Rotor part manufacturing method

Abstract

This disclosure relates to the technical field of rotor component manufacturing, and more particularly to a method for manufacturing rotor components, comprising: rough machining of the rotor component, wherein during the rough machining process, the position of the reinforcing layer of the rotor component is determined, and a corresponding cladding material tank is set according to the position of the reinforcing layer; the cladding material is filled into the tank using a laser cladding process to obtain a first cladding layer; the first cladding layer is processed to obtain a second cladding layer, such that the second cladding layer meets the design requirements for liquid penetration testing; and the rotor component with the second cladding layer is finished to the design dimensions. Compared to the mechanical bonding method used in existing nickel plating and brush nickel plating processes, the metallurgical bonding method of laser cladding eliminates the obvious physical interface between the cladding material and the rotor component's substrate, resulting in enhanced bonding strength, reduced peeling or detachment, and improved reliability and stability.

Description

Technical Field

[0001] This disclosure relates to the technical field of rotor component manufacturing, and more particularly to a method for manufacturing rotor components. Background Technology

[0002] Seals are the primary components for reducing leakage between the compressor rotor and stator. In pursuit of higher compressor performance, the gap between the rotor and stator is becoming increasingly smaller, which can easily lead to scraping between the stator seal and rotor components. Seals include aluminum alloy seals and carbon ring seals. Carbon ring seals have relatively high hardness. To prevent scratching of rotor components by the carbon ring seal, surface strengthening treatment is applied to the rotor components to improve their wear resistance, thereby preventing damage from the carbon ring seal. Current technology typically involves nickel plating or brushing nickel onto the surface of the rotor components. However, since the rotor components are subsequently processed again, the nickel layer on the cross-section of the rotor components is prone to cracking, leading to scraping between the seal and the rotor components, and potentially damaging the rotor components.

[0003] Therefore, it is necessary to propose a method for manufacturing rotor parts to at least partially solve the problems existing in the prior art. Summary of the Invention

[0004] This disclosure aims to address at least one of the technical problems existing in the prior art or related technologies.

[0005] Therefore, this disclosure proposes a method for manufacturing rotor parts.

[0006] In view of this, a method for manufacturing a rotor part is provided according to an embodiment of the present disclosure, comprising: The rotor parts are rough-machined, and during the rough-machined process, the position of the reinforcing layer of the rotor parts is determined, and the corresponding cladding material groove is set according to the position of the reinforcing layer. Before determining the location of the reinforcing layer on the rotor parts, the rotor parts are subjected to performance heat treatment and non-destructive testing. The cladding material is filled into the above-mentioned tank using a laser cladding process to obtain the first cladding layer; The first cladding layer is processed to obtain a second cladding layer, so that the second cladding layer meets the design requirements for liquid penetration testing; The rotor parts having the second cladding layer are precision machined to the design dimensions.

[0007] In one feasible implementation, the rough-machined rotor part has a mounting edge so that a clamping tool can clamp the rough-machined rotor part through the mounting edge.

[0008] In one feasible implementation, let the outer diameter of the rotor part after rough machining be D, and the inner diameter be d, where (Dd) / 2 ≥ 15 mm.

[0009] In one feasible implementation, along the axial direction of the rotor part after rough machining, the sidewalls of the groove are relatively inclined so that the opening size of the groove is larger than the bottom size of the groove.

[0010] In one feasible implementation, the thickness of the first cladding layer is greater than or equal to 1.5 mm and less than or equal to 2 mm. The hardness of the first cladding layer is ≥40HRC.

[0011] In one feasible implementation, the rotor component to which the first cladding layer is obtained is subjected to stress relief treatment.

[0012] In one feasible implementation, the temperature of the above-mentioned effect force treatment is between 500°C and 580°C.

[0013] In one feasible implementation, the thickness of the third cladding layer of the finished rotor part is ≥1mm, and the thickness of the body material of the finished rotor part is ≥2mm.

[0014] In one feasible implementation, the cladding material includes nickel-based alloys and nickel-iron-based alloys.

[0015] Compared to existing technologies, this disclosure offers at least the following advantages: The manufacturing method for rotor parts provided in this disclosure involves rough machining of the rotor parts, during which the location of the reinforcing layer is determined. Based on the design drawing structure and dimensions of the rotor parts, the location of the reinforcing layer is confirmed, and a corresponding cladding material tank is set up according to the location of the reinforcing layer to fill the cladding material. By filling the cladding material into the tank using a laser cladding process, a first cladding layer is obtained, and the height and length of the cladding layer can be observed at any time through the tank. The first cladding layer is then processed to expose it to light, resulting in a second cladding layer that meets the design requirements for liquid penetration testing. The rotor parts with the second cladding layer are then precision machined to ensure that the rotor parts meet the dimensions required by the design drawing. Compared to the mechanical bonding method used in nickel plating and brush nickel plating in existing technologies, the metallurgical bonding method of laser cladding eliminates the obvious physical interface between the cladding material and the rotor part's substrate, enhancing the bonding force and reducing the likelihood of peeling or detachment, thus improving reliability and stability. Attached Figure Description

[0016] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of exemplary embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this disclosure. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings: Figure 1 A schematic flowchart illustrating a method for manufacturing a rotor component according to an embodiment of this disclosure; Figure 2 This is a schematic structural diagram of a rotor part after rough machining, according to one embodiment of the present disclosure; Figure 3 This is a schematic structural diagram of a rotor part after finishing, according to one embodiment of the present disclosure; Figure 4 This is a schematic structural diagram of the rotor components after assembly, according to one embodiment of the present disclosure.

[0017] in, Figures 2 to 4 The correspondence between the reference numerals and component names in the attached drawings is as follows: 200 Rotor components, 210 Reinforcing layer, 220 Slot, 230 Mounting edge, 300 Seal. Detailed Implementation

[0018] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. It should be noted that the description of these embodiments is intended to aid in understanding the invention, but does not constitute a limitation thereof. The specific structural and functional details disclosed herein are merely for describing exemplary embodiments of the invention. However, the invention can be embodied in many alternative forms and should not be construed as being limited to the embodiments described herein.

[0019] like Figures 1 to 4 As shown, a method for manufacturing a rotor part 200 is proposed according to an embodiment of the present disclosure, including steps S110 to S150.

[0020] In step S110: the rotor part 200 is rough machined, and during the rough machining process, the position of the reinforcing layer 210 of the rotor part 200 is determined, and the corresponding cladding material groove 220 is set according to the position of the reinforcing layer 210. It is understandable that the blank of rotor part 200 is rough machined by mechanical processing to remove some excess material. During the rough machining process, the position of the reinforcing layer 210 of rotor part 200 is determined according to the design drawing dimensions and structure of rotor part 200. Based on the position of reinforcing layer 210, the corresponding groove 220 for filling cladding material is machined. Then, the specific situation of subsequent cladding process can be observed through the groove 220.

[0021] In some examples, the rotor part 200 is subjected to performance heat treatment and non-destructive testing before the location of the reinforcing layer 210 is determined.

[0022] Understandably, before determining the location of the reinforcing layer 210, the rotor part 200 can undergo performance heat treatment and corresponding non-destructive testing, such as ultrasonic testing, to ensure that the rotor part 200 after rough machining meets the process dimensional requirements.

[0023] In some examples, the rough-machined rotor part 200 has a mounting edge so that a clamping tool can clamp the rough-machined rotor part 200 through the mounting edge.

[0024] Understandably, during rough machining, the mounting edge of the rotor part 200 should be machined, such as... Figure 2 As shown, the mounting edge is located on the outer circle and avoids the position of the groove 220, so that in subsequent processes, the clamping tool can clamp the rotor part 200 through the mounting edge, which facilitates the machining of the inner circle and the machining of the cladding layer.

[0025] In some examples, let the outer diameter of the rotor part 200 after rough machining be D, and the inner diameter be d, where (Dd) / 2 ≥ 15 mm.

[0026] It is understandable that the rotor part 200 has a thin-walled rotating body structure. If the wall thickness allowance after rough machining is too small, the rotor part 200 will deform during the laser cladding process, affecting the machining reliability of the rotor part 200. Therefore, the relationship between the outer diameter D and the inner diameter d of the rotor part 200 should satisfy (Dd) / 2≥15 mm to ensure that the wall thickness of the rotor part 200 is sufficient to resist deformation and improve stability during the laser cladding operation.

[0027] Step S120: The cladding material is filled into the above-mentioned tank 220 using a laser cladding process to obtain the first cladding layer; Understandably, after the tank 220 is formed, the cladding material can be welded to the tank 220 using a laser cladding process to obtain the first cladding layer. Compared to the mechanical bonding method used in existing nickel plating and brush nickel plating processes for consumables and the substrate of rotor parts 200, the metallurgical bonding method of laser cladding ensures that there is no obvious physical interface between the cladding material and the substrate of rotor parts 200, resulting in enhanced bonding strength, reduced peeling or detachment, and improved reliability and stability.

[0028] It should be noted that by setting up the tank 220, it is convenient to observe the length and height of the first cladding layer. During the laser cladding operation, when the height of the first cladding layer is observed to be greater than or equal to the depth of the tank 220, it indicates that the thickness of the first cladding layer meets the preset thickness requirements. This avoids the first cladding layer being too thin, which would result in the cladding layer thickness failing to meet the usage requirements and necessitate secondary cladding to thicken it, thus reducing processing efficiency. Furthermore, due to the high hardness of the cladding material and the large residual stress of laser cladding, coupled with the secondary thermal cycle effect, the risk of secondary cladding cracking increases significantly.

[0029] In some examples, along the axial direction of the rotor part 200 after rough machining, the sidewalls of the groove 220 are relatively inclined so that the opening size of the groove 220 is larger than the bottom size of the groove 220.

[0030] Understandably, during rough machining, the groove 220 can be machined on the outer cylindrical sidewall of the rotor part 200 using turning. However, during laser cladding, the presence of right-angled structures in the cladding area can easily lead to stress concentration and subsequent cracking of the cladding layer. Therefore, the sidewall of the groove 220 is set at a relative angle. Specifically, the opening size of the groove 220 is larger than the bottom size; that is, the size of the groove 220 gradually decreases along the radial direction of the rotor part 200. This improves the stress distribution in the cladding area, enhances the quality of the cladding layer, and increases reliability.

[0031] For example, the inclination angle of both sides of the tank wall of the tank 220 can be set to 45°.

[0032] In some examples, the thickness of the first cladding layer is greater than or equal to 1.5 mm and less than or equal to 2 mm; the hardness of the first cladding layer is ≥40 HRC.

[0033] Understandably, the thickness of the first cladding layer in the radial direction of rotor part 200 should be greater than or equal to 1.5 mm and less than or equal to 2 mm. This is to avoid the first cladding layer being too thick, which could easily lead to cracking, and to avoid the first cladding layer being too thin, which could also easily lead to cracking during subsequent thermal assembly of rotor part 200, thus improving reliability. Furthermore, the hardness of the first cladding layer should be ≥40 HRC to ensure protection of rotor part 200, prevent scratches from the seal 300, improve the wear resistance of rotor part 200, and extend its service life.

[0034] In some examples, the rotor part 200 to which the first cladding layer is obtained is subjected to stress relief treatment.

[0035] Understandably, due to the difference in thermal expansion coefficients between the cladding material and the substrate of rotor part 200, and the temperature difference between the first cladding layer and the rest of the rotor part 200 during laser cladding, residual stress is easily generated at the first cladding layer. Stress relief treatment can release this residual stress, preventing deformation of the rotor part 200, which would affect its final dimensions, improve machining and assembly accuracy, and extend its service life. Appropriate stress relief methods can be selected based on actual usage, such as thermal aging, natural aging, or mechanical methods.

[0036] In some examples, the temperature of the above-mentioned stress treatment is between 500°C and 580°C.

[0037] Understandably, since laser cladding is a welding process, the localized high heat input generated during processing can lead to significant residual stress. This residual stress can be effectively removed through heat aging treatment. Specifically, the temperature is controlled between 500℃ and 580℃, and the mixture is held at that temperature before slow cooling.

[0038] Step S130: Process the first cladding layer to obtain a second cladding layer so that the second cladding layer meets the design requirements for liquid penetration testing; Understandably, after the first cladding layer is processed using laser cladding, it can be machined to obtain the second cladding layer. Specifically, the first cladding layer should be able to be seen through light and be circular, meet the requirements of liquid penetration testing, and comply with the Class I requirements of NB / T47013.3 standard.

[0039] Step S140: The rotor part 200 having the second cladding layer is precision machined to the design dimensions.

[0040] It is understandable that after the second cladding layer is completed, the rotor part 200 can be precision machined to bring it to the design dimensions before hot assembly.

[0041] In some examples, the thickness of the third cladding layer of the finished rotor part 200 is ≥1mm, and the thickness of the body material of the finished rotor part 200 is ≥2mm.

[0042] Understandably, during the finishing process, the second cladding layer is processed to obtain the third cladding layer, i.e., the reinforcing layer 210, and the body material of the rotor part 200 is also processed. The thickness of the third cladding layer after finishing should be ≥1mm, and the thickness of the body material of the rotor part 200 should be ≥2mm. By ensuring that the thickness of the body material of the rotor part 200 is greater than or equal to the minimum preset thickness of the base material, during hot assembly, the body material of the rotor part 200 can rely on its sufficient rigidity and expansion to deform uniformly and stably bear the load, avoiding additional tensile stress on the weld layer due to excessive deformation or stress concentration. Simultaneously, the thickness of the third cladding layer is greater than or equal to the minimum preset thickness of the weld layer, ensuring that the third cladding layer itself has sufficient load-bearing capacity during hot assembly to withstand the temperature difference stress caused by different coefficients of thermal expansion. This prevents the third cladding layer from cracking, peeling, or localized tearing due to excessive thinness or stress concentration, ensuring that the third cladding layer and the body material of the rotor part 200 deform collaboratively and reliably during hot assembly.

[0043] It should be noted that, as Figure 4 The diagram shown is an assembly diagram of rotor part 200. After the hot assembly is completed, alignment machining is required, along with magnetic particle testing.

[0044] For example, a commonly used machining method for a balance disc rotor part 200, wherein, as... Figure 3 As shown, the maximum outer diameter of the balance disc is entirely reinforced with a 210 layer. During rough machining, a machining allowance is left along the axial direction of the balance disc, and a groove 220 is machined on the outer circumference of the balance disc. Along the axial direction of the balance disc, one end of the groove 220 is 2mm away from the end face of the balance disc, while the other end of the groove 220 forms an mounting edge with the end face of the balance disc to facilitate subsequent machining and clamping. The inclination angle of both sides of the groove 220 is 45°. The second cladding layer, obtained after machining the first cladding layer, has a thickness of 1.5mm, and the third cladding layer, after finishing, has a thickness of 1mm. The stress relief temperature is 550℃, the hardness of the cladding layer is 45HRC, and non-destructive testing meets the requirements. No cracking occurs after the balance disc is hot-assembled.

[0045] It should be understood that the terms "first," "second," etc., are used only for distinguishing descriptions and should not be construed as indicating or implying relative importance. Although the terms "first," "second," etc., may be used herein to describe various units, these units should not be limited by these terms. These terms are only used to distinguish one unit from another. For example, a first unit may be referred to as a second unit, and similarly, a second unit may be referred to as a first unit, without departing from the scope of the exemplary embodiments of the invention.

[0046] It should be understood that the term "and / or" in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can mean: A exists alone, B exists alone, and A and B exist simultaneously. The term " / and" in this article describes another relationship between related objects, indicating that two relationships can exist. For example, A / and B can mean: A exists alone, and A and B exist alone. In addition, the character " / " in this article generally indicates that the related objects before and after it are in an "or" relationship.

[0047] It should be understood that in the description of this invention, the terms "upper," "vertical," "inner," "outer," etc., indicate the orientation or positional relationship as commonly placed when the disclosed product is used, or the orientation or positional relationship commonly understood by those skilled in the art. They are only for the convenience of describing this invention and simplifying the description, and do not 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 this invention.

[0048] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," and "connect" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0049] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the terms “comprising,” “including,” “containing,” and / or “including” as used herein specify the presence of the stated features, integers, steps, operations, units, and / or components, and do not exclude the presence or addition of one or more other features, quantities, steps, operations, units, components, and / or combinations thereof.

[0050] Specific details are provided in the following description to provide a complete understanding of the exemplary embodiments. However, those skilled in the art will understand that the exemplary embodiments can be implemented without these specific details. In other embodiments, well-known processes, structures, and techniques may be omitted in the depiction of non-essential details to avoid obscuring the exemplary embodiments.

[0051] The above are merely specific embodiments of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

[0052] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art.

Claims

1. A method for manufacturing a rotor part, characterized in that, include: The rotor parts are rough-machined, and during the rough-machined process, the position of the reinforcing layer of the rotor parts is determined, and a corresponding cladding material groove is set according to the position of the reinforcing layer. The cladding material is filled into the tank using a laser cladding process to obtain the first cladding layer; The first cladding layer is processed to obtain the second cladding layer, so that the second cladding layer meets the design requirements for liquid penetration testing; The rotor part having the second cladding layer is precision machined to the design dimensions.

2. The method for manufacturing rotor parts according to claim 1, characterized in that, Before determining the location of the reinforcing layer on the rotor component, the rotor component undergoes performance heat treatment and non-destructive testing.

3. The method for manufacturing rotor parts according to claim 1, characterized in that, The rough-machined rotor part has a mounting edge so that a clamping tool can clamp the rough-machined rotor part through the mounting edge.

4. The method for manufacturing rotor parts according to claim 1, characterized in that, Let the outer diameter of the rotor part after rough machining be D, and the inner diameter be d, where (Dd) / 2 ≥ 15 mm.

5. The method for manufacturing rotor parts according to claim 1, characterized in that, Along the axial direction of the rotor part after rough machining, the sidewalls of the groove are relatively inclined so that the opening size of the groove is larger than the bottom size of the groove.

6. The method for manufacturing rotor parts according to claim 1, characterized in that, The thickness of the first cladding layer is greater than or equal to 1.5 mm and less than or equal to 2 mm; The hardness of the first cladding layer is ≥40HRC.

7. The method for manufacturing rotor parts according to claim 1, characterized in that, The rotor component to which the first cladding layer is obtained is subjected to stress relief treatment.

8. The method for manufacturing rotor parts according to claim 7, characterized in that, The temperature of the effect force treatment is between 500°C and 580°C.

9. The method for manufacturing rotor parts according to claim 1, characterized in that, The thickness of the third cladding layer of the finished rotor part is ≥1mm, and the thickness of the body material of the finished rotor part is ≥2mm.

10. The method for manufacturing rotor parts according to claim 1, characterized in that, The cladding materials include nickel-based alloys and nickel-iron-based alloys.

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