关键词: GTA电弧熔丝沉积, 叶片修复, 加工路径规划, 焊枪姿态控制, 成形控制

Abstract: Repairing high-pressure compressor blades of aircraft engines using the gas tungsten arc（GTA） and wire-based deposition is a technical challenge, the fixed posture deposition of the welding torch is easy to cause the deviation between the repair region and the digital model. Aiming at the repair technical requirements of blisk blade, a path-planning method and a posture control-planning method of welding torch are proposed for GTA and wire-based deposition, which mainly regulating the yaw angle during the deposition to make the welding torch follow the blade’s curved surface inclination to improve the formation. The results show that the welding-torch inclination（WTI） changes the arc-pressure distribution and promotes the liquid metal filling into the inner edge, which increases the deposition width; With the increase of inclination angle, the liquid metal is more easily spread outward, simultaneously, which reduces the risk of collapse. The sidewall waviness of WTI is reduced by about 0.4 mm compared with that of the vertical posture, the effective thickness increases by about 0.44 mm, and the surface roughness is reduced by about 12.7%. The repaired blade has on obvious deposition defect, which avoids the forming deviation of vertical-posture deposition. The minimum unilateral machining allowance is about 0.88 mm, provides a guarantee for finish machining. Controlling the posture of the welding torch during the deposition process will provide a method reference for improving the formability of complex curved structures.

Key words: GTA and wire-based deposition, blade repair, machining path planning, welding-torch posture control, forming control