Laser cladding repairing method and system for damaged characteristic part of single crystal turbine blade

Abstract

The invention provides a laser cladding repairing method and system for a damaged feature part of a single-crystal turbine blade, belongs to the technical field of laser cladding, and is used for repairing a to-be-repaired single-crystal turbine blade with a to-be-repaired notch. The method comprises the steps that when a target notch parameter matched with a to-be-repaired notch parameter does not exist in a database, the to-be-repaired single-crystal turbine blade with the to-be-repaired notch parameter does not exist in the database; a first component is manufactured based on the to-be-repaired notch parameters, after the first component is repaired based on preset laser cladding parameters, whether repairing meets the preset requirement or not is determined, and when the requirement is met, multiple to-be-determined laser cladding parameters are obtained based on the preset laser cladding parameters; the multiple first components are repaired through the multiple to-be-determined laser cladding parameters, the repaired tensile strength of the different to-be-determined laser cladding parameters is determined, and the to-be-determined laser cladding parameter with the maximum repaired tensile strength and the to-be-repaired notch parameter serve as a data set to be recorded in a database; therefore, selection of target process parameters in real single crystal damaged blade repair can be accurately guided.

Description

Technical Field

[0001] This application relates to the field of laser cladding technology, and in particular to a laser cladding repair method and system for characteristic damaged areas of a single-crystal turbine blade. Background Technology

[0002] Single-crystal turbine blades possess excellent performance and are widely used in various engines in the aerospace field. However, the extreme environments of high temperature, high pressure, and high speed that engines operate under for extended periods make the blade tips of single-crystal turbine blades highly susceptible to defects and damage such as chipping or cracking. These defects and damage alter the aerodynamic shape and structural integrity of the blades, affecting engine performance and reducing efficiency in minor cases, and potentially leading to rotor blade fracture in severe cases, seriously threatening the safety of the engine and aircraft. Due to the complex internal cooling structure, low yield, and high manufacturing cost of single-crystal turbine blades, repair is often the first attempt made after blade damage.

[0003] Currently, most laser cladding repair methods for the tips of single-crystal turbine blades focus on planar laser cladding repair, which can effectively repair damage to the tips of single-crystal turbine blades.

[0004] However, the above-mentioned repair method cannot guarantee the repair effect on the surface with beveled notches, resulting in poor stability of the repair effect. Summary of the Invention

[0005] This application provides a laser cladding repair method and system for damaged characteristic areas of single-crystal turbine blades, which can solve the problems of poor epitaxial growth and difficulty in repairing inclined surfaces in laser cladding repair of single-crystal turbine blades in related technologies. The technical solution is as follows:

[0006] According to a first aspect of this application, a laser cladding repair method is provided for repairing damaged characteristic areas of a single-crystal turbine blade, for repairing a single-crystal turbine blade with a notch to be repaired, the method comprising:

[0007] Obtain the parameters of the notch to be repaired;

[0008] Based on the notch parameters to be repaired, search the database to see if there are target notch parameters that match the notch parameters to be repaired. The database includes multiple data groups, and each data group includes a notch parameter and a corresponding laser cladding parameter.

[0009] When the target notch parameter exists in the database, the notch to be repaired is repaired based on the laser cladding parameters corresponding to the target notch parameter;

[0010] When the target notch parameter is not found in the database, a first component is manufactured based on the notch parameter to be repaired. The substrate crystal orientation of the first component is consistent with the crystal orientation of the single-crystal turbine blade to be repaired. The first component has a notch that matches the notch parameter to be repaired.

[0011] The first component is repaired using preset laser cladding parameters to obtain the second component;

[0012] When the second component meets the preset requirements, multiple first components are acquired, and multiple undetermined laser cladding parameters are obtained based on the preset laser cladding parameters;

[0013] Based on the plurality of undetermined laser cladding parameters, the plurality of first components are repaired to obtain the plurality of third components corresponding to the plurality of undetermined laser cladding parameters;

[0014] Multiple fourth components are obtained by cutting from the plurality of third components;

[0015] Identify the target fourth component with the highest tensile strength among the plurality of fourth components;

[0016] The undetermined laser cladding parameters corresponding to the third component to which the target fourth component belongs, and the parameters of the notch to be repaired, are recorded as a data group in the database.

[0017] Optionally, the parameters of the notch to be repaired include the depth of the groove, the thickness of the groove, the width of the groove bottom, and the supplementary angle of the angle between one sidewall of the groove and the groove bottom. The groove is a groove on the single crystal turbine blade to be repaired that can include the notch to be repaired.

[0018] The types of the notch parameters to be repaired include V-shaped grooves, U-shaped grooves, and L-shaped opening grooves. The V-shaped groove includes two connected sidewalls. The bottom width of the V-shaped groove is zero. The angle between one sidewall of the V-shaped groove and the bottom of the groove is the angle between the sidewall and the target surface. The target surface is in contact with the connection position of the two sides and has the same angle with the two sidewalls.

[0019] The U-shaped groove includes two sidewalls and a groove bottom connected to the two sidewalls; the L-shaped opening groove includes one sidewall and a groove bottom connected to the one sidewall.

[0020] The step of obtaining the parameters of the notch to be repaired includes:

[0021] Based on the geometry of the notch to be repaired, determine the type of the notch parameter to be repaired and the notch parameter to be repaired.

[0022] Optionally, before repairing the first component with preset laser cladding parameters to obtain the second component, the method further includes:

[0023] Determine the initial laser cladding parameters;

[0024] The initial laser cladding parameters were optimized using finite element analysis to obtain the preset laser cladding parameters.

[0025] Optionally, the method further includes:

[0026] Cut the second component and determine whether the angle between the dendrite growth direction and the maximum principal stress direction at the repair location of the second component is less than a specified angle;

[0027] When the value is less than the preset requirement, it is determined that the second component meets the preset requirement;

[0028] If the value is greater than the preset requirement, it is determined that the second component does not meet the preset requirement;

[0029] When the second component does not meet the preset requirements, the supplementary angle of the angle between one side wall of the groove and the bottom of the groove in the parameter of the notch to be repaired is adjusted to obtain a new parameter of the notch to be repaired. Based on the new parameter of the notch to be repaired, the step of manufacturing the first component based on the parameter of the notch to be repaired is performed.

[0030] Optionally, the third component includes the first component, a repair portion located in a notch in the first component, and an extension portion connected to the repair portion and extending in a direction away from the first component.

[0031] Optionally, the step of cutting a plurality of fourth components from the plurality of third components includes:

[0032] The third component is cut using a wire cutting process to obtain the fourth component, which is I-shaped. One end of the fourth component is located in the extension, and the other end is located in the first component of the third component.

[0033] Optionally, determining the target fourth component with the highest tensile strength among the plurality of fourth components includes:

[0034] The average tensile strength of each of the plurality of fourth components was obtained by testing them separately.

[0035] The fourth component with the highest average tensile strength is determined as the target fourth component with the highest tensile strength.

[0036] Optionally, after recording the undetermined laser cladding parameters corresponding to the third component to which the target fourth component belongs, and the parameters of the notch to be repaired as a data set in the database, the method further includes:

[0037] Based on the undetermined laser cladding parameters corresponding to the third component to which the fourth component of the target belongs, and the parameters of the notch to be repaired, the notch to be repaired is repaired.

[0038] Optionally, when the second component meets the preset requirements, acquiring multiple first components and obtaining multiple undetermined laser cladding parameters based on the preset laser cladding parameters includes:

[0039] When the second component meets the preset requirements, multiple first components are obtained, and multiple undetermined laser cladding parameters are obtained through orthogonal experimentation based on the preset laser cladding parameters.

[0040] On the other hand, a laser cladding repair system for damaged characteristic areas of a single-crystal turbine blade is provided for repairing a single-crystal turbine blade with a defect to be repaired. The laser cladding repair system for the single-crystal turbine blade includes:

[0041] The parameter acquisition module is used to acquire the parameters of the notch to be repaired.

[0042] The search and acquisition module is used to search the database for a target notch parameter that matches the notch parameter to be repaired, based on the notch parameter to be repaired. The database includes multiple data groups, and each data group includes a notch parameter and a corresponding laser cladding parameter.

[0043] The first repair module is used to repair the gap to be repaired based on the laser cladding parameters corresponding to the target gap parameters when the target gap parameters exist in the database;

[0044] A first manufacturing module is configured to manufacture a first component based on the notch parameter to be repaired when the target notch parameter does not exist in the database. The substrate crystal orientation of the first component is consistent with the crystal orientation of the single-crystal turbine blade to be repaired, and the first component has a notch that matches the notch parameter to be repaired.

[0045] The second repair module is used to repair the first component using preset laser cladding parameters to obtain the second component;

[0046] The component acquisition module is used to acquire multiple first components when the second component meets the preset requirements, and to obtain multiple undetermined laser cladding parameters based on the preset laser cladding parameters;

[0047] The third repair module is used to repair the multiple first components based on the multiple undetermined laser cladding parameters, and obtain multiple third components corresponding to the multiple undetermined laser cladding parameters.

[0048] A cutting module is used to cut multiple fourth components from the plurality of third components;

[0049] The performance determination module is used to determine the target fourth component with the highest tensile strength among the plurality of fourth components;

[0050] The recording module is used to record the undetermined laser cladding parameters corresponding to the third component to which the target fourth component belongs, and the parameters of the notch to be repaired, as a data group in the database.

[0051] The beneficial effects of the technical solutions provided in this application include at least the following:

[0052] The first component is manufactured based on the parameters of the notch to be repaired, and then repaired based on preset laser cladding parameters. It is then determined whether the repair meets the preset requirements. If the requirements are met, multiple undetermined laser cladding parameters are obtained based on the preset laser cladding parameters. Multiple first components are then repaired using these multiple undetermined laser cladding parameters, and the tensile strength after repair for different undetermined laser cladding parameters is determined. The undetermined laser cladding parameter with the highest tensile strength after repair and the notch parameter to be repaired are then recorded as a data group in a database. Notches with undetermined notch parameters can then be repaired based on these undetermined laser cladding parameters. Since this repair method has been tested in advance, the repair effect can be guaranteed, thus improving the stability of the laser cladding repair method for single-crystal turbine blades. Attached Figure Description

[0053] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0054] Figure 1 This is a schematic diagram of a single-crystal turbine blade with damaged structural features and a pre-cutting position, as described in the embodiments of this application.

[0055] Figure 2 This is a flowchart of a laser cladding repair method for damaged characteristic areas of a single-crystal turbine blade provided in an embodiment of this application;

[0056] Figure 3This is a flowchart of another laser cladding repair method for damaged characteristic parts of a single-crystal turbine blade provided in this application embodiment;

[0057] Figure 4 This is a schematic diagram of three types of structures of a first component provided in an embodiment of this application;

[0058] Figure 5 This is a schematic diagram of three types of structures of a second component provided in an embodiment of this application;

[0059] Figure 6 This is a schematic diagram of three types of structures of a third component provided in an embodiment of this application;

[0060] Figure 7 This is a structural schematic diagram of a fourth component provided in an embodiment of this application;

[0061] Figure 8 This is a schematic diagram of a laser cladding repair system for damaged characteristic areas of a single-crystal turbine blade provided in an embodiment of this application.

[0062] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0063] In order to make the objectives, technical solutions and advantages of this application clearer, the implementation methods of this application will be further described in detail below with reference to the accompanying drawings.

[0064] Figure 1 This is a schematic diagram of a single-crystal turbine blade to be repaired, which has damaged structural features and pre-cut positions, according to an embodiment of this application. The single-crystal turbine blade to be repaired has multiple notches k, which may include a first notch k1, a second notch k2, and a third notch k3. For each notch k, there may be a corresponding groove (grooves include grooves c1, c2, and c3). The groove c is a slot that can contain the notch k. When repairing each notch, each notch k can be processed first. During processing, the notch k can be cut into the shape of the groove c based on the groove c, and then the subsequent repair work can be carried out.

[0065] The single-crystal turbine blade to be repaired could be a nickel-based single-crystal turbine blade. Nickel-based single-crystal alloys possess excellent high-temperature mechanical properties, with a temperature resistance exceeding 1300 Kelvin. Nickel-based single-crystal turbine blades can be used as high-pressure turbine blades. High-pressure turbine blades have complex internal cooling structures, making them difficult to manufacture, resulting in low yields and high costs. The harsh service environment makes them highly susceptible to localized damage such as cracks, wear, spalling, and ablation. Direct replacement of repairable single-crystal turbine blades would significantly increase maintenance costs and reduce the product's market competitiveness. Therefore, developing advanced single-crystal turbine blade repair technology to restore their aerodynamic shape and mechanical properties, enabling them to return to service, is of great significance for improving the maintenance capabilities of military and civilian aero engines and gas turbines, especially for enhancing the international competitiveness of commercial products.

[0066] Figure 2 This is a flowchart illustrating a laser cladding repair method for damaged characteristic areas of single-crystal turbine blades, as provided in an embodiment of this application. This method can be used to repair... Figure 1 The method for repairing a single-crystal turbine blade with a notch to be repaired, as shown in the illustration, may include the following steps:

[0067] Step 201: Obtain the parameters of the notch to be repaired.

[0068] Step 202: Based on the notch parameters to be repaired, search the database to see if there are any target notch parameters that match the notch parameters to be repaired. The database includes multiple data groups, each of which includes a notch parameter and the corresponding laser cladding parameter.

[0069] Step 203: If the target notch parameter exists in the database, repair the notch to be repaired based on the laser cladding parameter corresponding to the target notch parameter.

[0070] Step 204: When the target notch parameter does not exist in the database, manufacture a first component based on the notch parameter to be repaired. The crystal orientation of the substrate of the first component is consistent with the crystal orientation of the single crystal turbine blade to be repaired. The first component has a notch that matches the notch parameter to be repaired.

[0071] Step 205: Repair the first component using preset laser cladding parameters to obtain the second component.

[0072] Step 206: When the second component meets the preset requirements, acquire multiple first components and obtain multiple undetermined laser cladding parameters based on the preset laser cladding parameters.

[0073] Step 207: Repair multiple first components based on multiple undetermined laser cladding parameters to obtain multiple third components corresponding to the multiple undetermined laser cladding parameters.

[0074] Step 208: Cut multiple fourth components from multiple third components.

[0075] Step 209: Determine the target fourth component with the highest tensile strength among multiple fourth components.

[0076] Step 210: Record the undetermined laser cladding parameters corresponding to the third component to which the fourth component belongs, and the parameters of the notch to be repaired, as a data group in the database.

[0077] In summary, the laser cladding repair method for damaged characteristic parts of single-crystal turbine blades provided in this application involves manufacturing a first component based on the parameters of the notch to be repaired, repairing the first component based on preset laser cladding parameters, determining whether the repair meets preset requirements, and if it does, obtaining multiple undetermined laser cladding parameters based on the preset laser cladding parameters. Multiple first components are then repaired using these undetermined laser cladding parameters, and the tensile strength after repair for different undetermined laser cladding parameters is determined. The undetermined laser cladding parameter with the highest tensile strength after repair, along with the notch parameters to be repaired, are then recorded as a data set in a database. Notches with undetermined notch parameters can then be repaired based on these undetermined laser cladding parameters. Because this repair method undergoes prior testing, the repair effect is guaranteed, thus improving the stability of the laser cladding repair method for single-crystal turbine blades.

[0078] Figure 3 This is a flowchart illustrating another laser cladding repair method for damaged characteristic areas of a single-crystal turbine blade provided in this application embodiment. This method can be used to repair... Figure 1 The method for repairing a single-crystal turbine blade with a notch to be repaired, as shown in the illustration, may include the following steps:

[0079] Step 301: Based on the geometry of the notch to be repaired, determine the type of notch parameter to be repaired and the notch parameter to be repaired.

[0080] Three-dimensional blue light scanning can be used to scan irregular gaps to be repaired, extract their damage and defect features, including the damage depth, damage width, and blade thickness at the location of the damage. Based on these parameters, the type of gap parameter to be repaired and the gap parameter to be repaired can be determined.

[0081] The type of the notch parameter to be repaired can refer to the type of groove that can include the notch to be repaired. For example, please refer to... Figure 4 , Figure 4This is a schematic diagram of three types of structures of a first component provided in an embodiment of this application. The groove that can include the notch to be repaired may include a V-shaped groove 11, a U-shaped groove 12, and an L-shaped opening groove 13. The V-shaped groove 11 includes two connected sidewalls. The bottom width w of the V-shaped groove is zero. The angle between one sidewall of the V-shaped groove and the bottom of the groove is the angle between the sidewall and the target surface. The target surface is in contact with the connection position of the two sidewalls and has the same angle with the two sidewalls. The U-shaped groove 13 includes two sidewalls and a groove bottom connected to the two sidewalls. The L-shaped opening groove includes one sidewall and a groove bottom connected to the one sidewall.

[0082] The parameters of the notch to be repaired include the depth h of the groove, the thickness d of the groove, the width w of the groove bottom, and the complementary angle θ between one sidewall of the groove and the groove bottom. The groove is a groove that can include the notch to be repaired on the single crystal turbine blade to be repaired.

[0083] Step 302: Based on the notch parameters to be repaired, search the database to see if there are any target notch parameters that match the notch parameters to be repaired. The database includes multiple data groups, and each data group includes a notch parameter and the corresponding laser cladding parameter.

[0084] The laser cladding parameters can include laser power, scanning speed, powder feeding rate, interlayer lift, and spot diameter. Laser power refers to the power of the laser emitted from the laser in the laser cladding head; scanning speed is the speed at which the laser cladding head travels along the repair trajectory; powder feeding rate is the rate at which metal powder is ejected from the powder feeding head in the laser cladding head; interlayer lift is the lift of the laser cladding head after completing one trajectory layer and before proceeding to the next trajectory layer; and spot diameter is the diameter of the laser spot emitted from the laser in the laser cladding head.

[0085] Step 303: If the target notch parameter exists in the database, repair the notch to be repaired based on the laser cladding parameter corresponding to the target notch parameter.

[0086] When the target notch parameters are retrieved from the database, the notch to be repaired can be processed, such as cutting the notch to be repaired into a groove of the corresponding type, and repairing the notch to be repaired according to the laser power, scanning speed, powder feeding rate, interlayer lifting amount and spot diameter parameters corresponding to the target notch parameters.

[0087] Step 304: If the target gap parameter does not exist in the database, manufacture the first component based on the gap parameter to be repaired.

[0088] When the target notch parameters are not found in the database, a first component is manufactured based on the groove depth h, groove thickness d, groove bottom width w, and the complementary angle θ between one sidewall of the groove and the groove bottom. Figure 4 As shown, one of the following can be manufactured based on the parameters of the notch to be repaired: V-shaped groove 11, U-shaped groove 12, and L-shaped opening groove 13. The first component has a notch that matches the parameters of the notch to be repaired.

[0089] Step 305: Determine the initial laser cladding parameters.

[0090] The initial laser cladding parameters can be determined based on historical experience values, and the specific values ​​of the initial laser cladding parameters are not limited in this embodiment of the application.

[0091] Step 306: Optimize the initial laser cladding parameters through finite element analysis to obtain the preset laser cladding parameters;

[0092] The temperature field and residual stress field during laser cladding repair of the first component were simulated using finite element analysis. The temperature change of the molten pool during the cladding process and the maximum residual stress zone after cladding were observed. Based on the simulated temperature field changes and maximum residual stress, preset cladding process parameters were selected. For example, some parameters are shown in Table 1:

[0093] Table 1

[0094]

[0095] Within the range of each of the above preset parameters, a value is selected as the preset laser cladding parameter. For example, the preset laser cladding parameters obtained in this step are: laser power of 500 watts, scanning speed of 5 mm / s, powder feeding rate of 3.5 g / min, interlayer lift of 0.45 mm, and spot diameter of 0.75 mm. The laser power can also be any value among 450 watts, 480 watts, 550 watts, or 580 watts; the specific value is not limited in this embodiment.

[0096] Step 307: Repair the first component using preset laser cladding parameters to obtain the second component.

[0097] The repair process may include polishing and cleaning the surface of the first component substrate to make the substrate surface smooth, clean and flat, and then selecting appropriate alloy powder to dry in a vacuum environment. Figure 5 This is a schematic diagram illustrating three types of structures for a second component provided in an embodiment of this application. For example... Figure 4 and Figure 5 As shown, the laser cladding parameters are preset for... Figure 4 After repairing the three different types of first components, three different types of second components 21, 22 and 23 are obtained.

[0098] Step 308: Determine whether the second component meets the preset requirements. If it does not meet the preset requirements, proceed to step 309; if it meets the preset requirements, proceed to step 310.

[0099] Methods for determining whether the second component meets the preset requirements may include:

[0100] 1) Cut the second component and determine whether the angle between the dendrite growth direction and the maximum principal stress direction at the repair location of the second component is less than the specified angle;

[0101] The second component was cut along its longitudinal section (defect feature section) using a high-precision wire EDM device. The sample surface was then sequentially ground and chemically etched using sandpaper of different grits (400 grit, 600 grit, 800 grit, 1000 grit, 1200 grit, 2000 grit, and 5000 grit). After grinding, the sample surface was polished with a polishing cloth and polishing paste until a mirror finish was achieved, free of obvious scratches and defects. To clearly display the microstructure of the sample surface, the polished sample was chemically etched. The sample was immersed in the etchant for a certain period (usually a few seconds to tens of seconds), during which the corrosion was continuously observed. When the microstructure was clearly visible, the sample was immediately removed, rinsed thoroughly with water, wiped with alcohol, and dried to prevent further oxidation and corrosion. The sample was examined using a scanning electron microscope (SEM), and the grain orientation pattern was observed using electron backscatter diffraction (EBSD) to analyze the epitaxial growth direction of the dendrites and determine the deviation angle of the dendrite growth direction. Optionally, the specified angle can be 5°.

[0102] 2) When the value is less than the preset value, determine that the second component meets the preset requirements;

[0103] When the angle between the dendrite growth direction and the direction of maximum principal stress is within 5°, it indicates that the dendrite growth is good and the second component meets the preset requirements. Then, proceed to step 310.

[0104] 3) If the value is greater than the preset requirement, it is determined that the second component does not meet the preset requirement;

[0105] When the angle between the dendrite growth direction and the direction of maximum principal stress is greater than 5°, it indicates that the second component does not meet the preset requirements, and step 309 is executed.

[0106] In the repair methods of related technologies, the risk of dendrite orientation deviation is not considered, which makes it difficult to ensure the continuity of crystal orientation

[001] after repair. The repair method provided in the embodiments of this application can solve this problem.

[0107] Step 309: Adjust the supplementary angle of the angle between one sidewall of the groove and the bottom of the groove in the parameters of the notch to be repaired to obtain new parameters of the notch to be repaired. Proceed to step 304.

[0108] Adjust the supplementary angle of the angle between one sidewall of the groove and the bottom of the groove in the parameters of the notch to be repaired. The adjustment range of this angle can be within 5°. For example, reduce the supplementary angle by 5°, and then determine whether the second component meets the preset requirements based on the new parameters of the notch to be repaired by going through the process of steps 304 to 308 again.

[0109] Step 310: Obtain multiple first components and obtain multiple undetermined laser cladding parameters based on preset laser cladding parameters.

[0110] When the second component meets the preset requirements, multiple first components are obtained (the crystal orientation of the substrate of the first component is consistent with the crystal orientation of the single-crystal turbine blade to be repaired). Based on the preset laser cladding parameters, multiple undetermined laser cladding parameters are obtained through orthogonal experimental design. Orthogonal experimental design is a method that scientifically analyzes the influence of multiple factors and levels on the experimental results by selecting representative experimental combinations with balanced dispersion and neat comparability, using the fewest number of experiments, and finds the optimal combination of process parameters. In this embodiment, the multiple undetermined laser cladding parameters obtained are multiple parameter values ​​that are close to the preset laser cladding parameter values. The specific values ​​are not limited in this embodiment.

[0111] Step 311: Repair multiple first components based on multiple undetermined laser cladding parameters to obtain multiple third components corresponding to the multiple undetermined laser cladding parameters.

[0112] Unlike the second component, the third component includes the first component, a repair portion located in the notch of the first component, and an extension portion connected to the repair portion and extending away from the first component. Figure 6 This is a schematic diagram illustrating three types of structures for a third component provided in an embodiment of this application. For example... Figure 6 As shown, the third component 31 includes a first component 31a with a V-shaped groove, a repair portion 31b located in the notch of the first component 31a, and an extension portion 31c connected to the repair portion 31b and extending in a direction away from the first component 31a. The third component 32 includes a first component 321 with a U-shaped groove, a repair portion 322 located in the notch of the first component 321, and an extension portion 323 connected to the repair portion 322 and extending in a direction away from the first component 321. The third component 33 includes a first component 331 with an L-shaped opening groove, a repair portion 332 located in the notch of the first component 331, and an extension portion 333 connected to the repair portion 332 and extending in a direction away from the first component 331.

[0113] Step 312: Cut the third component using wire cutting technology to obtain the fourth component.

[0114] The fourth component is I-shaped, with one end located in the extension and the other end located in the first component of the third component. Figure 7 This is a structural schematic diagram of a fourth component provided in an embodiment of this application, such as... Figure 7 As shown, an I-shaped fourth component 41 is taken on the third component 31, an I-shaped fourth component 42 is taken on the third component 32, and an I-shaped fourth component 43 is taken on the third component 33. Half of the fourth components 41, 42, and 43 belong to the extension and repair portions, and the other half belongs to the first component of the third component, so that the joint position of the repair portion 332 and the first component 331 is located at the center of the I-shaped fourth component 41.

[0115] Step 313: Determine the target fourth component with the highest tensile strength among multiple fourth components.

[0116] Each fourth component is sampled by wire cutting along the extension direction of the groove thickness d. Typically, at least three sub-samples are taken from each fourth component. When the length of the fourth component along the extension direction of the groove thickness d is small, the number of sub-samples can be reduced to ensure that the length of each sub-sample along the extension direction of the groove thickness d is greater than or equal to 1 mm. The specific number of sub-samples in this embodiment is not limited. This situation can be resolved by adding a third component and cutting the fourth component from the added third component.

[0117] 1) Test multiple fourth components separately to obtain the average tensile strength of each fourth component;

[0118] For the obtained fourth components, room temperature tensile tests were conducted on a standard tensile testing machine with reference to GB / T 228.1—2010 "Metallic materials, tensile testing—Part 1: Test method at room temperature". The strain distribution on the specimen surface during the tensile process and the stress-strain curves at different angles were calculated. For high-temperature tensile tests, the tests were performed on a high-temperature deformation in-situ measurement platform with reference to GB / T 228.2—2015 "Metallic materials, tensile testing—Part 2: Test method at high temperature". The stress-strain curves at different angles and the strain distribution on the specimen surface during the high-temperature tensile process were obtained through high-temperature tensile tests. The data were processed to obtain the average tensile strength of multiple specimens at each angle under both room temperature and high-temperature conditions. In this embodiment, high temperature refers to 980℃, and room temperature refers to 25℃. The high temperature in the high-temperature tensile test can also be 850℃, 760℃, etc., and the specific values ​​are not limited in this embodiment.

[0119] 2) The fourth component with the highest average tensile strength is determined as the target fourth component with the highest tensile strength.

[0120] The fourth component, which has the highest average tensile strength at both high and normal temperatures, can be identified as the target fourth component with the highest tensile strength.

[0121] In addition, the elongation of the samples at room temperature and high temperature can be obtained as one of the reference values ​​for determining the target fourth component.

[0122] Step 314: Record the undetermined laser cladding parameters corresponding to the third component to which the fourth component belongs, and the parameters of the notch to be repaired as a data group in the database.

[0123] When repairing a single-crystal turbine blade with a notch to be repaired, if the target notch parameter exists in the database, the notch to be repaired can be directly repaired based on the laser cladding parameter corresponding to the target notch parameter. Therefore, recording the undetermined laser cladding parameter corresponding to the third component to which the target fourth component belongs, as well as the notch parameter to be repaired, as a data group in the database can further expand the data in the database and make subsequent repair work more convenient.

[0124] Through steps 303 to 314 above, a data set can be determined. This method can then be used to determine the data set corresponding to the different types of notch parameters to be repaired, and record the data set in the database. Subsequently, the data set corresponding to various notch parameters to be repaired can be retrieved from the database.

[0125] Step 315: Based on the undetermined laser cladding parameters corresponding to the third component to which the fourth component belongs, and the parameters of the notch to be repaired, repair the notch to be repaired.

[0126] After obtaining the undetermined laser cladding parameters corresponding to the third component to which the fourth component belongs, as well as the parameters of the notch to be repaired, the notch to be repaired can be repaired based on the undetermined laser cladding parameters.

[0127] During repair, the notch to be repaired can be cut first to obtain a corresponding groove. This can be done using electrical discharge machining (EDM). After cutting, the damaged area should be polished with 600-800 grit sandpaper to make the surface smooth, with scratches aligned and evenly distributed. Then, the area to be repaired should be cleaned by wiping with acetone and alcohol, followed by air drying to ensure a clean and dry surface.

[0128] Then, a laser metal deposition raw material with a particle size distribution of 53 to 150 micrometers that matches the material of the single crystal turbine blade to be repaired can be obtained. Highly spherical and dense metal powder is prepared by vacuum induction furnace gas atomization (VIGA) as the powder preparation process. The powder is then dried in a vacuum environment at 120°C for 4 hours to eliminate any moisture that may be present in the powder.

[0129] The defect to be repaired is drawn as a 3D CAD model and layered using slicing software. After layering, the components of the defective part of the blade to be repaired are formed by stacking layers one by one. The volume ratio of argon gas used has a purity greater than or equal to 99.999%. Under the argon protective atmosphere, dry metal powder prepared by a powder feeding head coaxial with the laser source is transported to each layer of the molten pool. Using the aforementioned laser cladding parameters to be determined, the geometric restoration of the blade with high cladding quality can be achieved by stacking layers one by one.

[0130] In summary, the laser cladding repair method for damaged characteristic parts of single-crystal turbine blades provided in this application involves manufacturing a first component based on the parameters of the notch to be repaired, repairing the first component based on preset laser cladding parameters, determining whether the repair meets preset requirements, and if it does, obtaining multiple undetermined laser cladding parameters based on the preset laser cladding parameters. Multiple first components are then repaired using these undetermined laser cladding parameters, and the tensile strength after repair for different undetermined laser cladding parameters is determined. The undetermined laser cladding parameter with the highest tensile strength after repair, along with the notch parameters to be repaired, are then recorded as a data set in a database. Notches with undetermined notch parameters can then be repaired based on these undetermined laser cladding parameters. Because this repair method undergoes prior testing, the repair effect is guaranteed, thus improving the stability of the laser cladding repair method for single-crystal turbine blades.

[0131] Figure 8 This is a schematic diagram of a laser cladding repair system for damaged characteristic areas of a single-crystal turbine blade, provided in an embodiment of this application. The system is used to repair single-crystal turbine blades with defects to be repaired. The laser cladding repair system 800 for single-crystal turbine blades includes:

[0132] The parameter acquisition module 801 is used to acquire the parameters of the notch to be repaired.

[0133] The search and acquisition module 802 is used to search the database for a target notch parameter that matches the notch parameter to be repaired, based on the notch parameter to be repaired. The database includes multiple data groups, and each data group includes a notch parameter and the corresponding laser cladding parameter.

[0134] The first repair module 803 is used to repair the notch to be repaired based on the laser cladding parameters corresponding to the target notch parameters when the target notch parameters exist in the database.

[0135] The first manufacturing module 804 is used to manufacture a first component based on the notch parameter to be repaired when the target notch parameter does not exist in the database. The crystal orientation of the substrate of the first component is consistent with the crystal orientation of the single crystal turbine blade to be repaired. The first component has a notch that matches the notch parameter to be repaired.

[0136] The second repair module 805 is used to repair the first component with preset laser cladding parameters to obtain the second component;

[0137] The component acquisition module 806 is used to acquire multiple first components when the second component meets the preset requirements, and to obtain multiple undetermined laser cladding parameters based on the preset laser cladding parameters.

[0138] The third repair module 807 is used to repair multiple first components based on multiple undetermined laser cladding parameters to obtain multiple third components corresponding to multiple undetermined laser cladding parameters.

[0139] Cutting module 808 is used to cut multiple fourth components from multiple third components;

[0140] Performance determination module 809 is used to determine the target fourth component with the highest tensile strength among multiple fourth components;

[0141] The recording module 810 is used to record the undetermined laser cladding parameters corresponding to the third component to which the fourth component of the target belongs, and the parameters of the notch to be repaired as a data group in the database.

[0142] In summary, the laser cladding repair system for damaged parts of single-crystal turbine blades provided in this application manufactures a first component based on the parameters of the notch to be repaired, repairs the first component based on preset laser cladding parameters, determines whether the repair meets preset requirements, and if it does, obtains multiple undetermined laser cladding parameters based on the preset laser cladding parameters. Multiple first components are then repaired using these undetermined laser cladding parameters, and the tensile strength after repair for different undetermined laser cladding parameters is determined. The undetermined laser cladding parameter with the highest tensile strength after repair, along with the notch parameters to be repaired, is recorded as a data set in a database. Notches with undetermined notch parameters can then be repaired based on these undetermined laser cladding parameters. Because this repair method has undergone prior testing, the repair effect is guaranteed, improving the stability of the laser cladding repair method for single-crystal turbine blades.

[0143] In this application, the term "at least one of A and B" merely describes the relationship between related objects, indicating that three relationships can exist. For example, "at least one of A and B" can represent: A existing alone, A and B existing simultaneously, and B existing alone. Similarly, "at least one of A, B, and C" indicates that seven relationships can exist, representing: A existing alone, B existing alone, C existing alone, A and B existing simultaneously, A and C existing simultaneously, C and B existing simultaneously, and A, B, and C existing simultaneously. Likewise, "at least one of A, B, C, and D" indicates that fifteen relationships can exist, representing: A existing alone, B existing alone, C existing alone, D existing alone, A and B existing simultaneously, A and C existing simultaneously, A and D existing simultaneously, C and B existing simultaneously, D and B existing simultaneously, C and D existing simultaneously, A, B, and C existing simultaneously, A, B, and D existing simultaneously, A, C, and D existing simultaneously, and A, B, C, and D existing simultaneously.

[0144] In this application, the terms "first," "second," "third," and "fourth" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. The term "multiple" means two or more, unless otherwise expressly defined.

[0145] In the several embodiments provided in this application, it should be understood that the disclosed systems and methods can be implemented in other ways. For example, the system embodiments described above are merely illustrative. For instance, the division of modules is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple modules or components may be combined or integrated into another system, or some features may be ignored or not executed. The modules described as separate components may or may not be physically separated. The components shown as modules may or may not be physical modules, that is, they may be located in one place or distributed across multiple network modules. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0146] The above description is merely an optional embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A laser cladding repair method for characteristic damaged areas of a single-crystal turbine blade, characterized in that, The method for repairing a single-crystal turbine blade with a notch to be repaired includes: Obtain the parameters of the notch to be repaired; Based on the notch parameters to be repaired, search the database to see if there are target notch parameters that match the notch parameters to be repaired. The database includes multiple data groups, and each data group includes a notch parameter and a corresponding laser cladding parameter. When the target notch parameter exists in the database, the notch to be repaired is repaired based on the laser cladding parameters corresponding to the target notch parameter; When the target notch parameter is not found in the database, a first component is manufactured based on the notch parameter to be repaired. The substrate crystal orientation of the first component is consistent with the crystal orientation of the single-crystal turbine blade to be repaired. The first component has a notch that matches the notch parameter to be repaired. The first component is repaired using preset laser cladding parameters to obtain the second component; When the second component meets the preset requirements, multiple first components are acquired, and multiple undetermined laser cladding parameters are obtained based on the preset laser cladding parameters; Based on the plurality of undetermined laser cladding parameters, the plurality of first components are repaired to obtain the plurality of third components corresponding to the plurality of undetermined laser cladding parameters; Multiple fourth components are obtained by cutting from the plurality of third components; Identify the target fourth component with the highest tensile strength among the plurality of fourth components; The undetermined laser cladding parameters corresponding to the third component to which the target fourth component belongs, and the parameters of the notch to be repaired, are recorded as a data group in the database.

2. The method according to claim 1, characterized in that, The parameters of the notch to be repaired include the depth of the groove, the thickness of the groove, the width of the groove bottom, and the supplementary angle of the angle between one sidewall of the groove and the groove bottom. The groove is a groove on the single crystal turbine blade to be repaired that can include the notch to be repaired. The types of the notch parameters to be repaired include V-shaped grooves, U-shaped grooves, and L-shaped opening grooves. The V-shaped groove includes two connected sidewalls. The bottom width of the V-shaped groove is zero. The angle between one sidewall of the V-shaped groove and the bottom of the groove is the angle between the sidewall and the target surface. The target surface is in contact with the connection position of the two sides and has the same angle with the two sidewalls. The U-shaped groove includes two sidewalls and a groove bottom connected to the two sidewalls; the L-shaped opening groove includes one sidewall and a groove bottom connected to the one sidewall. The step of obtaining the parameters of the notch to be repaired includes: Based on the geometry of the notch to be repaired, determine the type of the notch parameter to be repaired and the notch parameter to be repaired.

3. The method according to claim 2, characterized in that, Before repairing the first component with preset laser cladding parameters to obtain the second component, the method further includes: Determine the initial laser cladding parameters; The initial laser cladding parameters were optimized using finite element analysis to obtain the preset laser cladding parameters.

4. The method according to claim 3, characterized in that, The method further includes: Cut the second component and determine whether the angle between the dendrite growth direction and the maximum principal stress direction at the repair location of the second component is less than a specified angle; When the value is less than the preset requirement, it is determined that the second component meets the preset requirement; If the value is greater than the preset requirement, it is determined that the second component does not meet the preset requirement; When the second component does not meet the preset requirements, the supplementary angle of the angle between one side wall of the groove and the bottom of the groove in the parameter of the notch to be repaired is adjusted to obtain a new parameter of the notch to be repaired. Based on the new parameter of the notch to be repaired, the step of manufacturing the first component based on the parameter of the notch to be repaired is performed.

5. The method according to claim 4, characterized in that, The third component includes the first component, a repair portion located in a notch in the first component, and an extension portion connected to the repair portion and extending away from the first component.

6. The method according to claim 5, characterized in that, The process of cutting multiple fourth components from the plurality of third components includes: The third component is cut using a wire cutting process to obtain the fourth component, which is I-shaped. One end of the fourth component is located in the extension, and the other end is located in the first component of the third component.

7. The method according to claim 6, characterized in that, The determination of the target fourth component with the highest tensile strength among the plurality of fourth components includes: The average tensile strength of each of the plurality of fourth components was obtained by testing them separately. The fourth component with the highest average tensile strength is determined as the target fourth component with the highest tensile strength.

8. The method according to claim 6, characterized in that, After recording the undetermined laser cladding parameters corresponding to the third component to which the target fourth component belongs, and the parameters of the notch to be repaired as a data set in the database, the method further includes: Based on the undetermined laser cladding parameters corresponding to the third component to which the fourth component of the target belongs, and the parameters of the notch to be repaired, the notch to be repaired is repaired.

9. The method according to any one of claims 1 to 8, characterized in that, When the second component meets the preset requirements, multiple first components are acquired, and multiple undetermined laser cladding parameters are obtained based on the preset laser cladding parameters, including: When the second component meets the preset requirements, multiple first components are obtained, and multiple undetermined laser cladding parameters are obtained through orthogonal experimentation based on the preset laser cladding parameters.

10. A laser cladding repair system for characteristic damaged areas of a single-crystal turbine blade, characterized in that, A laser cladding repair system for repairing single-crystal turbine blades with unrepaired defects includes: The parameter acquisition module is used to acquire the parameters of the notch to be repaired. The search and acquisition module is used to search the database for a target notch parameter that matches the notch parameter to be repaired, based on the notch parameter to be repaired. The database includes multiple data groups, and each data group includes a notch parameter and a corresponding laser cladding parameter. The first repair module is used to repair the gap to be repaired based on the laser cladding parameters corresponding to the target gap parameters when the target gap parameters exist in the database; A first manufacturing module is configured to manufacture a first component based on the notch parameter to be repaired when the target notch parameter does not exist in the database. The substrate crystal orientation of the first component is consistent with the crystal orientation of the single-crystal turbine blade to be repaired, and the first component has a notch that matches the notch parameter to be repaired. The second repair module is used to repair the first component using preset laser cladding parameters to obtain the second component; The component acquisition module is used to acquire multiple first components when the second component meets preset requirements, and to obtain multiple undetermined laser cladding parameters based on the preset laser cladding parameters. The third repair module is used to repair the multiple first components based on the multiple undetermined laser cladding parameters, and obtain multiple third components corresponding to the multiple undetermined laser cladding parameters. A cutting module is used to cut multiple fourth components from the plurality of third components; The performance determination module is used to determine the target fourth component with the highest tensile strength among the plurality of fourth components; The recording module is used to record the undetermined laser cladding parameters corresponding to the third component to which the target fourth component belongs, and the parameters of the notch to be repaired, as a data group in the database.

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