Rapid repairing method for fracturing pump plunger

Abstract

The invention relates to the technical field of equipment part remanufacturing, and discloses a fracturing pump plunger rapid repairing method which comprises the steps that firstly, three-dimensional data of the surface of a plunger is obtained through a morphology scanning module so as to determine an abrasion area and depth; selectively filling the wear area with metal repair powder by using an acoustic inductive coupling additive module; and then, under the same clamping, an electrochemical finishing module is switched to carry out finish machining on the material increasing area so as to recover the dimensional precision of the material increasing area, and a layer of functionalized wear-resistant and corrosion-resistant conversion film is further constructed on the material increasing area in situ. The four steps of abrasion diagnosis, additive repairing, precision machining and surface strengthening are integrated into an automatic process which is uniformly scheduled by the central control module, and one-time clamping type in-situ repairing of the fracturing pump plunger is achieved. The technological process is simplified, the repairing efficiency and the size consistency are improved, and the protection performance of the repaired area is improved through surface modification.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of equipment component remanufacturing technology, in particular to a quick repair method for a fracturing pump plunger. BACKGROUND

[0002] The fracturing pump is a core power equipment in the energy exploitation of oil, natural gas and the like. The plunger as a key reciprocating component usually involves high pressure and high frequency reciprocating movement in the working environment, and the medium often contains hard particles such as quartz sand. The working conditions cause the plunger surface of the fracturing pump to be prone to abrasive wear, erosion and corrosion, thereby causing geometric size out-of-tolerance and sealing failure, affecting the overall performance and service life of the fracturing pump. In view of the fact that such a plunger is usually made of high-value alloy materials, after its wear and failure, if it is directly scrapped, it will cause great economic loss. Therefore, repairing the failed plunger to restore its performance has clear engineering value and economic benefit.

[0003] Currently, for the wear repair of such plunger parts, the technical means applied in the industry includes thermal spraying, laser cladding, surfacing or brush plating and the like. However, these traditional repair processes have certain limitations in application. For example, the thermal spraying layer is mainly mechanically bonded with the substrate, and the bonding strength is relatively limited. Under the working conditions of the fracturing pump, the coating layer may peel off or crack. In order to obtain metallurgical bonding, the industry often uses laser cladding or surfacing technology, but this kind of process is accompanied by high heat input, which produces thermal stress in the plunger substrate, causing workpiece deformation, and the heat affected zone formed also affects the microstructure and performance of the substrate material.

[0004] A common problem is that no matter what technology is used for material filling, the repaired plunger surface usually has profile deviation and high roughness, which needs to be restored to its final size accuracy and surface quality through subsequent mechanical processing (such as grinding). This makes the repair process present the characteristics of multi-process and non-continuity, and the workpiece needs to be transported and clamped again between the additive equipment and the machining machine. This non-integrated process prolongs the repair cycle, increases the labor cost, and the repeated clamping positioning process introduces cumulative errors, which brings challenges to the final repair accuracy control. In addition, the existing repair process mainly focuses on restoring the geometric size of the part, and less can modify the repaired surface in a unified process to improve its subsequent wear and corrosion resistance. SUMMARY

[0005] The technical problem to be solved by the present application is to provide a quick repair method and system for a fracturing pump plunger which integrates damage diagnosis, additive repair, precision subtractive and surface strengthening, so as to solve the problems of long repair process, large thermal damage and limited performance improvement of the repaired surface of the existing repair technology.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: The first aspect of this invention provides a method for rapid repair of a fracturing pump plunger, comprising the following steps: S1. Obtain the surface three-dimensional data of the fracturing pump plunger, and compare the surface three-dimensional data with the preset standard model data to determine the wear area and wear amount of the fracturing pump plunger; S2. Perform acoustic inductively coupled additive repair on the worn area; S3. Perform electrochemical finishing on the surface of the fracturing pump plunger after additive repair; S4. After the electrochemical finishing is completed, in-situ functionalized surface construction is carried out.

[0007] In one specific embodiment, in step S1, a two-dimensional wear depth map is generated by calculating the radial difference between the three-dimensional surface data and the standard model data in cylindrical coordinates. The calculation formula is as follows: ; in: For at coordinate point Wear depth at the location; For the standard model in axial position The radius at that location; The actual model obtained by scanning at coordinate points The radius at that point.

[0008] Preferably, the acoustically inductively coupled additive repair includes: High-frequency vibration is applied to the repair powder using an ultrasonic transducer nozzle; The repair powder is instantaneously activated using a high-frequency induction field before it flies to the surface of the fracturing pump plunger; The repair powder, after being instantaneously activated, forms a highly plastic state and is deposited in the wear area.

[0009] In one specific embodiment, the acoustic inductively coupled additive repair step further includes: The acoustic emission signal generated when the repair powder is deposited on the surface of the fracturing pump plunger is monitored in real time, and the power of the ultrasonic transducer nozzle or the parameters of the high-frequency induction field are adjusted according to the feedback of the acoustic emission signal.

[0010] Preferably, the electrochemical finishing is performed through a multi-nozzle cathode, and the specific steps of the electrochemical finishing include: Differentiated electrolyte supply or differentiated electrochemical processing parameter control is performed for different nozzles of the multi-nozzle cathode.

[0011] In one specific embodiment, the material removal process of the electrochemical finishing follows Faraday's law of electrolysis: ; in: The mass of metal removed by the electrochemical reaction; The applied current intensity; This refers to the electrolysis energizing time; The molar mass of the workpiece material; The valence of the metal ion in the reaction; is Faraday's constant.

[0012] Furthermore, the differentiated electrolyte supply includes: The amount of material to be removed is determined based on the wear amount or the surface profile after additive repair. Based on the amount of material removed, a first type of electrolyte or a second type of electrolyte is supplied accordingly.

[0013] In one specific embodiment, the targeted supply of the first type of electrolyte or the second type of electrolyte includes: The first type of electrolyte is supplied to areas where the material has a large amount of residue. The second type of electrolyte is supplied to areas where the material removal margin is small or close to the target size.

[0014] Preferably, the first type of electrolyte is a neutral salt solution, and the second type of electrolyte is a solution containing organic additives.

[0015] Preferably, the in-situ functionalized surface construction includes: The electrochemical finishing equipment supplies a phosphate-containing functionalized passivation solution to the surface of the fracturing pump plunger and applies a preset pulse electrical signal to form a phosphate conversion film on the surface of the fracturing pump plunger.

[0016] Preferably, steps S1, S2, S3, and S4 are all completed in one clamping operation of the fracturing pump plunger.

[0017] Preferably, the method further includes the following steps performed by a central control module: Receive the three-dimensional data of the surface; Based on the surface three-dimensional data, additive control commands are generated for controlling the acoustic inductively coupled additive repair. Based on the three-dimensional surface data, finishing and surface construction control commands are generated to control the electrochemical finishing and the in-situ functionalized surface construction.

[0018] This invention provides a rapid repair method for fracturing pump plungers. It has the following beneficial effects: 1. This invention integrates four steps: surface three-dimensional data acquisition, acoustic-induced coupling additive repair, electrochemical finishing, and in-situ functionalized surface construction, all completed in a single clamping operation of a fracturing pump plunger. This process reduces the need for workpiece transfer between different devices and repeated clamping and calibration, shortens the repair cycle, and reduces the cumulative positioning error introduced by multiple clamping operations, thereby improving repair accuracy.

[0019] 2. The acoustic-induced inductively coupled additive repair method used in this invention has low heat input to the fracturing pump plunger matrix during the repair process, which can suppress the generation of matrix thermal deformation, microstructure coarsening, or microcracks caused by high temperature. The subsequent electrochemical finishing is a non-contact process that does not introduce residual stress or work-hardened layer on the repair surface, which helps to maintain the original mechanical properties of the repair layer and the matrix material.

[0020] 3. After electrochemical finishing, this invention utilizes the clean and chemically active surface of the workpiece to immediately perform in-situ functionalization surface construction, which can generate a dense phosphate conversion film on the plunger surface. This conversion film can improve the wear resistance and corrosion resistance of the repaired plunger surface, thereby helping to extend its service life under operating conditions. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the rapid repair system for the fracturing pump plunger of the present invention; Figure 2 This is a schematic diagram illustrating the principle of the acoustic inductively coupled additive repair process of the present invention; Figure 3 This is a schematic diagram illustrating the principle of the electrochemical finishing process of the present invention. Detailed Implementation

[0022] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] See attached document Figure 1 , Figure 1This is a schematic diagram of the structure of a rapid repair system 1 for a fracturing pump plunger according to an embodiment of the present invention.

[0024] The present invention provides a method for rapid repair of fracturing pump plungers, which is performed by the fracturing pump plunger rapid repair system 1.

[0025] In one embodiment, the system 1 may include a topography scanning module 10, an acoustic inductively coupled additive manufacturing module 20, an electrochemical finishing module 30, and a central control module 50.

[0026] The morphology scanning module 10, the acoustic inductively coupled additive manufacturing module 20, and the electrochemical finishing module 30 all establish data and control connections with the central control module 50.

[0027] The repair method of the present invention begins with step S1, which is to obtain the three-dimensional surface data of the fracturing pump plunger and determine the wear area and wear amount.

[0028] After the fracturing pump plunger is fixed on the workpiece clamping device of the system 1, the entire repair process is completed in one clamping.

[0029] Step S1 is mainly executed by the topography scanning module 10 and the central control module 50 in cooperation.

[0030] In one specific embodiment, the topography scanning module 10 includes a laser scanning head.

[0031] The laser scanning head projects a linear laser onto the surface of the fixedly clamped fracturing pump plunger, while a camera integrated with the laser scanning head captures an image of laser stripes modulated by the contours of the plunger surface.

[0032] Using a pre-defined triangulation algorithm, the image is analyzed to calculate the coordinates of each point on the laser stripe in three-dimensional space, forming point cloud data.

[0033] Under the control of the central control module 50, the topography scanning module 10 moves along the axial and circumferential directions of the fracturing pump plunger, or rotates the fracturing pump plunger, to complete the scanning of the entire surface of the area to be repaired, and finally generates a three-dimensional point cloud model representing the current actual surface topography of the fracturing pump plunger.

[0034] The central control module 50 receives the three-dimensional point cloud model generated by the topography scanning module 10.

[0035] The central control module 50 stores preset standard model data of the plunger of this type of fracturing pump. The standard model data is a three-dimensional CAD model under ideal conditions.

[0036] The central control module 50 executes a registration algorithm to align the acquired 3D point cloud model with the preset standard model data in a unified coordinate system.

[0037] After alignment, the central control module 50 uses axial position and circumferential angle as indexes to compare the radial deviation of the two models point by point, thereby determining the position, outline and wear amount of the wear area.

[0038] Specifically, the amount of wear can be represented by a two-dimensional wear depth map. The quantification process is as follows: ; in: For cylindrical coordinate points Wear depth at the location; For the preset standard model in axial position The radius at that location; To the actual model obtained through surface 3D data at coordinate points The radius at that point.

[0039] After completing the above calculations, the central control module 50 generates a two-dimensional wear depth map. It is stored and serves as the direct input for subsequent steps S2 (acoustic inductively coupled additive repair) and S3 (electrochemical finishing).

[0040] See attached document Figure 2 , Figure 2 This is a schematic diagram illustrating the principle of an acoustic inductively coupled additive repair process according to an embodiment of the present invention.

[0041] After completing step S1, the central control module 50 calculates the wear depth based on the generated two-dimensional wear depth map. The acoustic inductively coupled additive manufacturing module 20 is driven to execute step S2 to repair the determined wear area.

[0042] The acoustic inductively coupled additive manufacturing module 20 includes an ultrasonic transducer nozzle 21, a high-frequency induction coil 22 located at the outlet end of the ultrasonic transducer nozzle 21, and a powder feeding system for conveying repair powder.

[0043] Both the ultrasonic transducer nozzle 21 and the high-frequency induction coil 22 are connected to and controlled by the central control module 50.

[0044] When the repair process is started, the powder feeding system delivers metal repair powder to the ultrasonic transducer nozzle 21 via the powder feeding channel 23 using a carrier gas (e.g., argon).

[0045] The ultrasonic transducer nozzle 21, under the action of the ultrasonic transducer inside, applies a high-frequency mechanical vibration with a frequency range of 20kHz to 40kHz to the flowing repair powder.

[0046] The effect of this vibration is: 1. Break up agglomerates of powder formed during the conveying process to ensure the uniformity and stability of the powder flow; 2. Impart an initial acceleration to the powder particles along the spray direction.

[0047] After the repair powder, accelerated by ultrasound, is ejected from the ultrasonic transducer nozzle 21, its flight path will pass through the high-frequency alternating magnetic field generated by the high-frequency induction coil 22.

[0048] The high-frequency induction coil 22 is powered by a high-frequency induction power supply.

[0049] Because the repair powder is a conductive material, it will generate eddy currents in an alternating magnetic field due to electromagnetic induction.

[0050] The presence of eddies causes the temperature of the powder particles to rise sharply due to Joule heating.

[0051] This heating process is extremely short, precisely controlled to activate the powder particles to a solid or semi-solid state that is not fully melted but has high plastic deformation capacity before they fly to the surface of the fracturing pump plunger.

[0052] This instantaneous activation during flight concentrates heat on the powder itself, while the heat input to the fracturing pump plunger matrix is ​​extremely low.

[0053] Ultimately, the kinetic energy-carrying, highly plastic repair powder particles impact and deposit on the surface defined by the two-dimensional wear depth map. The specified wear area.

[0054] Under impact, the particles undergo severe plastic deformation, causing the original oxide film on their surface to rupture and exposing a clean, active metal surface, thus forming a stable metallurgical bond with the fracturing pump plunger matrix and other deposited particles.

[0055] The entire process is carried out point by point or line by line until the worn area is filled to the preset height.

[0056] In a more preferred embodiment, the method further includes an online monitoring and feedback control mechanism.

[0057] See attached document Figure 1 An acoustic emission sensor 40 is installed in the non-repair area of ​​the workpiece clamping device or fracturing pump plunger.

[0058] The acoustic emission sensor 40 is used to monitor in real time the acoustic emission signals generated by impact, plastic deformation and phase change when repair powder particles are deposited on the surface of the fracturing pump plunger.

[0059] The acoustic emission sensor 40 transmits the collected signals to the central control module 50.

[0060] The central control module 50 analyzes the signal's amplitude, energy, ring count, and other characteristic parameters, which are directly related to the quality indicators of the deposition layer, such as its compactness and bonding strength.

[0061] The central control module 50 compares the real-time analyzed characteristic parameters with the preset quality standard database. Once a deviation is detected, it will immediately adjust the output power of the ultrasonic transducer nozzle 21 or the output current of the high-frequency induction coil 22, thereby changing the impact kinetic energy or flight temperature of the powder, so that the deposition quality returns to the target process window in real time, and realizes closed-loop control of the repair process.

[0062] See attached document Figure 3 , Figure 3 This is a schematic diagram illustrating the principle of an electrochemical finishing process according to an embodiment of the present invention.

[0063] After step S2 is completed, the central control module 50 calculates the distribution of the remaining material to be removed based on the initial wear data obtained in step S1 and the actual contour data after additive repair.

[0064] Subsequently, the central control module 50 drives the electrochemical finishing module 30 to execute step S3.

[0065] The core component of the electrochemical finishing module 30 is a multi-nozzle cathode 31. During the finishing process, the fracturing pump plunger serves as the anode, and the multi-nozzle cathode 31 serves as the cathode, with a preset processing gap maintained between them.

[0066] When the electrolyte is sprayed from the nozzle of the multi-nozzle cathode 31 onto the surface of the fracturing pump plunger, and a DC or pulse voltage is applied between them, the metal material on the surface of the fracturing pump plunger undergoes anodic dissolution, enters the electrolyte in ionic form, and is carried away by the high-speed flowing electrolyte, thereby achieving material removal.

[0067] The amount of material removed in this process follows Faraday's law of electrolysis, and the relationship can be expressed as: ; in: The mass of metal removed by the electrochemical reaction, The applied current intensity; This refers to the electrolysis energizing time; The molar mass of the workpiece material; The valence of the metal ion in the reaction; is Faraday's constant.

[0068] The tool head surface of the multi-nozzle cathode 31 is arrayed with multiple mutually insulated or group-controllable nozzles 32.

[0069] Each or each group of nozzles 32 is connected via an independent pipeline to a multi-channel electrolyte supply system controlled by the central control module 50.

[0070] This structure allows for differentiated electrochemical processing of different areas on the surface of the fracturing pump plunger.

[0071] The central control module 50 generates finishing control instructions based on the calculated material removal allowance distribution map.

[0072] For areas with a large amount of material removal residue, the central control module 50 instructs the multi-channel electrolyte supply system to supply a first type of electrolyte through the nozzle 32 directly facing the area.

[0073] The first type of electrolyte is a neutral salt solution, such as a sodium nitrate aqueous solution with a mass concentration of 15% to 20%.

[0074] This type of electrolyte has high conductivity and can generate a high current density at a set voltage, thereby achieving a high material removal rate and being used to quickly remove most of the processing allowance.

[0075] For areas where the material removal margin is small or close to the final target size, the central control module 50 instructs to switch to supplying the second type of electrolyte.

[0076] The second type of electrolyte is a solution containing organic additives, such as adding specific corrosion inhibitors or brighteners to a sodium nitrate solution.

[0077] These organic additives can form a dynamic, electric field-dependent passivation film on the workpiece surface.

[0078] This passivation film can suppress stray corrosion in areas with large processing gaps and more precisely confine the electrochemical reaction to the area with the smallest gap directly below the nozzle, thereby reducing the material removal rate and improving the dimensional accuracy and surface smoothness of the machining.

[0079] In addition, the central control module 50 can also perform differentiated electrochemical processing parameter control.

[0080] With a multi-channel power supply, the central control module 50 can independently adjust the voltage magnitude, current density, or pulse parameters (such as pulse width and duty cycle) applied to different nozzles 32 or nozzle groups.

[0081] By combining differentiated electrolyte supply, this method can perform deterministic and high-precision material removal on the surface of the repaired fracturing pump plunger until its overall contour and dimensions are restored to the requirements of the standard model.

[0082] After step S3 is completed, the geometry and profile of the fracturing pump plunger have been restored to the standard requirements, and its surface is in a clean state without oxide film or contaminant adhesion due to electrochemical finishing, and has high chemical activity.

[0083] At this time, the central control module 50 directly drives the electrochemical finishing module 30 to execute step S4, namely, in-situ functionalized surface construction, without re-clamping the workpiece.

[0084] See attached document Figure 3 In the device structure, the central control module 50 first instructs the multi-channel electrolyte supply system in the electrochemical finishing module 30 to stop supplying the second type of electrolyte and executes a pipeline cleaning procedure, such as using deionized water to drain the residual electrolyte in the multi-nozzle cathode 31 and its supply pipeline.

[0085] After the cleaning process is completed, the central control module 50 instructs the multi-channel electrolyte supply system to switch and supply a phosphate-containing functionalized passivation solution.

[0086] The passivation fluid is applied to the surface of the fracturing pump plunger to be treated through the nozzle 32 of the multi-nozzle cathode 31 in a low-pressure, laminar or low-turbulent state.

[0087] In one embodiment, the phosphate-containing functionalized passivation solution is an aqueous solution containing phosphoric acid, zinc phosphate or manganese phosphate, and a specific accelerator.

[0088] After the passivation fluid stably covers the workpiece surface, the central control module 50 applies a preset pulse electrical signal between the fracturing pump plunger (anode) and the multi-nozzle cathode 31 (cathode) through a multi-channel power supply.

[0089] The waveform, frequency, and duty cycle of this pulsed electrical signal are different from the electrical signal used for material removal in step S3. It is optimized to drive the surface chemical transformation reaction.

[0090] During the "conduction" phase of the pulsed electrical signal, weak anodic dissolution occurs on the surface of the fracturing pump plunger, releasing metal ions (e.g., It enters the passivation liquid boundary layer adjacent to the workpiece surface.

[0091] This leads to an increase in the concentration of metal ions and a rise in pH within the boundary layer, disrupting the original chemical equilibrium.

[0092] When the ion concentration product in a local area reaches the solubility product of phosphate, during the off-phase of the pulsed electrical signal or under the influence of the entire electric field, the dissolved metal ions react with the phosphate ions in the passivation solution. The reaction occurs, and a dense, crystalline phosphate conversion film that is insoluble in water is generated and deposited in situ on the surface of the fracturing pump plunger.

[0093] This process continues until a chemical conversion film of uniform thickness and strong bond with the substrate is formed on the entire repaired surface.

[0094] The phosphate conversion film is a non-metallic ceramic layer that provides corrosion resistance to the surface of the fracturing pump plunger. Its porous crystalline structure also enables it to store lubricant, thereby improving the wear resistance of the repaired plunger.

[0095] Once the thickness or electrochemical characteristic parameters of the conversion membrane reach a preset value, the central control module 50 stops applying pulse electrical signals, completing step S4.

[0096] This concludes the rapid repair process for the fracturing pump plunger.

[0097] See attached document Figure 1 The rapid repair method for fracturing pump plungers described in this invention has an integrated and automated process that is uniformly scheduled and executed by a central control module 50.

[0098] The central control module 50 is the core of the entire repair system. It establishes bidirectional communication and control connections with all functional units, such as the topography scanning module 10, the acoustic inductively coupled additive manufacturing module 20, the electrochemical finishing module 30, and the acoustic emission sensor 40, through a bus or dedicated data interface.

[0099] In one specific embodiment, the central control module 50 may be an industrial computer (IPC) or a high-performance programmable logic controller (PLC) system, which includes a hardware processor, memory and preset control program.

[0100] The control logic executed by the central control module 50 is to seamlessly integrate steps S1 to S4 into a continuous and automatic work process.

[0101] The process begins with receiving and processing the surface three-dimensional data acquired by the topography scanning module 10.

[0102] In generating accurate two-dimensional wear depth maps Then, the central control module 50 generates and executes control instructions for all subsequent steps based on this data.

[0103] For step S2, the central control module 50 first determines the two-dimensional wear depth map based on the data. Additive tool path planning is performed to determine the trajectory, moving speed, and amount of material to be filled at different locations of the ultrasonic transducer nozzle 21.

[0104] Subsequently, it generates a set of timing control instructions, which includes: The coordinate positioning commands for the motion axis of the repair system, the control signals for the start / stop and powder feeding rate of the powder feeding system, and the power setting values ​​for the ultrasonic transducer nozzle 21 and the high-frequency induction coil 22.

[0105] During the additive manufacturing process, the central control module 50 continuously receives and processes feedback signals from the acoustic emission sensor 40, and fine-tunes parameters such as induction heating power in real time through an internal closed-loop control algorithm to ensure the stability of deposition quality.

[0106] For step S3, after the additive repair is completed, the central control module 50 calculates the distribution of the material removal allowance to be refined based on the initial wear data and the additive process model.

[0107] Based on this, it generates a set of finishing instructions for the electrochemical finishing module 30.

[0108] This instruction set defines the movement path of the multi-nozzle cathode 31 and issues differentiated control signals for different points along the path: The multi-channel electrolyte supply system is instructed to supply a first or second type of electrolyte to a specific area, while the multi-channel power supply is instructed to apply precise voltage or current parameters to the corresponding nozzle 32.

[0109] For step S4, after the finishing reaches the target size, the central control module 50 automatically performs process switching.

[0110] It first instructs the electrochemical finishing module 30 to perform pipeline cleaning, and then switches to supply a phosphate-containing functionalized passivation solution.

[0111] Next, it instructs the multi-channel power supply to output specific pulsed electrical signals to drive surface chemical transformation.

[0112] In this way, the central control module 50 integrates four physically different process steps—diagnosis, additive manufacturing, finishing, and surface construction—into a data-driven, continuous, and uninterrupted automated process.

[0113] All operations are completed in a single clamping of the fracturing pump plunger, without the need for manual intervention or workpiece transfer, thus achieving an integrated repair process.

[0114] The present invention will be further described in detail below through a specific embodiment.

[0115] This embodiment is intended to illustrate the technical solution of the present invention, and is not intended to limit the scope of protection of the present invention in any way.

[0116] The objective of this embodiment is to repair a fracturing pump plunger that has failed due to wear.

[0117] The base material of the fracturing pump plunger is 42CrMo tempered steel, and the original working surface is a cobalt-based alloy layer.

[0118] Its nominal diameter is 120mm and its total length is 600mm. Inspection revealed a 50mm wide localized wear band in the central area of ​​the plunger.

[0119] Execution of step S1: The repair process begins by clamping the fracturing pump plunger onto the workpiece clamping device of the repair system 1.

[0120] The central control module 50 starts the topography scanning module 10.

[0121] The laser scanning head in the topography scanning module 10 scans the entire plunger surface with an axial step of 0.1 mm and a circumferential angular step of 0.5° to acquire three-dimensional point cloud data.

[0122] The central control module 50 registers and compares the collected point cloud data with a pre-stored standard model with a nominal diameter of 120mm.

[0123] Calculated two-dimensional wear depth map The wear area is located between 300mm and 350mm in the axial direction, with a maximum wear depth of 1.5mm.

[0124] Execution of step S2: Central control module 50 based on two-dimensional wear depth map Generate additive repair instructions.

[0125] The selected repair powder is Ni60 alloy powder with a particle size range of 50-100μm.

[0126] The powder feeding system uses argon as the carrier gas and delivers powder at a flow rate of 5L / min.

[0127] The acoustic inductively coupled additive manufacturing module 20 is activated.

[0128] The ultrasonic vibration frequency of the ultrasonic transducer nozzle 21 is set to 30kHz, and the power is 500W.

[0129] The high-frequency induction power supply frequency of the high-frequency induction coil 22 is set to 300kHz, and the initial power is set to 3kW.

[0130] The additive module fills the wear area in a spiral pattern until the wear area is completely filled, and forms a machining allowance of 0.3mm to 0.5mm in height on the basis of the original surface contour.

[0131] During this process, the acoustic emission sensor 40 monitors the deposition signal in real time.

[0132] When the signal amplitude is lower than the preset threshold, the central control module 50 automatically increases the sensing power by 50W until the signal returns to the normal range.

[0133] Execution of step S3: After the additive manufacturing process is completed, the central control module 50 drives the electrochemical finishing module 30 to perform finishing.

[0134] The first stage is the removal of large excess volume.

[0135] The central control module 50 instructs the supply of the first type of electrolyte, which is an 18% (w / w) NaNO3 aqueous solution.

[0136] A constant DC voltage of 15V is applied to the area to be processed, and the processing gap is maintained at 0.5mm.

[0137] This stage removes approximately 0.2mm to 0.4mm of material.

[0138] The second stage is precision finishing.

[0139] The central control module 50 commands to switch the supply of a second type of electrolyte, which consists of a 15% NaNO3 aqueous solution with 1% triethanolamine added.

[0140] The machining clearance was reduced to 0.3mm.

[0141] The applied electrical signal is switched to a pulse voltage with a peak value of 12V, a pulse on time of 1ms, and a pulse off time of 4ms.

[0142] After finishing, the diameter of the repaired area of ​​the fracturing pump plunger was restored to 120mm, with a dimensional tolerance within ±0.01mm and a surface roughness Ra of 0.2μm.

[0143] Execution of step S4: After finishing, the central control module 50 instructs the pipeline system of the electrochemical finishing module 30 to be cleaned with deionized water, and then supplied with a phosphate-containing functionalized passivation solution.

[0144] The passivation solution has the following components: The mixture consists of 1.5% phosphoric acid, 1% zinc oxide, and 0.05% sodium nitrite, with the remainder being water.

[0145] After the passivation fluid covers the repaired area, a square wave pulse electrical signal with a frequency of 100Hz, a duty cycle of 50%, and a peak voltage of 5V is applied.

[0146] The process lasts 180 seconds.

[0147] After the process is completed, a gray, dense zinc phosphate conversion film with a thickness of 5-10 μm is formed on the surface of the repaired Ni60 alloy layer.

[0148] At this point, the repair process of the fracturing pump plunger is complete, and it can be removed from the clamping device.

Claims

1. A method for rapid repair of a fracturing pump plunger, characterized in that, Includes the following steps: S1. Obtain the surface three-dimensional data of the fracturing pump plunger, and compare the surface three-dimensional data with the preset standard model data to determine the wear area and wear amount of the fracturing pump plunger; S2. Perform acoustic inductively coupled additive repair on the worn area; S3. Perform electrochemical finishing on the surface of the fracturing pump plunger after additive repair; S4. After the electrochemical finishing is completed, in-situ functionalized surface construction is carried out.

2. The rapid repair method for a fracturing pump plunger according to claim 1, characterized in that, The acoustic inductively coupled additive repair includes: High-frequency vibration is applied to the repair powder using an ultrasonic transducer nozzle; The repair powder is instantaneously activated using a high-frequency induction field before it flies to the surface of the fracturing pump plunger; The repair powder, after being instantaneously activated, forms a highly plastic state and is deposited in the wear area.

3. The rapid repair method for a fracturing pump plunger according to claim 1, characterized in that, The electrochemical finishing is performed through a multi-nozzle cathode, and the specific steps of the electrochemical finishing include: Differentiated electrolyte supply or differentiated electrochemical processing parameter control is performed for different nozzles of the multi-nozzle cathode.

4. The rapid repair method for a fracturing pump plunger according to claim 1, characterized in that, The in-situ functionalized surface construction includes: The electrochemical finishing equipment supplies a phosphate-containing functionalized passivation solution to the surface of the fracturing pump plunger and applies a preset pulse electrical signal to form a phosphate conversion film on the surface of the fracturing pump plunger.

5. The rapid repair method for a fracturing pump plunger according to claim 2, characterized in that, The acoustic inductively coupled additive repair step includes: The acoustic emission signal generated when the repair powder is deposited on the surface of the fracturing pump plunger is monitored in real time, and the power of the ultrasonic transducer nozzle or the parameters of the high-frequency induction field are adjusted according to the feedback of the acoustic emission signal.

6. The rapid repair method for a fracturing pump plunger according to claim 3, characterized in that, The differentiated electrolyte supply includes: The amount of material to be removed is determined based on the wear amount or the surface profile after additive repair. Based on the amount of material removed, a first type of electrolyte or a second type of electrolyte is supplied accordingly.

7. The rapid repair method for a fracturing pump plunger according to claim 6, characterized in that, Targeted supply of the first type of electrolyte or the second type of electrolyte includes: The first type of electrolyte is supplied to areas where the material has a large amount of residue. The second type of electrolyte is supplied to areas where the material removal margin is small or close to the target size.

8. The rapid repair method for a fracturing pump plunger according to claim 7, characterized in that, The first type of electrolyte is a neutral salt solution, and the second type of electrolyte is a solution containing organic additives.

9. A rapid repair method for a fracturing pump plunger according to claim 1, characterized in that, Steps S1, S2, S3, and S4 are all completed during a single clamping of the fracturing pump plunger.

10. A method for rapid repair of a fracturing pump plunger according to claim 1, characterized in that, The rapid repair method for fracturing pump plungers also includes the following steps performed by a central control module: Receive the three-dimensional data of the surface; Based on the surface three-dimensional data, additive control commands are generated for controlling the acoustic inductively coupled additive repair. Based on the three-dimensional surface data, finishing and surface construction control commands are generated to control the electrochemical finishing and the in-situ functionalized surface construction.

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