by precise control of the mouse as the first laser beam 508 and the second laser beam 510. Welds 110, 112 along the connection between the first and second components 102, 104 operate either by fixing the design team and moving 500 source of energy, emitting first and second laser beams 508, 510, or by fixing 500 source of energy and movement design team along the plate 502. The speed of the specified relative displacement is chosen such as to create an optimum welding conditions, wherein said IC�rate may correspond to one example of the speed, chosen from the range from approximately 10 to approximately 400 cm/min.

The size of the base weld 110 and the surface of the weld 112 depends in part on the size of the first and second components 102, 104, and accordingly the selected size of the first filler metal (for example, the strips 106) and the second filler metal (for example, filler wire 504). In one example, the thickness of the spacer 106 is selected within a range of approximately from 0.02 cm to about 0,08 see In one example, the diameter of welding wire 504 is chosen from the range from about 0.02 inches to about 0.15 to see it Should be understood that for large wire diameters (e.g., diameters greater than or equal to 0,075 cm) may be necessary to pre-heat the wire forming surface seam 112, prior to the introduction of the laser beam or welding zone.

In one illustrative embodiment, the energy source 500 corresponds to the source of laser radiation emitting a first laser beam 508 and the second laser beam 510. Used to provide similar radiation lasers can be of different types, including including solid-state lasers (e.g., fiber lasers, diode lasers, crystal lasers (e.g., Nd:YAG - neodymium lasers yttrium aluminum garnet), a semiconductor laser�s, gas lasers (e.g., carbon dioxide (CO2), helium-neon, argon ion), chemical lasers, excimer lasers, dye lasers or free electron lasers. Lasers can be executed by the opportunity to work in continuous mode or pulsed mode. In one example, the power level of the first and second laser beams 508, 510 are approximately the same. In another example, the power level of the first laser beam 508 may be greater than the power level of the second laser beam 510. For example, the power level of the first laser beam 508 may be about 70% of the output power of energy source, and the power level of the second laser beam 510 may be about 30% of the output power of energy source. In this case, the power level of the first laser beam 508 may actually exceed the power level of the second laser beam 510 is approximately two or more times.

As shown in more detail in Fig. 6, one illustrative source design 500 energy contains 600 laser that generates laser light source 602. The laser beam 602 is sent to the splitter 604 beam, which then splits the source beam 602 by two laser beam 508 and 510, which are used to create respectively the main weld 110 and the surface of the weld 112. The beam splitter may be a �pricheski element or combination of optical elements, for example a prism or a mirror, which provides the splitting of the laser beam 602 on two beams 508 and 510, which may take place essentially in a parallel direction. The beam splitter 604 can be attached to the controller 606 is used to set the distance between the laser beams 508 and 510, the vertical and/or horizontal position of the focal points and/or power level of each laser beam.

As shown in more detail in Fig. 7, another illustrative design 500 source of energy comprises a first laser 700, generates at the output of the first laser beam 508, and the second laser 702, generates at the output of the second laser beam. Variant of execution, shown in Fig. 7, may also contain a controller 704 that is attached to the respective lasers 700 and 702 to set the distance between the laser beams 508 and 510, the horizontal and/or vertical position of the focal points of the laser beams 508, 510, and power level of each laser beam. When using the first and second lasers 700 and 702 of the first and second laser beams 508 and 510 are not necessarily, substantially in the parallel direction. For example, the first laser beam 508 may be held essentially perpendicular (at an angle of about 90°) to the plate 502. However, the second laser beam 510 can be directed at an angle (to simplify the placement of individual equipment second�about laser 702). For example, the second laser beam 510 can be directed at any suitable angle in the range of 0-90° (e.g., 40°-70°) to the plate 502.

When using controllers 606 and 704 they may respectively contain at least a storage device, such as a storage medium to be read by the computer, for receiving and saving of user-entered data, as well as machine-readable commands, and computing device for executing specified commands and to operate the controller as a device for special purposes, and the interface for the implementation of specific operational parameters of 500 source of energy.

For illustrative operational parameters of the laser beam are the power levels, frequency, travel speed, etc. These parameters are chosen sufficiently high to ensure full weld penetration between the welded components in the creation of the main weld and low enough to avoid undesirable damage to the components, such as random slotting metals. The speed of movement of the components along the plate also specially selected to prevent overheating due to the low velocity of the melting or defects as a result of undercooked weld because of the great speed moved�me. In one particular embodiment, the first and second laser beams 508 and 510, respectively, provide the conditions of operation, including power levels in the range of about 500-20000 W, the velocity of 10-400 cm/min and a focal distance of about 10-25 cm

Additional description of the above welding methods in accordance with a variant implementation of the present invention shown in Fig. 8, which shows a block diagram of illustrative steps of the method of welding. At the first stage 800 between the first and second components from superalloys placed first filler metal (for example, by inserting a strip made of a first filler metal). In optional step 802 along a given plane connection between the first and second components form a groove. An example of such groove is shown in Fig. 3 and 5. In step 804 in the groove or along a specified surface between the first and second components, as shown in Fig. 5, serves a filler wire made of the second filler metal. In step 806 the second filler metal before welding can be preheated. For example, the filler wire can be made of the operation of the heating wire, such as resistive heating, induction heating or other heating operation, for the preparation of filler metal and�of Ucrania surface of the weld.

As shown in Fig. 8, step 808 includes guidance of the first and second laser beams on the first and second focal points located from each other at a distance of separation of the beams, the value of which, as stated above, is in the range of approximately 0.5-2.0 cm. In step 810 using the first laser beam to generate the primary of the weld between the first and second components with the use of gaskets, and use the second laser beam to create using filler wire weld surface of the main surface of the weld in the optional groove or on a given surface. Main surface and the seams perform in one pass of the first and second laser beams on top of the connection between the first and second components. An optional step 812 includes a main cooling surface and seams after their formation. Subsequent optional step 814 includes the heat treatment after welding for additional reinforcement of welds produced between the first and second components by deposition of the reinforcing elements on the first and/or second filler materials. In one example of step 814 heat treatment is an operation that contains two stages and comprising a first treatment on solid solution filler material and then the implementation of aging or solid�tion during aging. For example, the solution treatment may include effects on welded construction high temperature (e.g., 1000-1200°C) for 1-3 hours, and aging can include effects on welded construction temperature (e.g., 600-750°C for hardening of the primary gamma Prime and/or 750-900°C for hardening of dual primary gamma Prime) for 4-24 hours. Additional optional steps may include grinding sections of the main suture and/or the surface of the seam that extend beyond the top or bottom surfaces of the first and second components.

Although the proposed methods of welding covered for the join welding of components, it should be understood that the proposed methods can be used for welding many of any part of the turbine, for example for connection by welding of the exhaust steam pipe with nozzle, brace coronal parts of the blades, brace coronal part of the blade with nozzle cap, rear frame and transition elements, for sealing the end cap manifold, for welding the clad sections of the masts of the wind turbines in the open sea, to connect or weld repair of the inner clad diameter high-pressure chamber, for connection or repair of welded elements of the rotors, in which the surface of the welded seam in conjunction with the main swar�th seam has a high ductility, etc.

The advantages of the proposed design lies in the fact that in one single working pass are multiple welded joints, which increases the speed of manufacture. The described method also contribute to the prevention of cracking that could potentially occur in welded components and filler metals used to create welds between components (for example, cracks that may appear in the welded connection between components, or transverse cracks along the top surface of the welded components). Preventing cracking of welds reduces the possible amount of re-processing that may be required for welded components under dynamic conditions of operation.

Although the present invention is described in detail with reference to specific illustrative embodiments of, and how, you should understand that after reading this document, specialists in the art can easily make modifications, changes and technical equivalents to such embodiments. Accordingly, the content of this description is given as an example and not for limitation, and the present description does not preclude inclusion of such modifications, modified�and/or additions to the present invention, what is clear for the person skilled in the art.

The LIST of COMPONENTS

The first component 102

The second component 104

105 groove

106 gasket

107 height strip

108 the height of the component

109 the height of the groove

110 main weld

112 surface weld

114 upper surface

500 energy source

502 stove

504 filler wire

506 source filler material

508 first laser beam

509 explode distance rays

510 second laser beam

512 first focal point

514 second focal point

600 laser

602 laser light source

604 beam splitter

606 the controller

700 first laser

702 second laser

704 the controller

800 first stage of the method

802 the second stage of the method

804 third stage of the method

806 fourth stage of the method

808 fifth stage of the method

810 sixth stage of the method

812 seventh stage of the method

814 eighth stage of the method.

1. Method of laser beam welding at least two adjacent components (102, 104) of superalloys, including:
providing a first filler metal (106) within a connection formed between the at least first and second components (102, 104) of superalloys;
feeding a second filler metal (504) over the connection formed between said at least pyo�the first and second components (102, 104);
guidance of the first and second laser beams (506, 510) on the respective first and second focal point (512, 514) located at a predetermined distance (509) from each other;
the use of the first laser beam (508) for the core weld (110) using a first filler metal between said at least first and second components (102, 104);
use a second laser beam (510) to perform the surface of the weld (112) using the second filler metal on the top of the main weld (110);
the main weld (110) surface and a welded seam (112) creating in a single pass of the first and second laser beams (508, 510) at the joint formed between said at least first and second components (102, 104); and
the main cooling of the weld (110) surface and the weld (112), made between the said at least first and second components (102, 104).

2. A method according to claim 1, which additionally create the groove (105) along the top surface (114) of each of the first and second components (102, 104) of superalloys on the connection made between the said at least first and second components (102, 104), and surface weld (112) performed on the upper surface of the main weld (110), perform inside �elonka (105).

3. A method according to claim 2, wherein the depth (109) of the groove (105) that runs along the top surface (114) of each of the first and second components (102, 104) for connection between said at least first and second components (102, 104), is chosen in the range from approximately 20% to approximately 40% of the height (108) of the said first and second components (102, 104) directly outside of the groove (105).

4. A method according to claim 1, wherein the power level of the first laser beam (508) is greater than the power level of the second laser beam (510).

5. A method according to claim 1, wherein the predetermined distance (509) between the first and second laser beams (508, 510) is selected from the range from about 0.5 cm to about 1.5 cm.

6. Setup for laser beam welding at least two components (102, 104) of superalloys containing:
the energy source (500), arranged to generate first and second laser beams (508, 510) to the respective first and second focal points (512, 514);
the controller (606, 704) connected to the energy source (500) and structurally arranged to control the power and position of the first and second laser beams (508, 510) and to regulate the depth of the first and second focal points (512, 514) so that the depth of the first focal point (512) is greater than the depth of the second focal point (514), and the power level of the first �ozernogo beam (508) is greater than the power level of the second laser beam (510) for generating the first laser beam (508) of the main weld (110) between said at least first and second components (102, 104) and the creation of a second laser beam (510) seam surface (112) at the top of the main weld (110) in a single pass of the mentioned first and second laser beams (508, 510) for connection performed between said at least first and second components (102, 104).

7. Apparatus according to claim 6, in which the specified controller (606, 704) is additionally designed with the possibility of regulating the distance (509) between the first and second focal points (512, 514) in the range from about 0.05 cm to about 1.5 cm.

8. Apparatus according to claim 6, in which the specified source (500) of energy comprises a first laser (700), creating the first laser beam (508) essentially in a perpendicular direction at least to said first and second components (102, 104), and the second laser (702) that generates a second laser beam (510) in a direction angled to said at least first and second components.

9. Apparatus according to claim 6, in which the specified source (500) energy includes a laser (600) and the splitter (604) beam, and the said laser (600) is located at the specified splitter (604) beam so that the beam splitter (604) generates at the output of said first and second laser beams (508, 510).



 

Same patents:

FIELD: process engineering.

SUBSTANCE: invention relates to production of pipes by laser welding. Laser welding comprises emitting of two laser beams along edges at open pipe upper surface. Said laser beams are transmitted via different optical fibre glass and have focused spots of diameters making over 0.3 mm. Said laser beams are emitted so that front laser beam and rear laser beam are inclined to welding direction. Note here that incidence angles are defined relative to direction perpendicular to open pipe top surface. Front laser beam falls on open pipe top surface in welding direction before rear laser beam while the letter falls on open pipe top surface in welding direction after front laser beam. Front laser beam incidence angle is set larger than that of rear laser beam. Gap between front laser beam centre and that of rear laser beam is set at open pipe rear surface equal to 1 mm and more.

EFFECT: higher quality of weld, higher yield.

17 cl, 4 dwg, 3 tbl, 1 ex

FIELD: metallurgy.

SUBSTANCE: temporary beads 3 and 4 are made on thick 2 and thin 1 parts. The bead 3 height is by 3-4 times higher than thickness of part 1. Height of bead 4 is equal to height of bead 3. Bead 4 thickness is determined by equation S2=(1+Δ)·S1. Beads 3 and 4 contact surface is treated by ultrasound in ethyl alcohol. Parts 1 and 2 are secured in welding fixture. Butt joint gap and beads 3 and 4 shift at least 10% of part 1 thickness are ensured. Laser beam 5 is directed to butt joint of beads 3 and 4.

EFFECT: invention increases weld strength due to rational design of the temporary beads.

3 cl, 4 dwg

FIELD: metallurgy.

SUBSTANCE: device to manufacture items by layer-by-layer laser agglomeration of powders contains tanks for powder and powder surpluses, located between them module for item forming including table with drive of its vertical movement, device for powder supply to the table from powder tank, and powder discharge to power surpluses tank, optical laser system for agglomeration of the powder nozzles installed above the table for air or inert gas supply on the powder layer, and gas intake installed under the table with possibility of connection with vacuum system. The table is made gas permeable and is equipped with installed on its top surface of the refractory gas permeable plate intended for powder layer arrangement on its surface and agglomeration.

EFFECT: improved quality of obtained items.

1 dwg

FIELD: machine building.

SUBSTANCE: module comprises a guide belt, a movable orbital carriage mounted on the guide belt and able of travelling along it. The carriage includes a longitudinal movement drive and a moving device consisting of a carrying roller system and a gear wheel. A joint monitoring sensor, a welding wire reeling device and a handler are installed on the carriage. The handler consists of two mutually perpendicular linear guides with motors, which can move in respect to each other. The transverse linear guide is equipped by a laser welding head, a wire feeding unit, an arc welding torch, a video camera and a controller.

EFFECT: invention allows for the increase of productivity and efficiency of welding process for fixed ring pipe joints and for the improvement of welded joint quality.

3 cl, 3 dwg

FIELD: process engineering.

SUBSTANCE: invention relates to low-inertia robot for laser cutting of flat sheets. Robot comprises support appliance (15) for laser cutting head (14) displacing in axes X and Y. Said support appliance is provided with two sliding units (5, 6) actuated by independent drives (7, 8). They serve for their displacement in axis Y to vary their mutual spacing while bars (9, 10) intended for swivelling said sliding units (5, 6) with laser cutting head (14).

EFFECT: higher quality of cutting.

4 cl, 8 dwg

FIELD: process engineering.

SUBSTANCE: invention relates to protection of steam turbine blades against erosion. Proposed process comprises application of protective coating on the blade. Coating is applied by laser surfacing. Laser head is displaced at the rate of linear interpolation Vi not over 0.05 m/s at laser radiation power making 800-1200 W.

EFFECT: hardened ply of 1/3 length of the blade root at sufficient aerodynamics.

2 dwg

FIELD: process engineering.

SUBSTANCE: invention relates to repair of turbine blades. Proposed process comprises preparation of blade surface. Coating is applied with the help of laser radiation with simultaneous feed of additive powder to melt belt. At hard-facing, radiation power P is varied from 300 to 2500 W, and/or as radiation source feed rate V from 0.1-0.01 m/s, and/or amount of powder fed from 3 to 15 g/min.

EFFECT: accelerated process, higher hard-facing quality.

FIELD: process engineering.

SUBSTANCE: invention relates to welding of metal wires. Welding is performed with the help of laser source to make the weld, in fact, not extending beyond the wire radial cross-section. Prior to welding, at least one of wires to be welded together is subjected to annealing in hot gas flow and/or, in welding, produced weld point is subjected to annealing by hot gas flow.

EFFECT: high-quality weld without further machining.

20 cl, 5 dwg

FIELD: metallurgy.

SUBSTANCE: powder composition mixture for laser build-up on the metal base includes powders of titanium and silicone carbide with particles size 20-100 mcm at the following ratio of components, parts by weight: titanium - 5-7; silicon carbide - 3-6. Titanium powder particles can be in form of spheres.

EFFECT: assurance of uniform distribution of hard inclusions over volume of coating due to synthesis of the titanium carbide, resulting in improvement of the coating quality, namely its hardness and wear resistance.

2 cl, 1 tbl

FIELD: physics, optics.

SUBSTANCE: invention relates to the technology of making complex holes using a laser beam, particularly a through hole for film cooling of a turbine component. At the first step, the internal part (7) of the hole (1) is made from the surface (12) to the opposite internal surface (13) of the substrate (4) using a laser (22) located in a first angular position (1) and simultaneously making a diffuser (10) part. The diffuser (10) residue (16, 18, 28) is removed at the next second and third steps. At the second step, the angular position of the laser (22) is changed to a position (II), different from angular position (I), and the laser is moved to the angular position (II) until the lateral side (17a) of the diffuser (10) is open and part of the volume (18) of the residue (16, 18, 28) remains. At the third step the angular position of the laser is changed from the angular position (II) at the second step so as to remove said residue (18). The angle in the angular positions (I, II, III) is defined as the angle between the middle line of the laser beam (25) and the surface (12) around the film cooling hole (1).

EFFECT: using a laser in three different angular positions relative to the processed substrate significantly simplifies the making of complex holes in the substrate.

13 cl, 12 dwg

FIELD: physics.

SUBSTANCE: laser welding is carried out by emitting two laser beams along a fusion line on the side of the upper surface of the processed component. The two laser beams are transmitted through different optical fibres with diameter of focused spots of 0.3 mm or more. The leading laser beam and rear laser beam of the two laser beams is inclined in the welding direction at an angle of incidence relative to the direction perpendicular to the upper surface of the processed component. The leading laser beam is ahead of the rear laser beam on the upper surface of the processed component in the welding direction. The rear laser beam is behind the leading laser beam. The angle of incidence of the leading laser beam is set greater than that of the rear laser beam.

EFFECT: preventing sputtering and sticking to the upper surface of the processed component and the optical component during welding, preventing undercut or underfill of the joint on the back surface of the processed component.

3 cl, 4 dwg, 3 tbl, 2 ex

FIELD: physics.

SUBSTANCE: system comprises a laser beam source (1), a laser beam collimator (2) and a focusing device (3). An optical element (5) is placed between the collimator and the focusing device (3) and is designed to branch the system for distributing the laser beam power in a first direction at an angle to the axis of the collimated laser beam. In the system according to a first version, a bifocal element (6) is placed either between the optical element (5) and the collimator (2) or between the optical element (5) and the focusing device (3). In a second version, a bifocal element (6) is placed between the collimator (2) and the focusing device (3).

EFFECT: homogeneity of power distribution of laser radiation in the welded area.

22 cl, 9 dwg

FIELD: physics, optics.

SUBSTANCE: invention can be used in making high-power laser systems for focusing radiation at remote targets. The system includes a first lens, the first and second lens components of which are capable of moving along the optical axis of the lens. A third lens component is immovably mounted. The system includes an additional laser and at least one additional lens, which is identical to the first, arranged such that optical axes of the laser and all lenses cross at one point. The distances from the optical axis of the laser to optical axes of the lenses are equal. Each lens further includes a plane-parallel plate placed in front of the first component such that it is able to turn about an axis perpendicular to the meridian plane of the system. All optical components of the lenses are made of quartz glass. The plane-parallel plates, first and second lens components are kinematically synchronised with each other.

EFFECT: high accuracy of adjusting parameters of laser radiation at a target while simultaneously increasing the transmitted radiation power, high reliability and broader technical capabilities.

3 dwg

FIELD: process engineering.

SUBSTANCE: invention relates to laser welding and may be used in various branches of machine building. Two laser beams are directed to the surface of article to be welded at an angle to each other, to the butt of said article so that one melt molten pool is created. One, the main, laser beam is sent at right angle to article surface to form liquid molten pool, Steam-to-gas channel is formed in said pool. Second beam is sent at angle to said main beam onto preset section of the formed steam-to-gas channel surface.

EFFECT: preset characteristics of weld, higher reliability.

2 cl, 3 dwg, 1 ex

FIELD: physics.

SUBSTANCE: device has a laser and, optically connected to the laser, a system for dividing the initial beam, a beam convergence system, galvano scanner with a focus lens and a telescope-radiation homogeniser, fitted on the beam path in front of the system for dividing the initial beam. The system for dividing the initial beam and the beam convergence system are in form of mirror matrices. The mirrors in the matrices have equal surface area and can independently rotate and move in two mutually perpendicular planes. Mirrors in the matrix of the beam convergence system can additionally move in the plane of the matrix.

EFFECT: multiple increase in efficiency of laser beam machines and reduced power consumption at high quality of the product.

1 dwg

FIELD: technological processes, metal working.

SUBSTANCE: invention is related to the field of laser processing of materials, in particular, to device of multiway laser processing and may be used in production of large number of products at single laser complex, also in process of laser cutting, welding, pad welding and selective sintering. Device comprises N+1 lasers of initial beam division system and system of beam convergence, which is arranged in the form of set of N+1 telescopes, every of which is optically connected to laser. Telescopes are arranged with the possibility of independent rotation and displacement in two mutually perpendicular planes.

EFFECT: provision of multiple rise of efficiency of laser technological complexes, reduced power inputs at high quality of product.

1 dwg

FIELD: working by laser beam.

SUBSTANCE: device comprises emitter, power source, control unit, telescopic device, beam splitter with polyhedral prism, focusing lens, and positioning table. The beam splitter has cassette, is movable, and is provided with the drive for linear movement along the optical axis of the laser beam and drive for rotating the polyhedron prism around the optical axis of the laser bean in the plane perpendicular to the axis. Both of the drives are connected with the control unit.

EFFECT: expanded functional capabilities.

4 dwg

The invention relates to metallurgy and can find application in electronics, instrument and mechanical engineering

The invention relates to the field of engineering, in particular to a device for laser welding of thin wires, and can be used in electronics, instrument and mechanical engineering

FIELD: working by laser beam.

SUBSTANCE: device comprises emitter, power source, control unit, telescopic device, beam splitter with polyhedral prism, focusing lens, and positioning table. The beam splitter has cassette, is movable, and is provided with the drive for linear movement along the optical axis of the laser beam and drive for rotating the polyhedron prism around the optical axis of the laser bean in the plane perpendicular to the axis. Both of the drives are connected with the control unit.

EFFECT: expanded functional capabilities.

4 dwg

FIELD: technological processes, metal working.

SUBSTANCE: invention is related to the field of laser processing of materials, in particular, to device of multiway laser processing and may be used in production of large number of products at single laser complex, also in process of laser cutting, welding, pad welding and selective sintering. Device comprises N+1 lasers of initial beam division system and system of beam convergence, which is arranged in the form of set of N+1 telescopes, every of which is optically connected to laser. Telescopes are arranged with the possibility of independent rotation and displacement in two mutually perpendicular planes.

EFFECT: provision of multiple rise of efficiency of laser technological complexes, reduced power inputs at high quality of product.

1 dwg

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