Turbine Blade Erosion Shield Cladding via Laser Welding
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Solution Overview
Problem
Existing methods for forming erosion shields on turbine blades, such as arc welding and laser welding, may result in defects or insufficient hardness, and can lead to separation or damage of the erosion shield from the blade body, compromising erosion resistance.
Innovation Solution
A cladding-by-welding device and method that uses a powder supply head, laser head, line generator, imaging device, and movement mechanism to perform laser welding, ensuring precise positioning and overlapping of the projection image with a predetermined position to form a high-quality erosion shield with improved hardness and resistance by suppressing incomplete fusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If arc welding is used to form an erosion shield, then the erosion shield can be formed on the turbine blade, but defects are generated and hardness is insufficient
Solution Approach 1:
The patent replaces arc welding with laser welding technology. The laser beam provides concentrated thermal energy for precise melting and welding, eliminating the defects and insufficient hardness associated with arc welding. The laser processing enables controlled material melting and fusion without the harmful effects of arc welding, achieving high-precision erosion shield formation with improved hardness and quality.
Solution Approach 2:
The patent changes the welding parameters by using laser welding instead of arc welding. The laser parameters (power, focal point, scanning speed) are precisely controlled to achieve optimal melting depth and width, ensuring complete fusion between the erosion shield and blade body. This parameter change eliminates incomplete fusion defects and achieves the required hardness and quality standards.
2Manufacturing precision
If laser welding is used to form an erosion shield, then hardness is improved, but the erosion shield may be separated from the blade body or damaged
Solution Approach 1:
The patent performs preliminary surface treatment and preparation before laser welding. The blade surface and erosion shield surface are pre-treated to ensure proper wetting and adhesion. The laser parameters are pre-adjusted to achieve optimal penetration depth and fusion zone characteristics, preventing separation and damage during and after the welding process.
Solution Approach 2:
The patent implements feedback control during laser welding to maintain optimal bonding strength. The welding parameters are dynamically adjusted based on real-time monitoring of the welding process, ensuring consistent fusion quality and preventing erosion shield separation or damage while maintaining the required hardness.
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 a high-quality erosion shield with enhanced erosion resistance by preventing defects and dilution of the deposited material, thereby improving the performance and durability of the turbine blade.
Implementation Method 1
a laser head configured to irradiate a laser
Implementation Method 2
cladding processing by laser welding
Implementation Method 3
a line generator configured to irradiate a measurement line beam
Data Source
AI summary
A cladding-by-welding device, an erosion shield forming method, and a turbine blade manufacturing method forming an erosion shield having high erosion resistance including: a powder supply head; a laser head; a line generator configured to irradiate a measurement line beam; a imaging device; a movement mechanism configured to move the powder supply head and the laser head with respect to a base body; and at least one controller configured to cause a projection image on the base body of the measurement line beam acquired by the imaging device to overlap a predetermined position of the imaging device, to set a position where the projection image overlaps the predetermined position of the imaging device as a copying position, to control the movement mechanism based on the copying position, and to move the powder supply head and the laser head with respect to the base body.