Method for improving thermal spraying debugging efficiency

Abstract

The invention relates to the technical field of thermal spraying, and discloses a method for improving thermal spraying debugging efficiency, which comprises the following steps of spraying process confirmation, positioning tool confirmation, powder feeding amount test, flat plate weight increment test, spot test, workpiece clamping and point position confirmation. According to the method for improving the thermal spraying debugging efficiency, the universal base positioning tool is designed, high-precision installation of the universal base positioning tool and the spraying rotary table is guaranteed, and before debugging, state confirmation (including powder feeding amount testing, flat plate weight increasing testing and spot testing) of the thermal spraying equipment is conducted; after confirmation, the workpiece to be machined is accurately fixed to the spraying rotary table through the universal base positioning tool, and then thermal spraying product development is conducted, so that the equipment state stability and consistency and the workpiece positioning precision of each round of thermal spraying development test are effectively guaranteed; the misjudgment and the period prolonging of the thermal spraying debugging method caused by the equipment state and the positioning accuracy are avoided, so that the development efficiency of thermal spraying products is greatly improved.

Description

Technical Field

[0001] This invention relates to the field of thermal spraying technology, and in particular to a method for improving the efficiency of thermal spraying commissioning. Background Technology

[0002] In the aero-engine and gas turbine industry, thermal spraying of the outer surface of blades plays a crucial role in improving their performance in terms of oxidation resistance, high-temperature resistance, and fretting wear resistance. However, due to the complex blade structure, small coating thickness tolerance, and numerous factors affecting the coating result, the commissioning of thermal spraying of blades is difficult and time-consuming. Furthermore, the coating result is greatly affected by positioning accuracy and equipment condition. Poor positioning or unstable equipment condition can seriously affect the technicians' judgment on adjusting the thermal spraying path, leading to a significant reduction in coating development efficiency.

[0003] Therefore, adopting a reasonable tooling positioning method and confirming the equipment status before debugging can significantly reduce the deviation in coating thickness caused by inconsistent blade clamping and positioning and equipment instability, thereby avoiding misjudgment of the debugging method by these two factors and improving the debugging efficiency of thermal spraying. Summary of the Invention

[0004] Based on the above, the purpose of this invention is to provide a method to improve the efficiency of thermal spraying commissioning, increase the positioning of thermal spraying fixtures and the confirmation of equipment status, and reduce the thermal spraying commissioning cycle.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A method for improving the commissioning efficiency of thermal spraying includes:

[0007] Step 1: Confirm the spraying process: Select the spraying formula that meets the customer's specifications and has the highest deposition rate;

[0008] Step 2: Positioning Fixture Confirmation: Design a universal base positioning fixture and accurately connect the universal base positioning fixture to the spraying turntable to avoid lateral and circumferential positioning deviations.

[0009] Step 3, Powder Feeding Test: Run several powder feeding operations and compare whether the increase in powder feeding volume on both sides of the spray gun is the same after each powder feeding, and whether there is no significant difference between the increase in powder feeding volume each time and the previous increase in powder feeding volume. If so, the debugging conditions are met.

[0010] Step 4, Plate Weight Gain Test: Spray the specified area of ​​the standard-sized plate several times, and compare whether the weight gain of the plate after each spray is significantly different from the previous weight gain. If so, the debugging conditions are met.

[0011] Step 5, Spot Test: Spray coating on designated points of a standard-sized flat plate and check whether the shape of the sprayed spot has only one peak and is nearly circular. If so, the debugging conditions are met.

[0012] Step Six: Workpiece Clamping and Position Confirmation: Install a laser emitter on the spray gun, ensuring that the laser beam emitted by the laser emitter coincides with the peak of the spray spot. Then, install the universal base positioning fixture on the spray turntable, clamp the workpiece to be processed using the universal base positioning fixture, and run the spraying program to make the spray gun reach the spraying positioning point on the workpiece. Determine whether there is no deviation between the position of the laser beam and the spraying positioning point. If so, the debugging conditions are met.

[0013] As an optional solution, in step two, the universal base positioning fixture includes a positioning column, one end of which is provided with a positioning disc, the center of which is provided with a boss that matches the center hole of the spraying turntable, the positioning disc is provided with a radial slot, and a positioning block is provided in the radial slot. The positioning block protrudes from the surface of the positioning disc and matches the positioning groove of the spraying turntable. The other end of the positioning column is provided with a mounting flange for mounting the workpiece to be processed, and a fixing hole is reserved on the mounting flange.

[0014] As an alternative, in step one, in addition to determining the spraying formula, it is also necessary to determine the spraying distance, speed, angle, number of passes, and powder feed rate.

[0015] As an optional approach, in step three, the powder delivery tubes on both sides of the spray gun are removed and inserted into two identical bottles one by one. After delivering powder for 2 minutes, the two bottles are weighed. The powder delivery and weighing operation is repeated at least three times.

[0016] As an optional approach, in step four, the standard-sized plate is a thin stainless steel sheet. A 70mm*70mm area on the thin stainless steel sheet is sandblasted to form the designated area. The spraying speed is 400mm / s, and at least five coats are applied.

[0017] As an optional approach, in step five, the spray gun is aimed at the designated point on the stainless steel sheet and sprayed for 5 seconds before stopping.

[0018] As an alternative, in step six, a laser emitter is installed in the barrel of the spray gun to simulate the actual thermal spraying point with the focal position of the laser beam.

[0019] The beneficial effects of this invention are:

[0020] This method for improving the efficiency of thermal spraying debugging involves designing a universal base positioning fixture to ensure high-precision installation with the spraying turntable. Before debugging, the status of the thermal spraying equipment is confirmed (including powder feeding test, plate weight gain test, and spot test). After confirmation, the workpiece to be processed is accurately fixed to the spraying turntable using the universal base positioning fixture before thermal spraying product development. This effectively ensures the stability and consistency of the equipment status and the positioning accuracy of the workpiece in each round of thermal spraying development tests, avoiding misjudgments and extended cycles in thermal spraying debugging methods caused by equipment status and positioning accuracy, thereby significantly improving the efficiency of thermal spraying product development. Attached Figure Description

[0021] Figure 1 This is a flowchart of a method for improving the debugging efficiency of thermal spraying provided in an embodiment of the present invention;

[0022] Figure 2 This is a schematic diagram of a universal base positioning fixture used in the method for improving the debugging efficiency of thermal spraying provided in the embodiments of the present invention.

[0023] In the attached image:

[0024] 1. Positioning pin; 2. Positioning disc; 3. Boss; 4. Radial slot; 5. Positioning block; 6. Mounting flange; 7. Fixing hole. Detailed Implementation

[0025] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0026] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0027] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0028] In the description of this embodiment, terms such as "upper," "lower," "left," and "right" are based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of description and simplification of operation, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0029] Furthermore, the terms "first" and "second" are merely used to distinguish between different terms in description and do not have any special meaning.

[0030] Please see Figure 1 As shown, this embodiment provides a method for improving the debugging efficiency of thermal spraying, including the following steps:

[0031] Step 1: Confirm the spraying process: Select the spraying formula that meets the customer's specifications and has the highest deposition rate;

[0032] Step 2: Positioning Fixture Confirmation: Design a universal base positioning fixture and accurately connect the universal base positioning fixture to the spraying turntable to avoid lateral and circumferential positioning deviations.

[0033] Step 3, Powder Feeding Test: Run several powder feeding operations and compare whether the increase in powder feeding volume on both sides of the spray gun is the same after each powder feeding, and whether there is no significant difference between the increase in powder feeding volume each time and the previous increase in powder feeding volume. If so, the debugging conditions are met.

[0034] Step 4, Plate Weight Gain Test: Spray the specified area of ​​the standard-sized plate several times, and compare whether the weight gain of the plate after each spray is significantly different from the previous weight gain. If so, the debugging conditions are met.

[0035] Step 5, Spot Test: Spray coating on designated points of a standard-sized flat plate and check whether the shape of the sprayed spot has only one peak and is nearly circular. If so, the debugging conditions are met.

[0036] Step Six: Workpiece Clamping and Position Confirmation: Install a laser emitter on the spray gun, ensuring that the laser beam emitted by the laser emitter coincides with the peak of the spray spot. Then, install the universal base positioning fixture on the spray turntable, clamp the workpiece to be processed using the universal base positioning fixture, and run the spraying program to make the spray gun reach the spraying positioning point on the workpiece. Determine whether there is no deviation between the position of the laser beam and the spraying positioning point. If so, the debugging conditions are met.

[0037] Therefore, by using a universal base positioning fixture, high-precision installation with the spraying turntable is ensured. Before debugging, the status of the thermal spraying equipment is confirmed (including powder feeding test, plate weight gain test, and spot test). After confirmation, the workpiece to be processed is accurately fixed to the spraying turntable using the universal base positioning fixture before thermal spraying product development. This effectively ensures the stability and consistency of the equipment status and the positioning accuracy of the workpiece in each round of thermal spraying development and testing, avoiding misjudgments and extended cycles in thermal spraying debugging methods caused by equipment status and positioning accuracy.

[0038] Specifically, in step one, the powder coating process is adjusted according to the customer's specifications. After adjusting key parameters such as spraying distance, spraying speed, spraying angle, number of spraying passes, gas content, and powder feed rate, metallographic, deposition rate, and mechanical tests are conducted. The coating formula that meets the customer's specifications and has the highest deposition rate is selected, and all subsequent debugging steps are conducted using this coating formula.

[0039] Specifically, in step two, such as Figure 2 As shown, the universal base positioning fixture includes a positioning post 1, a positioning disc 2 at one end of the positioning post 1, a boss 3 at the center of the positioning disc 2, the boss 3 being adapted to the center hole of the spraying turntable, a radial slot 4 on the positioning disc 2, a positioning block 5 in the radial slot 4, the positioning block 5 protruding from the surface of the positioning disc 2 and being adapted to the positioning groove of the spraying turntable, and a mounting flange 6 for mounting the workpiece to be processed at the other end of the positioning post 1, with a fixing hole 7 pre-drilled on the mounting flange 6.

[0040] To ensure the workpiece's relative clamping position is error-free during each round of debugging, a positioning design needs to be added to the existing thermal spraying fixture. Based on the characteristics of the spraying turntable, a boss 3 is added to the positioning disc 2 to connect with the center hole of the spraying turntable, preventing lateral positioning deviation. A radial slot 4 is added to the positioning disc 2, and a positioning block 5 locks the positioning disc 2 to the positioning slot of the spraying turntable, preventing circumferential positioning deviation. Furthermore, by connecting workpieces of different shapes to the universal base positioning fixture, the problem of positioning loss caused by inconsistent positioning methods and frequent product changes can be effectively avoided.

[0041] Specifically, in step three, the powder feeding tubes on both sides of the spray gun are removed and inserted into two identical bottles one by one. After feeding powder for 2 minutes, the two bottles are weighed. The powder feeding and weighing operation is repeated at least three times.

[0042] The powder feeding process adopts the spraying process determined in step one. Taking the operation as repeated three times as an example, compare whether the increase in powder feeding amount on both sides is the same in the three times, and whether there is no significant difference between the increase in powder feeding amount on both sides and the previous increase in powder feeding amount. If there is no significant difference, it means that there is no problem with the powder feeding system of the equipment.

[0043] Specifically, in step four, the standard-sized plate is a thin stainless steel sheet. A 70mm*70mm area is taken from the thin stainless steel sheet and sandblasted to form the designated area. The spraying speed is 400mm / s, and at least five coats are applied.

[0044] The spraying process adopts the spraying process determined in step one. Taking the operation as an example of repeating it five times, compare whether there is a significant difference between the weight gain of the plate after five sprayings and the previous weight gain of the plate. If there is no significant difference, it means that there is no problem with the equipment spraying system.

[0045] Powder delivery rate testing and plate weight gain testing are effective means to ensure that thermal spraying equipment and thermal spraying systems are in good condition and leak-free.

[0046] Specifically, in step five, the spray gun is aimed at the designated point on the stainless steel sheet and sprayed for 5 seconds before stopping.

[0047] Before each debugging, a spot test must be performed to check whether the nozzle of the spray gun is severely worn. If the shape of the spray spot is normal, it means that there is no problem with the equipment's carrier air system and the spray gun.

[0048] Specifically, in step six, the laser emitter is installed in the barrel of the spray gun to simulate the actual thermal spraying point with the focal position of the laser beam.

[0049] After step five is completed, the spraying program is run again to move the spray gun to the position of the spraying spot, and the laser emitter is installed so that the laser beam coincides with the peak of the spraying spot. This ensures that under the spraying process determined in step one, the laser beam coincides with the actual thermal spraying point. The universal base positioning fixture is placed on the spraying turntable. After clamping the workpiece to be processed, it is necessary to confirm that there is no shaking between the workpiece to be processed and the universal base positioning fixture. The spray gun with the laser emitter clamped is run to the spraying positioning point to determine whether there is any deviation between the laser beam and the spraying positioning point. If there is no deviation, it means that the positioning of the universal base positioning fixture and the workpiece to be processed is correct.

[0050] Therefore, by increasing tooling positioning and equipment status confirmation, the thermal spraying commissioning cycle is reduced, the thermal spraying commissioning efficiency is improved, and thus the thermal spraying product development efficiency is increased.

[0051] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A method for improving the debugging efficiency of thermal spraying, characterized in that, include: Step 1: Confirm the spraying process: Select the spraying formula that meets the customer's specifications and has the highest deposition rate; Step 2: Positioning Fixture Confirmation: Design a universal base positioning fixture and accurately connect the universal base positioning fixture to the spraying turntable to avoid lateral and circumferential positioning deviations. Step 3, Powder Feeding Test: Run several powder feeding operations and compare whether the increase in powder feeding volume on both sides of the spray gun is the same after each powder feeding, and whether there is no significant difference between the increase in powder feeding volume each time and the previous increase in powder feeding volume. If so, the debugging conditions are met. Step 4, Plate Weight Gain Test: Spray the specified area of ​​the standard-sized plate several times, and compare whether the weight gain of the plate after each spray is significantly different from the previous weight gain. If so, the debugging conditions are met. Step 5, Spot Test: Spray coating on designated points of a standard-sized flat plate and check whether the shape of the sprayed spot has only one peak and is nearly circular. If so, the debugging conditions are met. Step Six: Workpiece Clamping and Position Confirmation: Install a laser emitter on the spray gun, ensuring the laser beam emitted by the laser emitter coincides with the peak of the spray spot. Then, install the universal base positioning fixture on the spraying turntable. Clamp the workpiece to be processed using the universal base positioning fixture. Run the spraying program to bring the spray gun to the spraying positioning point on the workpiece. Determine whether there is no deviation between the laser beam and the spraying positioning point. If so, the debugging conditions are met.

2. The method for improving the debugging efficiency of thermal spraying according to claim 1, characterized in that, In step two, the universal base positioning fixture includes a positioning column (1), one end of which is provided with a positioning disc (2), and the center of the positioning disc (2) is provided with a boss (3), which is adapted to the center hole of the spraying turntable. The positioning disc (2) is provided with a radial slot (4), and a positioning block (5) is provided in the radial slot (4). The positioning block (5) protrudes from the surface of the positioning disc (2) and is adapted to the positioning groove of the spraying turntable. The other end of the positioning column (1) is provided with a mounting flange (6) for mounting the workpiece to be processed, and a fixing hole (7) is reserved on the mounting flange (6).

3. The method for improving the debugging efficiency of thermal spraying according to claim 1, characterized in that, In step one, in addition to determining the spraying formula, it is also necessary to determine the spraying distance, speed, angle, number of passes, and powder feed rate.

4. The method for improving the debugging efficiency of thermal spraying according to claim 1, characterized in that, In step three, the powder feeding tubes on both sides of the spray gun are removed and inserted into two identical bottles one by one. After feeding powder for 2 minutes, the two bottles are weighed. The powder feeding and weighing operation is repeated at least three times.

5. The method for improving the debugging efficiency of thermal spraying according to claim 1, characterized in that, In step four, the standard-sized plate is a thin stainless steel sheet. A 70mm*70mm area is taken from the thin stainless steel sheet and sandblasted to form the designated area. The spraying speed is 400mm / s, and at least five coats are applied.

6. The method for improving the debugging efficiency of thermal spraying according to claim 5, characterized in that, In step five, the spray gun is aimed at the designated point on the stainless steel sheet and sprayed for 5 seconds before stopping.

7. The method for improving the debugging efficiency of thermal spraying according to claim 1, characterized in that, In step six, the laser emitter is installed in the barrel of the spray gun to simulate the actual thermal spraying point with the focal position of the laser beam.

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