面向叶片损伤修复的机器人电弧熔丝沉积工艺研究

doi:10.3901/JME.2024.06.187

摘要/Abstract

摘要： 电弧熔丝沉积修复薄壁变宽度叶片时，控制尖角处熔塌和确保各层等高是一大技术难题。本文面向整体叶盘叶片损伤修复工艺技术需求，通过设计TC4钛合金叶片模拟件，进行机器人操作钨极气体保护电弧(Gas tungsten arc，GTA)熔丝沉积工艺技术研究。提出一种控形拘束片控制尖角处熔塌及沉积成形的方法。针对界面上散热条件的不同，结合脉冲电流工艺精确调控热输入分布，实现了首层至前5层沉积宽度及高度一致性良好的成形。此时沉积层成形宽度均匀，上表面高度波动范围在± 0.12 mm。随后结合恒定工艺参数进行了40层沉积，沉积区壁厚控制精度为± 0.17 mm，各层上表面成形基本平整。模拟修复件组织细小均匀，平均极限抗拉强度和伸长率分别达到基体的92.5%和94.7%，为叶片高精度修复奠定了工艺基础。

关键词: GTA电弧熔丝沉积, 控形拘束片, 电流调控, 脉动送丝, 成形控制

Abstract: In repairing thin-walled variable-width blades through gas tungsten arc (GTA) and wire-based deposition, the management of collapse at sharp corners and the maintenance of uniform layer height pose significant technical challenges. Referring to the technical requirements for the repair of the damaged blisk blade, this study explored the technology of robot-operated GTA and wire-based deposition by designing a simulated blade of TC4 titanium alloy. A method for controlling the collapse of sharp corners and deposition by a shape-controlled restraint sheet was proposed. Aiming at varying heat dissipation conditions at the interface, with precise regulation of the heat input distribution through pulse current processing, consistent deposition width and height were achieved for the first five layers. The forming width of the deposition layer at this moment was uniformly distributed, and the fluctuation range of the upper surface height was within ±0.12 mm. Subsequently, 40 layers were deposited with consistent deposition parameters. The deposition area exhibited a wall thickness control accuracy of ±0.17 mm and each layer displayed a predominantly flat upper surface. The microstructure of the simulated repair part was fine and uniform with an average ultimate tensile strength and elongation reaching 92.5% and 94.7% of the matrix, respectively. This provides a solid technological foundation for high-precision blade repair.

Key words: GTA and wire-based deposition, shape-controlled restraint sheet, current regulation, pulse wire feeding, forming control

中图分类号:

TG444

陈祉旭, 李晨星, 杨春利. 面向叶片损伤修复的机器人电弧熔丝沉积工艺研究[J]. 机械工程学报, 2024, 60(6): 187-196.

CHEN Zhixu, LI Chenxing, YANG Chunli. Research on Robotic Gas Tungsten Arc and Wire-Based Deposition Process for Repairing Damaged Blades[J]. Journal of Mechanical Engineering, 2024, 60(6): 187-196.

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