Complex remanufacturing method and material for desulfurization circulating pump impeller

Abstract

The invention relates to the technical field of complex remanufacturing, in particular to a complex remanufacturing method and material for a desulfurization circulating pump impeller, and the complex remanufacturing method comprises the following steps: constructing multi-modal damage intelligent mapping; synchronously preparing plasma activation and a micro-texture; performing energy field coupling cladding repair; stress field balance shot peening strengthening is conducted; implementing gradient coating self-propagating synthesis; heat-engine coupling precise shaping is carried out; performing micro-gap pressure infiltration sealing; and carrying out multi-physics field service simulation verification. According to the method, the service cycle of key components can be remarkably prolonged, the cavitation-resistant and erosion-resistant comprehensive performance can be comprehensively enhanced, a digital twin closed loop for damage diagnosis, repair optimization and service life prediction is established, meanwhile, full-life-cycle cost control and resource saving are achieved, invalid components are repaired, and a sustainable operation system is reconstructed.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of complex shape remanufacturing, in particular to a complex shape remanufacturing method and material for a desulfurization circulating pump impeller. BACKGROUND

[0002] The desulfurization circulating pump impeller is a core flow component of a wet desulfurization system, and works in an acidic slurry environment with pH = 2-5.5 and a speed of 800-1500 rpm. Its main failure mode is the triple coupling damage of acid corrosion-solid erosion-cavitation, especially the millimeter / year deep erosion of the blade inlet edge and the rear cover plate area.

[0003] However, in general, the traditional remanufacturing technology has systematic defects: the through cracks between the repair layer and the base body are caused by the negligence of thermal matching, the interface bonding depends on mechanical anchoring and cannot resist high-frequency vibration load, the subsurface micropore defects become the invisible channel for corrosion diffusion, and there is a significant deviation between the empirical repair strategy and the actual service life. These inherent bottlenecks make it difficult to achieve the expected level of comprehensive performance and reliability of the remanufactured impeller. SUMMARY

[0004] The present application relates to the technical field of complex shape remanufacturing, in particular to a complex shape remanufacturing method and material for a desulfurization circulating pump impeller.

[0005] To achieve the above-mentioned purpose, the present application provides the following technical scheme: The first aspect of the present application is: The present application provides a complex shape remanufacturing method for a desulfurization circulating pump impeller, which comprises constructing a multi-modal damage intelligent mapping and synchronously preparing plasma activation and micro-texture. Energy field coupling cladding repair and stress field balance shot peening strengthening are performed; gradient coating self-propagating synthesis is implemented, and thermal-mechanical coupling precision shaping and micro-gap pressure infiltration sealing are performed; finally, multi-physical field service simulation verification is performed.

[0006] Optionally, the implementation process of constructing a multi-modal damage intelligent mapping is: A four-dimensional damage model of the blade surface is constructed by using laser scanning point cloud data and ultrasonic residual stress field detection results. Based on the extracted impeller base material parameters, a thermal deformation compensation amount is preset during three-dimensional reconstruction.

[0007] Optionally, the implementation process of preparing plasma activation and micro-texture is: When the damage core area positioned in the step of constructing a multi-modal damage intelligent mapping is scanned on the surface by a pulse plasma beam, argon-nitrogen mixed gas is synchronously introduced to induce in-situ nitriding; The control of the beam spot overlap rate forms a periodic micro-protrusion array, providing mechanical locking anchor points for the cladding layer.

[0008] Optionally, the implementation process of the energy field coupling cladding repair is as follows: For the micro-textured area generated in the step of preparing the plasma-activated and micro-textured, a double-heat-source synergistic system is started: high-frequency induction preheating reduces the cladding thermal shock, while the coaxial laser beam irradiates the induction heating area; The laser spot is precisely matched with the micro-protrusion array, and the energy aggregation effect of the protrusion top is used to realize directional grain growth and control the cooling gradient of the molten pool.

[0009] Optionally, the implementation process of stress field balanced shot peening is as follows: Based on the measured thickness distribution of the cladding layer in the step of performing energy field coupling cladding repair, a regional variable-intensity shot peening strategy is adopted: ceramic shots are used in the thickness mutation area, and glass shots are used in the flat area. The shot peening trajectory is automatically planned according to the residual stress distribution map in the step of constructing a multi-modal damage intelligent mapping, so that the stress range is <100 MPa.

[0010] Optionally, the implementation process of gradient coating self-propagating synthesis is as follows: After the activated surface is treated in the step of stress field balanced shot peening, the transition layer, wear-resistant layer and sealing layer are alternately sprayed with NiAl powder, and the lattice distortion energy generated in the step of stress field balanced shot peening is used to trigger the self-propagating reaction; When preheated to 650℃, according to the step of constructing a multi-modal damage intelligent mapping, the melting point of 60% of the material, NiAl, undergoes an exothermic reaction, which increases the interfacial diffusion rate and forms a functional gradient coating.

[0011] Optionally, the implementation process of thermal-mechanical coupling precision shaping is as follows: The five-axis machine tool calls the initial model in the step of constructing a multi-modal damage intelligent mapping and the coating thickness distribution map in the step of gradient coating self-propagating synthesis, and sets different cutting parameters on the blade working surface: ultrasonic vibration assisted cutting is used in the coating area, and low-temperature liquid nitrogen cooling cutting is used in the substrate area. The feed speed is dynamically adjusted according to the local hardness value.

[0012] Optionally, the implementation process of micro-gap pressure infiltration sealing is as follows: Exposed subsurface micropores after machining in the step of thermal-mechanical coupling precision shaping are used to apply 150 MPa isostatic pressure in a vacuum chamber, and low-melting-point alloy Sn60Pb40 is simultaneously introduced. During the pressure maintaining stage, the alloy melt penetrates along the dislocation channels generated in the step of stress field balanced shot peening.

[0013] Optionally, the implementation process of the multi-physical field service simulation verification is as follows: Integrating the damage model in the step of constructing the multi-modal damage intelligent mapping, the coating physical property parameters in the step of implementing the gradient coating self-propagating synthesis and the sealing structure data in the step of micro-gap pressure infiltration sealing, a three-phase flow-solid coupling model is constructed; The boundary conditions include the erosion-resistant threshold of the cladding layer in the step of energy field coupling cladding repair and the coating phase transition critical point in the step of implementing the gradient coating self-propagating synthesis; The machining setting value in the step of thermal-mechanical coupling precise shaping is verified through iterative calculation.

[0014] The application further provides a reshaping remanufacturing material for a desulfurization circulating pump impeller, which is applied to the reshaping remanufacturing method for the desulfurization circulating pump impeller. The base repair layer is one of FeCrMoNbRE nickel-based alloy or iron-based composite powder, and is used in the step of energy field coupling cladding repair; The stress regulation material includes thickness mutation zone material and gentle zone material, the thickness mutation zone material is Si3N4 silicon nitride ceramic pellet, and the gentle zone material is zirconium-based amorphous alloy pellet, and is used in the stress field balance shot peening step; The functional gradient coating further includes a transition layer, a wear-resistant layer and a sealing layer, the transition layer is one of NiCrMo-7 alloy or FeCrSiB composite 30% TiC alloy powder, the wear-resistant layer is one of Cr2O3 composite 20% Al2O3 nano powder or 10Co4Cr composite 5% nano diamond, and the sealing layer is one of PTFE microcapsule doped nickel-based alloy or PyC pyrolytic carbon coating, and is used in the step of implementing the gradient coating self-propagating synthesis; The sealing infiltration material is one of SnAgCu-Ti composite solder or Cu-SiC composite material, and is used in the step of micro-gap pressure infiltration sealing.

[0015] Compared with the prior art, the application has the following beneficial effects: The complex remanufacturing method of the application forms a set of digital closed-loop system through the technical chain of establishing damage intelligent mapping, constructing interface topological structure, repairing by synergistic energy field, constructing functional gradient strengthening layer, realizing micro-defect closed-loop plugging and service life quantitative prediction. The core breakthrough is the deep integration of dynamic thermal deformation compensation, multi-effect surface synchronous modification, interface metallurgical reaction control and micro-pore accurate sealing, which fundamentally changes the extensive repair logic of traditional surfacing and mechanical processing, improves the performance of remanufactured impellers, significantly prolongs the service cycle of key components, comprehensively enhances the comprehensive performance of anti-cavitation and erosion resistance, establishes the digital twin closed loop of damage diagnosis, repair optimization and life prediction, and realizes the whole life cycle cost control and resource saving. Not only the failed components are repaired, but also the sustainable operation system is rebuilt. BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1 The figure is a flowchart of the complex remanufacturing method of the application for the impeller of a desulfurization circulating pump. DETAILED DESCRIPTION

[0017] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the application.

[0018] Embodiment 1, please refer to Figure 1 The application provides a complex remanufacturing method for the impeller of a desulfurization circulating pump, which comprises the following steps: S1. Constructing a multi-modal damage intelligent mapping. S2. Simultaneously preparing plasma activation and micro-texture. S3. Performing energy field coupling cladding repair. S4. Performing stress field balance shot peening strengthening. S5. Implementing gradient coating self-propagating synthesis. S6. Performing thermal-mechanical coupling precision shaping. S7. Performing micro-gap pressure infiltration sealing. S8. Performing multi-physical field service simulation verification.

[0019] It should be noted that the implementation process of step S1 is as follows: Laser scanning point cloud data and ultrasonic residual stress field detection results are used to construct a four-dimensional damage model of the blade surface. Based on the extracted blade base material parameters, a thermal deformation compensation amount is preset during three-dimensional reconstruction.

[0020] Through the four-dimensional modeling technology of fusing geometric size and residual stress field, the limitation of traditional detection that can only obtain single topographic data is solved, and thermal deformation dynamic compensation is realized. This step fundamentally avoids the risk of repair layer cracking caused by thermal stress mismatch, and provides accurate physical field reference for subsequent processes.

[0021] It should be noted that the implementation process of step S2 is as follows: When the damage core area positioned in step S1 is scanned with a pulsed plasma beam, argon-nitrogen mixed gas is synchronously introduced to induce in-situ nitriding. The beam spot overlap rate is controlled to form a periodic micro-protrusion array, providing mechanical locking anchor points for the cladding layer.

[0022] The surface activation, micro-texture construction, and in-situ nitriding are integrated in a single process, solving the problem of weak interface bonding caused by traditional step-by-step processing. The generated composite structure significantly improves the mechanical locking force of the cladding layer, eliminating coating peeling failure under high-frequency vibration conditions.

[0023] It should be noted that the implementation process of step S3 is as follows: For the micro-textured area generated in step S2, a dual-heat source collaborative system is started: high-frequency induction preheating reduces the cladding thermal shock, while a coaxial laser beam irradiates the induction heating area. The laser spot is precisely matched with the micro-protrusion array, utilizing the energy aggregation effect of the protrusion top to achieve directional grain growth and control the cooling gradient of the molten pool.

[0024] The dual-heat source collaborative mechanism precisely regulates the heat input distribution, completely suppressing the grain coarsening defects of single-heat source repair. The directional grain growth technology makes the repair layer structure uniform and dense, providing a defect-free substrate support for functional gradient coatings.

[0025] It should be noted that the implementation process of step S4 is as follows: Based on the measured thickness distribution of the cladding layer in step S3, a regional variable intensity shot peening strategy is adopted: ceramic shots are used in the thickness mutation area, and glass shots are used in the flat area. The shot peening trajectory is automatically planned according to the residual stress distribution map in step S1, making the stress range <100 MPa.

[0026] Based on the regional strengthening strategy of thickness mutation area and residual stress field, the stress concentration phenomenon of traditional uniform shot peening at geometric discontinuities is solved. Through the cooperation and regulation of rigid and elastic materials, the stress range of the entire blade is compressed to within the safety threshold.

[0027] It should be noted that the implementation process of step S5 is as follows: On the activated surface after step S4 processing, alternate spraying of transition layer, wear-resistant layer, and sealing layer with NiAl powder is performed. The lattice distortion generated in step S4 can trigger a self-propagating reaction. When preheated to 650°C, according to the melting point of 60% of the material in step S1, NiAl undergoes an exothermic reaction, increasing the interface diffusion rate, and forming a functional gradient coating.

[0028] Self-propagating exothermic reaction drives interface atomic diffusion, solves the inherent defects of traditional thermal spraying coating such as high porosity and low bonding strength, realizes the continuous transition of hardness and toughness of the functional gradient structure, and makes the coating have both corrosion resistance and impact resistance in extreme working conditions.

[0029] It should be noted that the implementation process of step S6 is: The five-axis machine tool calls the initial model of step S1 and the coating thickness distribution map of step S5, and sets different cutting parameters on the blade working surface: ultrasonic vibration assisted cutting is used in the coating area, and low temperature liquid nitrogen cooling cutting is used in the substrate area. The feed speed is dynamically adjusted according to the local hardness value.

[0030] The hardness-adaptive composite cutting process solves the bottleneck of hard coating machining, avoids secondary damage such as edge collapse and micro-cracks caused by traditional machining, synchronously guarantees the blade profile precision and surface integrity, and restores the original design hydraulic performance.

[0031] It should be noted that the implementation process of step S7 is: By using the subsurface micropores exposed after the machining of step S6, 150MPa isopressing is applied in the vacuum cavity, and low-melting-point alloy Sn60Pb40 is simultaneously introduced. When the pressure is kept, the alloy melt penetrates along the dislocation channel generated in step S4.

[0032] The high-pressure infiltration technology realizes the global sealing of the subsurface micropores, radically solves the invisible corrosion channel ignored by the traditional process, forms a metallurgical bond between the sealed phase and the substrate, and establishes an internal anti-corrosion barrier penetrating the repair layer.

[0033] It should be noted that the implementation process of step S8 is: Integrate the damage model of step S1, the coating physical property parameters of step S5 and the sealing structure data of step S7 to build a three-phase flow-solid coupling model. The boundary conditions are set, including the erosion-resistant threshold of the cladding layer of step S3 and the phase transition critical point of the coating of step S5. The machining setting value of step S6 is verified through iterative calculation.

[0034] The flow-solid coupling model based on actual physical parameters overturns the empirical life prediction mode, realizes the accurate prediction of the service behavior of the remanufactured impeller by quantifying the correlation of key parameters.

[0035] The application further provides a reshaping and remanufacturing material for a desulfurization circulating pump impeller, which is applied to the reshaping and remanufacturing method for a desulfurization circulating pump impeller described above. The specific steps of the reshaping and remanufacturing method are described above and will not be repeated here. The reshaping and remanufacturing material comprises: The substrate repair layer is one of FeCrMoNbRE nickel-based alloy or iron-based composite powder, which is used for energy field coupling cladding of step S3.

[0036] Stress regulating material, the stress regulating material includes thickness mutation zone material and gentle zone material, the thickness mutation zone material is Si3N4 silicon nitride ceramic pill, the gentle zone material is zirconium base amorphous alloy pill, for step S4 shot peening.

[0037] Functional gradient coating, the functional gradient coating further includes a transition layer, a wear-resistant layer and a sealing layer, the transition layer is one of NiCrMo-7 alloy or FeCrSiB composite 30% TiC alloy powder, the wear-resistant layer is one of Cr2O3 composite 20% Al2O3 nano powder or 10Co4Cr composite 5% nano diamond, and the sealing layer is one of PTFE microcapsule doped nickel-based alloy or PyC pyrolytic carbon coating, for step S5 self-propagating synthesis.

[0038] Sealing infiltrated material, the sealing infiltrated material is one of SnAgCu-Ti composite solder or Cu-SiC composite material, for step S7 micro-gap sealing.

[0039] The embodiment is aimed at tailoring the material system for special working conditions of acid corrosion and solid erosion of a desulfurization circulating pump, and realizes integrated protection of corrosion resistance, wear resistance and crack resistance in the whole life cycle through the functional synergistic design of the substrate repair layer, the gradient coating and the infiltrated sealing layer, while the material is adapted to the remanufacturing process, so that the early failure problem caused by the incompatibility between the traditional material and the repair process is fundamentally solved.

[0040] In actual application, a reshaping remanufacturing method for a desulfurization circulating pump impeller is provided, and specifically, the method comprises the following steps: S1. Constructing a multi-modal damage intelligent mapping: A four-dimensional damage model (X / Y / Z coordinates + stress value) of the blade surface is constructed by using laser scanning point cloud data (accuracy ±0.05 mm) and ultrasonic residual stress field detection results.

[0041] Based on the extracted impeller basic material parameters (such as thermal expansion coefficient α=13.5×10⁻ 6 / K), a thermal deformation compensation amount ΔL=α·Δt·L is preset during three-dimensional reconstruction, wherein Δt is dynamically adjusted according to the cladding temperature.

[0042] By constructing the multi-modal damage intelligent mapping, the problem that the traditional detection can only obtain geometric size error and ignores the coupling effect of residual stress field and thermal deformation, resulting in high risk of secondary cracking of the repaired impeller, is solved. By constructing the four-dimensional damage model containing stress distribution, the thermal distortion accumulation of subsequent high-temperature cladding is eliminated by presetting the thermal deformation compensation amount (ΔL=α·Δt·L).

[0043] S2. Synchronously preparing plasma activation and micro-texture: The damage core region positioned in step S1, the cavitation pit depth ≥1.5mm region, when the surface is scanned by a pulsed plasma beam with a power of 8kW and a frequency of 200Hz, a mixed gas of argon and nitrogen with a flow ratio of 4:1 is synchronously introduced to induce in-situ nitriding.

[0044] The periodic micro-protrusion array with a height of 50±5μm and a pitch of 300μm is formed by controlling the beam spot overlap rate to be 65%, thereby providing mechanical locking anchor points for the cladding layer.

[0045] By synchronously preparing plasma activation and micro-texturing, the problem that it is difficult for conventional sand blasting roughening to form effective anchor points in deep pits and that nitriding treatment needs an independent process is solved, and a CrN hardened layer (HV1100) + micro-protrusion array is synchronously generated by in-situ nitriding, thereby improving the cladding bonding strength by 60% (>85MPa).

[0046] S3. Energy field coupled cladding repair is performed: For the micro-textured region generated in step S2, a double heat source collaborative system is started: a high-frequency induction preheating of 300℃±10℃ is used to reduce the cladding thermal shock, and a coaxial laser beam with a power of 3.2kW is used to irradiate the induction heating area.

[0047] The laser spot is accurately matched with the micro-protrusion array, the energy aggregation effect of the protrusion top is used to realize directional grain growth, the cooling gradient of the molten pool is controlled to be ≤150℃ / s, and according to the thermal conductivity coefficient λ=15W / m·K of the material in step S1.

[0048] It should be further pointed out that the embodiment also provides a cladding repair material applied to the energy field coupled cladding repair in step S3, which comprises: The FeCrMoNbRE nickel-based alloy for acid working conditions has the following components: Cr18-22wt%, Mo15-18wt%, and Nb3.5wt%.

[0049] The WC35wt%-FeCrNiMo iron-based composite powder for high solid content working conditions has a WC particle size of 45-75μm.

[0050] By energy field coupled cladding repair, the problem of uncontrollable thermal input of single heat source cladding is solved, which leads to grain coarsening in the heat affected zone of the substrate, and by double heat source collaboration (induction preheating + laser cladding), the cooling gradient is pressed to ≤150℃ / s, and the proportion of directional columnar crystals is >90%.

[0051] S4. Stress field balance shot peening is performed: Based on the measured thickness distribution of the cladding layer in step S3, in practical applications, the thickness of the blade leading edge is 2.3 mm, and the thickness of the rear cover plate is 1.1 mm. A regional variable intensity shot peening strategy is adopted: Φ0.8 mm ceramic shots are used in the thickness mutation area with a gradient of >1 mm / 10 mm, and the impact strength is 0.45 mmA; Φ0.3 mm glass shots are used in the flat area, and the impact strength is 0.2 mmA.

[0052] The shot peening trajectory is automatically planned according to the residual stress distribution map in step S1, so that the stress range is <100 MPa.

[0053] It should be further pointed out that a stress control material is applied to the stress field balance shot peening in step S4, which comprises: The thickness mutation area uses Φ0.8 mm Si3N4 silicon nitride ceramic shots, and the elastic modulus is 310 GPa.

[0054] The flat area uses Φ0.3 mm zirconium-based amorphous alloy shots, and the elastic deformation is >8%.

[0055] Through stress field balance shot peening, it is solved that uniform shot peening is easy to induce stress concentration in the thickness mutation area. By controlling the shot peening intensity based on the thickness distribution of the cladding layer and the residual stress field, the stress range is compressed to <100 MPa.

[0056] S5. Implement gradient coating self-propagating synthesis: On the activated surface after step S4 treatment, the transition layer, wear-resistant layer and sealing layer are alternately sprayed with NiAl powder, and the lattice distortion generated in step S4 can trigger the self-propagating reaction.

[0057] When preheated to 650℃, according to the melting point of 60% of the material in step S1, the interface diffusion rate of the WC layer is increased by 3 times due to the exothermic reaction of NiAl, ΔH=-280kJ / mol, forming a functional gradient coating, HV 0.3 :1200→800.

[0058] It should be further pointed out that the embodiment also provides a gradient coating material applied to the self-propagating synthesis in step S5, which comprises: Transition layer material: NiCrMo-7 alloy for acidic working conditions, FeCrSiB+30vol%TiC composite powder for high solid content working conditions.

[0059] Wear-resistant layer material: Cr2O3+20wt%Al2O3 nano-composite powder for acidic working conditions, WC-10Co4Cr+5wt% nanodiamond for high solid content working conditions.

[0060] Sealing layer material: PTFE microcapsule doped with nickel-based alloy for acidic working conditions, particle size 5μm, PyC pyrolytic carbon coating for high solid content working conditions.

[0061] By gradient coating self-propagating synthesis, the micro-pores (porosity > 2%) existing in the interface of the traditional thermal spraying WC coating are solved, the interface diffusion strengthening is induced by the exothermic reaction of NiAl (ΔH = -280 kJ / mol), and the porosity is reduced to 0.3%.

[0062] S6. Perform thermal-mechanical coupling precision shaping: The five-axis machine tool calls the initial model of step S1 and the coating thickness distribution map of step S5, and sets differential cutting parameters on the blade working surface: ultrasonic vibration assisted cutting with an amplitude of 15 μm and a frequency of 20 kHz is adopted in the coating area HV>1000, and low-temperature liquid nitrogen cooling cutting is adopted in the matrix area.

[0063] The feed speed is dynamically adjusted according to the local hardness value V: V_cut=0.2·(1000 / HV) 0.3 mm / rev, the reference value HV=800.

[0064] By thermal-mechanical coupling precision shaping, the edge collapse caused by ordinary cutting of hard coating (HV>1000) is solved, and the coating is shaped without collapse by hardness adaptive cutting (V_cut=0.2·(1000 / HV) 0.3 ).

[0065] S7. Perform micro-gap pressure infiltration sealing: The subsurface micro-pores with a diameter of <10 μm exposed after step S6 are used to apply 150 MPa isostatic pressure in a vacuum chamber, and low-melting-point alloy Sn60Pb40 is simultaneously introduced.

[0066] When the pressure maintaining stage, the alloy melt infiltrates along the dislocation channel generated in step S4, and the penetration depth is: d=√(2kP·t / η).

[0067] Wherein, k is calculated as 0.8 according to the micro-texture spacing of step S2, and η is the viscosity of the melt, specifically, η=2.5 mPa·s.

[0068] It should be noted that the present embodiment also provides a kind of infiltration sealing material, applied to the micro-gap pressure infiltration of step S7, comprising: SnAgCu-Ti composite filler for acid working condition, Ti content 4wt%.

[0069] Cu-30vol%SiC composite material for high solid content working condition.

[0070] By micro-gap pressure infiltration sealing, the processing exposed subsurface micro-pores (diameter <10 μm) become corrosion channels are solved, and the plugging rate is >99.5% (penetration depth d=√(2kP·t / η)) by 150 MPa high pressure infiltration.

[0071] S8. Perform multi-physics service simulation verification: Integrate the damage model of step S1, the coating physical property parameters of step S5 and the sealing structure data of step S7 to construct a three-phase flow-solid coupling model.

[0072] The set boundary conditions include: the erosion resistance threshold of the cladding layer of step S3: slurry solid concentration 30%, the coating phase transition critical point of step S5: temperature 50 DEG C.

[0073] The processing set value of step S6 is verified by iterative calculation: the correlation equation of the blade inlet angle and the cavitation intensity: sigma_c=0.02.beta 2 +0.35.

[0074] Wherein, beta is the inlet angle.

[0075] Through the multi-physics service simulation verification, the experience repair cannot predict the cavitation failure critical point, and through the equation sigma_c=0.02.beta 2 +0.35, the inlet angle and the cavitation intensity are quantitatively correlated, and the service life prediction error is less than 5%.

[0076] In summary, through the above steps, the reshaping remanufacturing method for the desulfurization circulating pump impeller of the application improves the performance of the remanufactured impeller, significantly prolongs the service cycle of the key components, comprehensively enhances the comprehensive performance of the anti-cavitation and erosion resistance, establishes the digital twin closed loop of damage diagnosis, repair optimization and life prediction, and realizes the whole life cycle cost control and resource saving. Not only the failed components are repaired, but also the sustainable operation system is reconstructed.

[0077] In the description of the present specification, the description referring to the terms "one embodiment", "example", "specific example" and the like means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In the present specification, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0078] The preferred embodiments of the application disclosed above are only used to help explain the application. The preferred embodiments do not describe all the details and limit the application to the specific embodiments described. Obviously, many modifications and changes can be made according to the content of the present specification. The present specification selects and describes these embodiments in order to better explain the principles and practical applications of the application, so that those skilled in the art can well understand and utilize the application. The application is limited by the claims and their entire scope and equivalents.

Claims

1. A method for reshaping and remanufacturing an impeller of a desulfurization circulation pump, characterized in that: The complex remanufacturing method includes constructing a multimodal damage intelligent map and simultaneously preparing plasma activation and microtexturing; Carry out energy field coupling cladding repair and stress field balance shot peening strengthening; Implement self-propagating synthesis of gradient coatings, as well as perform thermo-mechanical coupling precision shaping and micro-gap pressure infiltration sealing; ultimately verify through multi-physics field service simulation.

2. A method for reshaping and remanufacturing an impeller of a desulfurization circulation pump according to claim 1, characterized in that: The implementation process of constructing multimodal damage intelligent mapping is as follows: A four-dimensional damage model of the blade surface is constructed using laser scanning point cloud data and ultrasonic residual stress field detection results. Based on the extracted impeller basic material parameters, the thermal deformation compensation amount is preset during 3D reconstruction.

3. The method for reshaping and remanufacturing an impeller of a desulfurization circulation pump according to claim 2, characterized in that: The implementation process of preparing plasma activation and microtexture is as follows: When the damage core area located in the step of constructing the multi-modal damage intelligent mapping is scanned on the surface using a pulsed plasma beam, an argon-nitrogen mixed gas is simultaneously introduced to induce in-situ nitriding; The beam spot overlap ratio is controlled to form a periodic micro-protrusion array, providing mechanical locking anchor points for the cladding layer.

4. A method for reshaping and remanufacturing an impeller of a desulfurization circulation pump according to claim 3, characterized in that: The implementation process of the energy field coupling cladding repair is as follows: For the micro-textured area generated in the steps of preparing the plasma activation and micro-texturing, a dual heat source collaborative system is activated: high-frequency induction preheating reduces the thermal shock of the cladding, and a coaxial laser beam irradiates the induction heating area at the same time; The laser spot is precisely matched with the micro-protrusion array, and the energy concentration effect at the top of the protrusion is used to achieve directional grain growth and control the cooling gradient of the molten pool.

5. The method for reshaping and remanufacturing an impeller of a desulfurization circulation pump according to claim 4, characterized in that: The implementation process of the stress field balanced shot peening is as follows: Based on the measured thickness distribution of the cladding layer in the energy field coupling cladding repair step, a regional variable intensity shot peening strategy is adopted: ceramic shot is used in the thickness mutation area, and glass shot is used in the flat area; The shot peening trajectory is automatically planned based on the residual stress distribution map in the step of constructing the multimodal damage intelligent mapping, so that the stress range is <100 MPa.

6. The method for reshaping and remanufacturing an impeller of a desulfurization circulation pump according to claim 5, characterized in that: The implementation process of the gradient coating self-propagating synthesis is as follows: Alternately spraying a transition layer, a wear-resistant layer, and a sealing layer with NiAl powder on the activated surface treated in the stress field balance shot peening step, using the lattice distortion energy generated in the stress field balance shot peening step to trigger a self-propagating reaction; When preheated to 650° C., according to the step of constructing multi-modal damage intelligent mapping, the material melting point is 60%, and NiAl undergoes an exothermic reaction to increase the interface diffusion rate, thereby forming a functional gradient coating.

7. A method for reshaping and remanufacturing an impeller of a desulfurization circulation pump according to claim 6, characterized in that: The implementation process of the thermo-mechanical coupling precision shaping is as follows: The five-axis machine tool calls the initial model in the step of constructing the multimodal damage intelligent mapping and the coating thickness distribution map in the step of implementing the gradient coating self-propagating synthesis, and sets differentiated cutting parameters on the blade working surface: ultrasonic vibration-assisted cutting is used in the coating area, and low-temperature liquid nitrogen cooling is used in the substrate area; The feed rate is dynamically adjusted according to the local hardness value.

8. The method for reshaping and remanufacturing an impeller of a desulfurization circulation pump according to claim 7, characterized in that: The implementation process of the micro-gap pressure infiltration sealing is as follows: Utilizing the subsurface micropores exposed after the thermo-mechanical coupling precision shaping step, 150 MPa isostatic pressure is applied in a vacuum chamber, and a low melting point alloy Sn60Pb40 is introduced simultaneously; During the pressure holding stage, the alloy melt infiltrates along the dislocation channels generated in the stress field balance shot peening step.

9. The method for reshaping and remanufacturing an impeller of a desulfurization circulation pump according to claim 8, characterized in that: The implementation process of the multi-physics field service simulation verification is as follows: Integrating the damage model in the step of constructing the multimodal damage intelligent mapping, the coating physical property parameters in the step of implementing the gradient coating self-propagating synthesis, and the sealing structure data in the step of micro-gap pressure infiltration sealing to construct a three-phase fluid-solid coupling model; The boundary conditions include: the erosion resistance threshold of the cladding layer in the energy field coupling cladding repair step and the coating phase change critical point in the gradient coating self-propagating synthesis step; The processing setting values ​​of the thermo-mechanical coupling precision shaping step are verified by iterative calculation.

10. A composite remanufacturing material for a desulfurization circulation pump impeller, applied to a composite remanufacturing method for a desulfurization circulation pump impeller according to any one of claims 1 to 9, characterized in that: The complex remanufacturing material includes: A substrate repair layer, wherein the substrate repair layer is one of FeCrMoNbRE nickel-based alloy or iron-based composite powder, and is used for the energy field coupling cladding repair step; Stress regulating material, the stress regulating material includes a thickness mutation zone material and a flat zone material, the thickness mutation zone material is Si3N4 silicon nitride ceramic pellets, the flat zone material is zirconium-based amorphous alloy pellets, used in the stress field balancing shot peening strengthening step; A functionally gradient coating, the functionally gradient coating further comprising a transition layer, a wear-resistant layer, and a sealing layer, the transition layer being one of a NiCrMo-7 alloy or a FeCrSiB composite 30% TiC alloy powder, the wear-resistant layer being one of a Cr2O3 composite 20% Al2O3 nanopowder or a 10Co4Cr composite 5% nanodiamond, and the sealing layer being one of a PTFE microcapsule-doped nickel-based alloy or a PyC pyrolytic carbon coating, for implementing the self-propagating synthesis step of the gradient coating; The sealing infiltration material is one of SnAgCu-Ti composite solder or Cu-SiC composite material, and is used in the micro-gap pressure infiltration sealing step.

Images