Method for repairing superficial cracks of 30CrMnSiA steel based on high-throughput additive manufacturing

Abstract

The invention discloses a method based on a high-throughput additive manufacturing technology, which ensures effective repair of cracks and recovery of part performance through the steps of accurate crack detection, surface pretreatment, additive manufacturing repair, post-treatment, performance verification and the like. In the surface pretreatment stage, oil stains and organic impurities in a crack area are thoroughly removed through a laser cleaning technology, and then the binding force of the repairing material and a base material is enhanced through physical polishing and sand blasting treatment. In the repairing process, appropriate additive manufacturing equipment is selected, and technological parameters are optimized to achieve accurate filling of cracks. And after repairing, necessary post-treatment including surface polishing and heat treatment is carried out, so that internal stress is eliminated, and the mechanical property of the repaired area is improved. The method is suitable for crack repair of the high-strength alloy steel, has the characteristics of simplicity and convenience in operation, high repair efficiency and reliable quality, and is suitable for component maintenance and repair in the fields of aviation, automobiles, military industry and the like.

Description

Technical Field

[0001] The invention relates to a repair technology for metal materials, in particular to a high-throughput additive manufacturing method for repairing shallow cracks in a 30CrMnSiA alloy material. Background Art

[0002] In the field of modern industrial manufacturing, the performance optimization and defect repair of metal materials have always been a hot topic of research. Especially for high-strength alloy steel such as 30CrMnSiA, due to its wide application in aviation, automobile, military and other fields, how to effectively repair the shallow cracks generated during its use or manufacturing process has become an urgent problem to be solved. Traditional repair methods such as welding and bonding often have problems such as low efficiency, unstable quality or the possibility of introducing new defects. Therefore, exploring new and efficient crack repair technologies has important practical significance.

[0003] In recent years, with the rapid development of additive manufacturing technology (also known as 3D printing technology), its application in the field of material repair has gradually attracted attention. Additive manufacturing technology can accurately control the deposition of materials by stacking materials layer by layer, and achieve accurate filling and repair of crack areas. Especially with the application of high-throughput additive manufacturing technology, multiple single substances can be fed at the same time, which not only improves manufacturing efficiency, but also provides new possibilities for the development of new materials and the optimization of material properties.

[0004] The core of high-throughput additive manufacturing technology is that it can prepare multiple samples with continuous gradient changes or discrete changes in composition characteristics through a single experiment, and quickly obtain a large amount of experimental data through high-throughput characterization technology. This method greatly accelerates the research and development of new materials and forms a complete set of new material development methods. For example, through the concurrent material calculation screening of high-throughput computing platforms, high-throughput preparation of discrete / gradient change samples, high-throughput material characterization and service evaluation, etc., the data of material composition can be quickly and intelligently evaluated and predicted.

[0005] In the crack repair of 30CrMnSiA material, high-throughput additive manufacturing technology can be used to accurately control the powder feeding ratio and deposition path of various metal powders to achieve efficient filling and repair of the crack area. This method can not only ensure good metallurgical bonding between the repair material and the base material, but also improve the mechanical properties of the repair area by optimizing process parameters such as laser power, scanning speed, layer thickness, etc., thereby effectively extending the service life of the material.

[0006] In addition, high-throughput additive manufacturing technology also shows great potential in the development of new materials. Through high-throughput preparation and characterization of composition gradient materials, new alloy materials or new alloy components can be obtained, the intrinsic connection between material composition, structure and performance can be established, and the material database can be improved, making the development of new materials simpler and more scientific. Summary of the invention

[0007] The present invention proposes a method for repairing shallow cracks in 30CrMnSiA steel based on high-throughput additive manufacturing, the method comprising the following steps:

[0008] a. Identify the superficial cracks on the surface of 30CrMnSiA material;

[0009] b. Use laser cleaning technology to pre-treat the crack area to remove the surface oxide layer, oil and other contaminants to provide a clean surface for subsequent repair;

[0010] c. Preset a repair path to cover the crack area;

[0011] d. using a high-throughput additive manufacturing device, such as a direct energy deposition device, to repair the crack area;

[0012] e. Filling the cracks layer by layer by precisely controlling the molten metal powder until the cracks are completely covered;

[0013] f. Optimizing process parameters, including but not limited to laser power, scanning speed and layer thickness, to ensure metallurgical bonding of the repair material to the base material;

[0014] g. Post-process the repaired area, including heat treatment and surface polishing, to eliminate stress concentration and improve surface quality.

[0015] Further: the preset repair path of the crack area is generated by computer-aided design (CAD) software.

[0016] Furthermore: the repair material is a spherical single-element metal powder whose chemical composition matches that of the 30CrMnSiA material.

[0017] Furthermore: the optimized process parameters include laser power, scanning speed and layer thickness, wherein the laser power is set to 600W to 2400W, the scanning speed is set to 500mm / s to 1200mm / s, and the layer thickness is set to 0.05mm to 0.2mm.

[0018] Further: the post-treatment includes quenching and low-temperature tempering of the repaired sample to eliminate thermal effects.

[0019] Furthermore: the surface polishing step uses a dust-free environment and precision polishing equipment to achieve a surface roughness of less than Ra1.6μm.

[0020] A repair device, comprising:

[0021] a. High-throughput additive manufacturing equipment;

[0022] b. A control system for controlling elemental metal powders in the additive manufacturing process;

[0023] c. Heat treatment equipment and surface polishing equipment for post-processing;

[0024] d. Laser cleaning equipment, used for pre-treatment and cleaning of crack areas.

[0025] The beneficial effects of the present invention are:

[0026] The present invention uses high-throughput additive manufacturing technology to achieve rapid and accurate repair of shallow cracks in 30CrMnSiA materials using simple powder, significantly improving the repair efficiency and quality. The precisely controlled material deposition process and subsequent heat treatment steps ensure that the mechanical properties of the repaired area match or even exceed those of the original material, thereby extending the service life of the component and improving its safety of use. In addition, the automation and simplified operation process of the present invention reduces the technical threshold and labor costs, making the repair work more economical and efficient. At the same time, the environmental friendliness of the present invention reduces environmental pollution during the repair process, and its wide applicability provides a new solution for crack repair of various high-strength alloy steels. In general, the present invention not only optimizes the performance of the repair material, but also ensures the consistency and repeatability of the repair work, which has important practical significance for reducing maintenance costs and improving the maintenance quality and reliability of industrial components. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a flow chart of a method for repairing shallow cracks in 30CrMnS iA steel based on high-throughput additive manufacturing of the present invention.

[0028] Figure 2 This is a macroscopic schematic diagram of a method for repairing shallow cracks in 30CrMnS iA steel based on high-throughput additive manufacturing according to the present invention after repair. DETAILED DESCRIPTION

[0029] The present invention is described in detail below through specific examples, but the use and purpose of these exemplary implementation modes are only used to illustrate the present invention, and do not constitute any form of limitation on the actual protection scope of the present invention, nor limit the protection scope of the present invention to them.

[0030] Example 1

[0031] A heat treatment process method for 30CrMnSiA additive manufacturing repair in this embodiment includes the following steps:

[0032] S1: Crack Identification and Analysis

[0033] Ultrasonic testing technology is used to comprehensively scan the 30CrMnSiA material to identify tiny cracks on the surface of the material. Detailed analysis of the detected cracks is performed, including the use of high-resolution imaging technology to record the length, width and depth of the cracks. Based on the characteristics of the cracks, corresponding repair strategies are formulated and appropriate additive manufacturing parameters and materials are selected.

[0034] S2: Repair surface preparation

[0035] First, the component to be repaired is fixed on the workbench of the laser cleaning equipment to ensure precise alignment between the component surface and the laser beam.

[0036] Start the laser cleaning system and select appropriate laser parameters, including wavelength, pulse width and energy, to ensure effective removal of oil and organic impurities without damaging the substrate.

[0037] Use a laser beam to scan the surface of the component area by area. The high energy of the laser evaporates dirt and grease instantly, thus achieving the purpose of cleaning.

[0038] During the cleaning process, the scanning speed and repetition rate of the laser beam are adjusted to ensure uniform cleaning of the component surface and avoid over-treatment or omission.

[0039] After laser cleaning, the surface of the component is inspected to ensure that all oil and organic impurities have been completely removed. The crack edge is lightly sandblasted to increase the adhesion of the repair material to the substrate.

[0040] S3: Restoration Design

[0041] Use high-precision 3D scanning equipment to scan the damaged parts and obtain detailed geometric shape and size data. Use computer-aided design (CAD) software to reconstruct the 3D model of the parts based on the scan data and mark the crack area. Based on the 3D model of the crack, design the repair path to ensure that the repair material can fill the crack evenly and continuously.

[0042] S4. Additive Manufacturing Equipment Configuration

[0043] According to the size and shape of the crack, select the appropriate high-throughput additive manufacturing equipment. Adjust the process parameters of the equipment, including laser power, scanning speed, layer thickness and powder feeding rate, to achieve the best repair effect.

[0044] A single metal spherical powder matching the chemical composition of the 30CrMnSiA material is prepared, with a particle size maintained between 53 and 150 microns, wherein the carbon content of the spherical iron powder is 0.15 to 0.45, as a repair material.

[0045] S5. Crack repair operation

[0046] The parts to be repaired are loaded into the additive manufacturing equipment and automatically repaired according to the designed repair path. The repair process is monitored in real time through a closed-loop control system to ensure the uniformity of material deposition and the density of the repair layer. During the repair process, the parts are continuously monitored by thermal imaging to prevent overheating and the expansion of the heat-affected zone.

[0047] S6. Post-repair processing

[0048] After the repair is completed, use precision grinding and polishing equipment to remove excess material in the repair area and restore the original geometry of the component. Perform surface treatment on the repair area, such as sandblasting or electrolytic polishing, to obtain a uniform surface roughness. According to the characteristics of the material, select a suitable heat treatment process, such as annealing or normalizing, to eliminate the internal stress generated during the repair process.

[0049] The series of detailed descriptions listed above are only specific descriptions of feasible embodiments of the present invention. They are not intended to limit the scope of protection of the present invention. All equivalent embodiments or changes that do not deviate from the technical spirit of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for repairing shallow cracks in 30CrMnSiA steel based on high-throughput additive manufacturing, characterized in that: The method comprises the following steps: a. Identify the superficial cracks on the surface of 30CrMnSiA material; b. Use laser cleaning technology to pre-treat the crack area to remove the surface oxide layer, oil and other contaminants to provide a clean surface for subsequent repair; c. Preset a repair path to cover the crack area; d. using a high-throughput additive manufacturing device, such as a direct energy deposition device, to repair the crack area; e. Filling the cracks layer by layer by precisely controlling the molten metal powder until the cracks are completely covered; f. Optimizing process parameters, including but not limited to laser power, scanning speed and layer thickness, to ensure metallurgical bonding of the repair material to the base material; g. Post-process the repaired area, including heat treatment and surface polishing, to eliminate stress concentration and improve surface quality.

2. A method for repairing shallow cracks in 30CrMnSiA steel based on high-throughput additive manufacturing according to claim 1, characterized in that: The preset repair path of the crack area is generated by computer-aided design (CAD) software.

3. The method for repairing shallow cracks in 30CrMnSiA steel based on high-throughput additive manufacturing according to claim 1, characterized in that: The repair material is a spherical single-element metal powder whose chemical composition matches that of the 30CrMnSiA material.

4. The method for repairing shallow cracks in 30CrMnSiA steel based on high-throughput additive manufacturing according to claim 1, characterized in that: The optimized process parameters include laser power, scanning speed and layer thickness, wherein the laser power is set to 600W to 2400W, the scanning speed is set to 500mm / s to 1200mm / s, and the layer thickness is set to 0.05mm to 0.2mm.

5. The method for repairing shallow cracks in 30CrMnSiA steel based on high-throughput additive manufacturing according to claim 1, characterized in that: The post-treatment includes quenching and low-temperature tempering of the repaired sample to eliminate thermal effects.

6. The method for repairing shallow cracks in 30CrMnSiA steel based on high-throughput additive manufacturing according to claim 1, characterized in that: The surface polishing step uses a dust-free environment and precision polishing equipment to achieve a surface roughness of Ra 1.6 μm or less.

7. A repair device, characterized in that: A method for repairing shallow cracks in 30CrMnSiA steel based on high-throughput additive manufacturing as described in any one of claims 1 to 6, the device comprising: a. High-throughput additive manufacturing equipment; b. A control system for controlling elemental metal powders in the additive manufacturing process; c. Heat treatment equipment and surface polishing equipment for post-processing; d. Laser cleaning equipment, used for pre-treatment and cleaning of crack areas.

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