Optimization of Processing Parameters for Wear-resistant Cladding Coatings in Crankshaft Remanufacturing

Abstract

Abstract: In order to remanufacture and repair worn crankshafts by PTAW method, orthogonal experiments were designed to optimize the processing parameters of PTAW for wear-resistant cladding coatings. Ni60 wear-resistant cladding coatings were produced on the surfaces of 45 steel samples. The multi-factor effects of main arc current, travel speed and powder feed rate on microhardness and wear volume loss of the coatings were investigated. The performance of the cladding coatings produced with the optimal processing parameters was verified and characterized by the single factor tests. The optimal processing parameters were successfully applied to the remanufacturing of worn crankshafts. The results show that the powder feed rate is the significant factor which affects microhardness and wear volume loss of the cladding coatings within a certain range. With the increase of powder feed rate, the microstructure of cladding coatings is changed from columnar crystal to dendrite crystal and equiaxed crystal, and the microstructure properties, microhardness and wear-resistance are also significantly improved. The optimal processing parameters are given as below: main arc current is as 100 A, travel speed is as 70 mm/min, and powder feed rate is as 22 g/min. The surface quality of the remanufactured and repaired crankshaft main journals is good by using the optimal processing parameters.

Key words: plasma transferred arc welding(PTAW), crankshaft remanufacturing, processing parameter optimization, orthogonal experiment, cladding coating, wear-resistance

摘要： 为了利用等离子喷焊技术对磨损曲轴进行再制造修复，采用正交试验优化等离子喷焊制备耐磨熔覆层的工艺参数。在45钢样件表面制备了Ni60耐磨熔覆层，研究了多因素作用下喷焊电流、喷焊速度和送粉流量对熔覆层显微硬度、磨损体积的影响规律；采用单因素试验对最优工艺参数下制备的熔覆层性能进行了验证与表征，并成功应用到磨损曲轴的再制造修复中。结果表明：在一定范围内，送粉流量是影响熔覆层显微硬度和磨损体积的最显著因素，且随着送粉流量的增加，熔覆层显微组织由柱状晶向树枝晶、等轴晶转变，组织性能得到改善，显微硬度和耐磨性也显著提升；最优工艺参数为喷焊电流100A，喷焊速度70mm/min，送粉流量22g/min；使用最优工艺参数再制造修复的曲轴主轴颈表面质量良好。

关键词: 等离子喷焊, 曲轴再制造, 工艺参数优化, 正交试验, 熔覆层, 耐磨性

CLC Number:

TG174.442

HUANG Haihong, TANG Jie, QIAN Zhengchun, . Optimization of Processing Parameters for Wear-resistant Cladding Coatings in Crankshaft Remanufacturing[J]. China Mechanical Engineering.

黄海鸿, 汤杰, 钱正春, . [机械装备再制造]曲轴再制造耐磨熔覆层工艺参数优化[J]. 中国机械工程.

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