Research on Robotic Gas Tungsten Arc and Wire-Based Deposition Process for Repairing Damaged Blades

doi:10.3901/JME.2024.06.187

Abstract

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

CLC Number:

TG444

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.

Add to citation manager EndNote|Reference Manager|ProCite|BibTeX|RefWorks

URL: http://www.cjmenet.com.cn/EN/10.3901/JME.2024.06.187

http://www.cjmenet.com.cn/EN/Y2024/V60/I6/187

References

[1] YAN S，CHU W. Investigation on the influence of the structure parameters of blade tip recess on the performance of axial flow compressor[J]. Proceedings of the Institution of Mechanical Engineers Part G-Journal of Aerospace Engineering，2021，235(16)：1-15.
[2] ZHUO Y，YANG C，FAN C. Grain refinement of wire arc additive manufactured titanium alloy by the combined method of boron addition and low frequency pulse arc[J]. Materials Science and Engineering A，2020，805(7)：140557.
[3] 卓义民，陈远航，杨春利. 航空发动机叶片焊接修复技术的研究现状及展望[J]. 航空制造技术，2021，64(8)：22-28. ZHUO Yimin，CHEN Yuanhang，YANG Chunli. Research status and prospect of welding repair technology for aero-engine blades[J]. Aeronautical Manufacturing Technology，2021，64(8)：22-28.
[4] ZHAO W，LIU Y，LU M. FEA on vibration characteristics analysis of an aero-engine compressor blade[C]//24th Chinese Control and Decision Conference，2012：3248-3250.
[5] CARTER T. FEA on vibration characteristics blades[J]. Engineering Failure Analysis，2005，12(2)：237-247.
[6] CHEN R，LV F，LI Q. Failure analysis on foreign object damage of aero-engine compressor blade[C]//8th International Conference on Reliability，Maintainability and Safety，2009：1085-1088.
[7] MOHAGHEGH K，SADEGHI M，ABDULLA A. Reverse engineering of turbine blades based on design intent[J]. International Journal of Advanced Manufacturing Technology，2007，10：1009-1020.
[8] 侯廷红，何勇，陈海生. 压气机整体叶盘叶片损伤修复技术研究[J]. 航空维修与工程，2019(4)：37-40. HOU Tinghong，HE Yong，CHEN Haisheng. Research on blade damage repair technology for compressor blisk [J]. Aviation Maintenance & Engineering，2019(4)：37-40.
[9] 王浩，王立文，王涛. 航空发动机损伤叶片再制造修复方法与实现[J]. 航空学报，2016，37(3)：1036-1048. WANG Hao，WANG Liwen，WANG Tao. Method and implementation of remanufacture and repair of aircraft engine damaged blades[J]. Acta Aeronautica et Astronautica Sinica，2016，37(3)：1036-1048.
[10] ÜNAL-SAEWE T，GAHN L，JOCHEN KITTEL. Process development for tip repair of complex shaped turbine blades with IN718[J]. Procedia Manufacturing，2020，474：1050-1057.
[11] FENG Y，REN J，XU Y. Tool path planning in milling of repaired blades of blisks[J]. International Forum on Energy， Environment and Sustainable Development，2016，75：739-744.
[12] GAO J，CHEN X，YILMAZ O. An integrated adaptive repair solution for complex aerospace components through geometry reconstruction[J]. International Journal of Advanced Manufacturing Technology，2008，36(12)：1170-1179.
[13] 王刚，陈国庆，张秉刚. 电子束钎焊修复K465镍基高温合金叶片[J]. 焊接学报，2010，31(9)：85-88. WANG Gang，CHEN Guoqing，ZHANG Binggang. Repair of K465 nickel base superalloy blade by electron beam brazing[J]. Transactions of the China Welding Institution，2010，31(9)：85-88.
[14] 姚希珍，胡泽. 钛合金整体叶盘线性摩擦焊技术综述[J]. 航空制造技术，2011(6)：43-47. YAO Xizhen，HU Ze. Linear friction welding technology for titanium alloy disc[J]. Aeronautical Manufacturing Technology，2011(6)：43-47.
[15] ZHOU Yimin，YANG Chunli，FAN Chenglei，et al. Microstructure and mechanical properties of wire arc additive repairing Ti-6.5Al-2Sn-2Zr-4Mo-4Cr titanium alloy[J]. Materials Science and Technology，2020，36(15)：1712-1719.
[16] FUDE W，WILLIAMS S，COLEGROVE P. Microstructure and mechanical properties of wire and arc additive manufactured Ti-6Al-4V[J]. Metallurgical and Materials Transactions A-Physical Metallurgy and Materials Science，2013，44(2)：968-977.
[17] LIU J，XU Y，GE Y. Wire and arc additive manufacturing of metal components：a review of recent research developments[J]. International Journal of Advanced Manufacturing Technology，2020，111(1-2)：149-198.
[18] PAGONE E，ANTONISSEN J，MARTINA F. Life cycle sustainability assessment of repair through wire and arc additive manufacturing[J]. Minerals Metals & Materials Series，2022：387-394.
[19] WILLIAMS J C，BOYER R R. Opportunities and issues in the application of titanium alloys for aerospace components[J]. Metals，2020，10(6)：1-22.
[20] NESPOR D，DENKENA B，GROVE T. Differences and similarities between the induced residual stresses after ball end milling and orthogonal cutting of Ti-6Al-4V[J]. Journal of Materials Processing Technology，2015，(226)：15-24.
[21] DING D，PAN Z，CUIURI D. A practical path planning methodology for wire and arc additive manufacturing of thin-walled structures[J]. Robotics and Computer-Integrated Manufacturing，2015(34)：8-19.
[22] 周冠男，曲伸，李英. K4169高温合金机匣的精密脉冲弧焊修复技术[J]. 焊接生产应用，2017(5)：60-63. ZHOU Guannan，QU Shen，LI Ying. Precision pulsed arc welding repair technology of K4169 superalloy casing[J]. Production Theme，2017(5)：60-63.
[23] DING D，PAN Z，CUIURI D. A tool-path generation strategy for wire and arc additive manufacturing[J]. International Journal of Advanced Manufacturing Technology，2014，73(1-4)：173-183.
[24] ZHANG J，WANG Q，XIAO G. Filling path planning and polygon operations for wire arc additive manufacturing process[J]. Mathematical Problems in Engineering，2021，(2021)：1-12.
[25] DING D，PAN Z，CUIURI D. A multi-bead overlapping model for robotic wire and arc additive manufacturing (WAAM)[J]. Robotics and Computer-Integrated Manufacturing，2015，31：101-110.
[26] QI H，AZER M，SINGH P. Adaptive toolpath deposition method for laser net shape manufacturing and repair of turbine compressor airfoils[J]. International Journal of Advanced Manufacturing Technology，2010，48(1-4)：121-131.
[27] 宋涛，赵萌，戴士杰. 航空发动机叶片焊接轨迹规划研究[J]. 机械设计与制造，2018(9)：182-184. SONG Tao，ZHAO Meng，DAI Shijie. Research on welding trajectory planning of aero engine blade[J]. Machinery Design and Manufacture，2018(9)：182-184.
[28] 戴士杰，张熠，王志平. 基于NURBS的航空发动机叶片焊接修复的轨迹规划[J]. 焊接学报，2015，36(1)：23-26. DAI Shijie，ZHANG Yi，WANG Zhiping. NURBS-based trajectory planning for welding repair of aero-engine blades[J]. Transactions of the China Welding Institution，2015，36(1)：23-36.
[29] XIONG J，CHEN H，ZHENG S. Feedback control of variable width in gas metal arc-based additive manufacturing[J]. Journal of Manufacturing Processes，2022，76：11-20.
[30] DING D，PAN Z，CUIURI D. Bead modelling and implementation of adaptive MAT path in wire and arc additive manufacturing[J]. Robotics and Computer- Integrated Manufacturing，2016，39：32-42.
[31] ROUT A，DEEPAK B，BISWAL B. Advances in weld seam tracking techniques for robotic welding：A review[J]. Robotics and Computer-Integrated Manufacturing，2019，56：12-37.
[32] ARTURO L，SÉBASTIEN R，FRÉDÉRIC D. Effect of welding parameters on the quality of multilayer deposition of aluminum alloy[C]//Advances in Materials & Processing Technologies Conference，Dec 2017，Vellore，India.
[33] GONCALVES E，RIFFEL K，OKUYAMA M. Effect of dynamic wire in the GTAW process[J]. Journal of Materials Processing Technology，2019，269：91-101.
[34] ZHAO H，ZHANG G，YIN Z. A 3D dynamic analysis of thermal behavior during single-pass multi-layer weld-based rapid prototyping[J]. Journal of Materials Processing Technology，2011，211(3)：488-495.
[35] KELLY S，KAMPE S. Microstructural evolution in laser-deposited multilayer Ti-6Al-4V builds：part I. Microstructural characterization[J]. Metallurgical and Materials Transactions A，2022，35A：2004-1867.
[36] ZHOU Y，QIN G，LI L. Formability，microstructure and mechanical properties of Ti-6Al-4V deposited by wire and arc additive manufacturing with different deposition paths[J]. Materials Science and Engineering：A，2020，772.
[37] BERND B，OMER B，ROSEMARY G. Microstructure of Ti-6Al-4V specimens produced by shaped metal deposition[J]. Int. J. Mat. Res.，2009，100(11)：1536-1542.