Laser Cladding Repair for Surface Damage With Low Deformation
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Solution Overview
Problem
Current repair methods for surface damage on parts, such as fretting wear and crevice corrosion, often result in microstructure damage, deformation, and out-of-tolerance sizes, leading to ineffective repairs and the need for part replacement rather than repair.
Innovation Solution
A laser cladding repair method that involves preparing a cladding material and groove based on defect characteristics, optimizing and qualifying the repair procedure, and performing laser cladding to form a cladding layer with minimal substrate damage, good bonding, small deformation, and high precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional thermal processing repair method is used, then repair can be performed on surface damage, but microstructure damage and deformation occur due to large heat input
Solution Approach 1:
The patent changes the thermal processing parameters by using laser cladding with controlled heat input parameters (laser power, scanning speed, hatch spacing) to achieve precise thermal management during repair, avoiding the microstructure damage and deformation caused by traditional thermal processing
Solution Approach 2:
The patent replaces traditional mechanical thermal processing methods with laser-based cladding technology, substituting conventional heat source mechanisms with focused laser energy to achieve more precise and controlled repair with minimal thermal damage
2Ease of repair
If traditional thermal processing repair method is used, then repair can be performed on surface damage, but bonding performance between repair layer and substrate is poor
Solution Approach 1:
The patent performs preliminary surface preparation actions including groove preparation with specific geometric parameters (width, depth, angle) and surface treatment before cladding to ensure optimal bonding conditions between the repair layer and substrate
Solution Approach 2:
The patent uses composite material approach by selecting cladding materials with specific compositions (alloying elements, powder morphology) that are compatible with the substrate and provide excellent bonding performance while maintaining the desired repair properties
3Reliability
If replacement instead of repair is adopted, then safe operation is ensured, but productivity and cost efficiency decrease
Solution Approach 1:
The patent applies the discarding and recovering principle by enabling recovery and reuse of damaged parts through effective repair, preventing premature discarding and replacement, thus improving productivity and cost efficiency while maintaining safety through quality repair
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves effective repair with small damage to the substrate, excellent bonding between the cladding layer and substrate, minimal deformation, and high precision, enabling the reuse of parts and improving their service performance.
Implementation Method 1
performing, based on a result of the procedure optimization and the procedure qualification, laser cladding repair procedure on a defect location to form a cladding layer on the groove
Implementation Method 2
a spot diameter of a laser thermal source is greater than or equal to 3 millimeters and less than or equal to 6 millimeters
Data Source
AI summary
The present application relates to the field of remanufacturing, particularly to a laser cladding repair method and apparatus for surface damage of part, and a part. The laser cladding repair method for surface damage of part includes: preparing a cladding material for repair, and preparing a groove based on a defect characteristic of a to-be-repaired part obtained from inspection and assessment; performing procedure optimization and procedure qualification; performing, based on a result of the procedure optimization and the procedure qualification, laser cladding repair procedure on a defect location to form a cladding layer on the groove; and performing quality evaluation on the cladding layer. This method may be used for surface repair of damaged surfaces of parts during service, achieving dimensional recovery, performance maintenance, and repeatedly installing and using parts, to solve the practical problems of traditional “replacement instead of repair”.