激光束补焊：精密修复、表面熔覆、3D金属沉积

激光束补焊：精密修复、表面熔覆、3D金属沉积Steffen Nowotny, Siegfried Scharek, Eckhard Beyer, and Karl-Hermann Richter

(Submitted April 28, 2006; in revised form February 9, 2007)

摘要高价值的部件和工具的表面熔覆、修复、快速设计更改对当今的制造技术提出了挑战。在这一领域，先进的激光技术在模具制造、航空航天、以及汽车工业等相关领域具有突出的重要性。近几年，许多激光熔覆方案已经被转化为一系列的工业产品。这一技术越来越受关注，这主要是源自于其几个显著特色：基于完整的CAD/CAM产业链，可以对于复杂形状和高受力部件的快速合全面的建模。和TIG或者PTA焊接相比，在保证与基体形成冶金结合的条件下，对工件的热输入较少。而且，还有一个很好的优点就是即使在小工件上也可以实现精确定位。熔覆材料包括金属合金（如Co、Ni、Ti、钢），高硬度材料（如WC/Co、TiC、带有金属粘结剂的VC），氧化物陶瓷（Al2O3/TiO2）。典型的基体材料为钢、铸铁、轻合金（如铝合金、钛合金、镁合金）。生产出的三维构件的精度可以达到0.1mm，这几乎是现在所有焊接技术中最高的。另一方面，目前可利用的系统（激光、送粉和喷嘴、CAD/CAM系统）保证了可以很容易的把激光技术集成到其他制造系统中。其典型的应用有：轻型汽车发动组件的表面防护，金属工具的快速修复，以及修复航空发动机或燃气轮机受损的叶片和盘片。

关键词航空发动机修复，直接金属沉积，激光熔覆，表面防护，系统技术

Laser Beam Build-Up Welding: Precision in Repair, Surface Cladding, and Direct 3DMetal Deposition Steffen Nowotny, Siegfried Scharek, Eckhard Beyer, and Karl-Hermann Richter

(Submitted April 28, 2006; in revised form February 9, 2007)

Abstract

Surface coating, repair, and rapid design changes of high-value components and tools are demanding challenges of modern manufacturing technology. In this field, advanced laser-based techniques are of outstanding importance for the related applications in mould and tool, aircraft and aerospace, as well as automotive industry. Many laser cladding solutions have been transferred into industrial series production within the last years. The motivations for the raising interest are given by the typical features of the technology: on the base of closed CAD/CAM chains, a quick and comprehensive treatment even of complex shaped and highly stressed components is possible. The heat input into the workpiece is less compared to TIG or PTA welding, although a metallurgical bonding to the substrate is guaranteed. Furthermore, the precise material deposition even at small partial areas is an advantageous characteristic. The coating materials include metal alloys (Co, Ni, Cu basis, Titanium, and steel), hard metals (e.g., WC/Co, TiC, and VC with metallic binders), and oxide ceramics (Al2O3/TiO2). Typical base materials are steel, cast iron, and lightweight metal alloys based on Aluminum, Titanium, and Magnesium. The accuracy of the produced 3D structures in the range of 0.1 mm is the highest possible in the group of welding techniques. On the other hand, the available system technology (lasers, powder feeders and nozzles, CAD/CAM systems) permits a very easy and successful integration of the laser technology into manufacturing systems. Examples of application are the surface protection of lightweight automotive motor components, repair and quick modifications of metal forming tools as well as the complete restoration of damaged blades and disks of aero engines and gas turbines.

Keywords aero engine repair, direct metal deposition, laser cladding, surface protection, system technology