Strength-ductility Synergy Control of Key Overflow Components of Hydro- turbines by Follow-up Hot-hammering-assisted Wire Arc Additive Remanufacturing

doi:10.3969/j.issn.1004-132X.2025.12.025

China Mechanical Engineering ›› 2025, Vol. 36 ›› Issue (12): 3010-3016.DOI: 10.3969/j.issn.1004-132X.2025.12.025

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Strength-ductility Synergy Control of Key Overflow Components of Hydro- turbines by Follow-up Hot-hammering-assisted Wire Arc Additive Remanufacturing

Xiaochen XIONG¹^,³(), Yan ZHOU², Xiangman ZHOU¹^,³, Haihua WU¹^,³, Lin HUA⁴, Zeqi HU⁴, Xunpeng QIN⁵, Shaohua DENG¹^,³()

^1.Hubei Engineering Research Center for Graphite Additive Manufacturing Technology and Equipment，China Three Gorges University，Yichang，Hubei，443002
^2.School of Mechanical and Electrical Engineering，Wuhan Business University，Wuhan，430056
^3.Hubei Key Laboratory of Hydroelectric Machinery Design & Maintenance，China Three Gorges University，Yichang，Hubei，443002
^4.Hubei Key Laboratory of Advanced Technology for Automotive Components，Wuhan University of Technology，Wuhan，430070
^5.Hubei Longzhong Laboratory，Wuhan University of Technology，Xiangyang，Hubei，441000

Received:2024-12-18 Online:2025-12-25 Published:2025-12-31
Contact: Shaohua DENG

随动热锤辅助水轮机关键过流部件电弧增材再制造强塑协同调控

熊晓晨¹^,³(), 周岩², 周祥曼¹^,³, 吴海华¹^,³, 华林⁴, 胡泽启⁴, 秦训鹏⁵, 邓少华¹^,³()

^1.三峡大学石墨增材制造技术与装备湖北省工程研究中心, 宜昌, 443002
^2.武汉商学院机电工程学院, 武汉, 430056
^3.三峡大学水电机械设备设计与维护湖北省重点实验室, 宜昌, 443002
^4.武汉理工大学现代汽车零部件技术湖北省重点实验室, 武汉, 430070
^5.武汉理工大学隆中实验室, 襄阳, 441000

通讯作者: 邓少华
作者简介:熊晓晨，男，1989年生，博士、讲师。研究方向为水电机械设备修复与再制造。E-mail：Xiaochen.Xiong@hotmail.com
邓少华^*（通信作者），男，1988年生，博士、讲师。研究方向为智能传感技术。E-mail：ctgudsh@163.com。
基金资助:
湖北省自然科学基金(2024AFB266);水电机械设备设计与维护湖北省重点实验室基金(2023KJX06);三峡大学科研启动基金(2024RCKJ004)

Abstract

Abstract:

The wire arc additive remanufacturing of key over-flow components of hydroturbines was prone to the formation of coarse grains and high residual stress， severely compromising the mechanical properties of the repaire layers. The introduction of the follow-up hot-hammering-assisted（FH） processes in the preparation of thin repair layers might significantly enhance strength but tended to reduce ductility. To address the problems， a strategy of FH-assisted single-pass multi-layer additive manufacturing was proposed to achieve the synergy control of strength and ductility in additive layers. Based on the optimal FH processing parameters， the single-pass multi-layer additive layers were prepared， followed by opticl microscope， X-ray diffraction and mechanical property testing. The effects of the FH processes on microstructure and mechanical properties of the additive layers were studied， and the underlying mechanism was revealed. The results indicate that under the FH processes during single-pass multi-layer additive manufacturing， the additive layers achieve simultaneous improvements in strength and ductility. In the rolling direction， the yield strength and tensile strength increase by approximately 18.7% and 13.5% respectively， while the elongation is basically the same compared with the as-deposited group. In the normal direction， the yield strength and tensile strength increase by approximately 15.2% and 9.1% respectively， with the elongation being improved by 14.9%. The mechanism of synergy control of strength and ductility in additive layers is as follows： the grain refinement and homogenization are achieved through repeated high-temperature deformation and austenite recrystallization. Moreover， the high-density dislocations within the deformed layers are effectively reduced by the cyclic tempering heat treatment of single-pass multi-layer additive manufacturing.

Key words: key over-flow components of hydroturbine, wire arc additive manufacturing, remanufacturing, follow-up hot-hammering, strength-ductility synergy control

摘要：

水轮机关键过流部件电弧增材再制造易产生粗晶和高水平残余应力，严重影响其力学性能，引入随动热锤工艺辅助制备薄型修复层可提高强度，却易损失塑性。针对该问题，提出随动热锤辅助单道多层增材实现强塑协同的构想，基于最优随动热锤参数制备单道多层增材层，采用光学显微镜、X射线衍射仪及力学性能测试，研究了随动热锤对增材层组织力学性能的影响规律，并揭示其作用机理。结果表明，随动热锤作用下单道多层增材工艺可使增材层强度、塑性得到同步提高，轧制方向屈服强度和抗拉强度与对照组相比分别提高约18.7%和13.5%，延伸率与对照组基本持平；法向屈服强度和抗拉强度分别提高约15.2%和9.1%，延伸率提高约14.9%。增材层强塑协同调控机制为：通过反复高温变形和奥氏体再结晶实现晶粒细化和均匀化；通过单道多层增材对先变形层进行循环回火热处理，有效消减变形层内高密度位错。

关键词: 水轮机关键过流部件, 电弧增材制造, 再制造, 随动热锤, 强塑协同调控

CLC Number:

TG14

Xiaochen XIONG, Yan ZHOU, Xiangman ZHOU, Haihua WU, Lin HUA, Zeqi HU, Xunpeng QIN, Shaohua DENG. Strength-ductility Synergy Control of Key Overflow Components of Hydro- turbines by Follow-up Hot-hammering-assisted Wire Arc Additive Remanufacturing[J]. China Mechanical Engineering, 2025, 36(12): 3010-3016.

熊晓晨, 周岩, 周祥曼, 吴海华, 华林, 胡泽启, 秦训鹏, 邓少华. 随动热锤辅助水轮机关键过流部件电弧增材再制造强塑协同调控[J]. 中国机械工程, 2025, 36(12): 3010-3016.

Figures/Tables 9

Tab.1 Chemical composition of 0Cr13Ni5Mo welding wire

材料	w（C）	w（Cr）	w（Ni）	w（Mn）	w（Si）
0Cr13Ni5Mo	≤0.06	11.5~13.5	4.0~5.0	≤0.6	≤0.50
材料	w（Mo）	w（Cu）	w（S）	w（P）
0Cr13Ni5Mo	0.4~0.7	≤0.72	≤0.03	≤0.03

Fig.1 Process principle of the follow-up hot-hammering-assisted（FH） single-bead multi-layer wire arc additive manufacturing

Tab.2 Process parameters of the FH

工艺参数	数值
锤击介入温度/℃	950
锤击跟随距离/mm	33
锤击变形量/%	约40
锤击频率/Hz	29
锤击速度/（m· $s - 1$ ）	2.56
锤头形状	平面锤头
锤头平动速度/（mm· $s - 1$ ）	6
焊接电压/V	24
送丝速度/（m· $m i n - 1$ ）	6.5
保护气	80%Ar₂+20%CO₂

Tab.2 Process parameters of the FH

工艺参数	数值
锤击介入温度/℃	950
锤击跟随距离/mm	33
锤击变形量/%	约40
锤击频率/Hz	29
锤击速度/（m· $s - 1$ ）	2.56
锤头形状	平面锤头
锤头平动速度/（mm· $s - 1$ ）	6
焊接电压/V	24
送丝速度/（m· $m i n - 1$ ）	6.5
保护气	80%Ar₂+20%CO₂

Fig.2 Additive blocks for the FH group and the as-deposited one

Fig.3 Sampling diagram of the single-bead multi-layer additive blocks

Fig.4 Grain distribution of primary austenite in the FH group and the as-deposited one

Fig.5 Histogram of tensile properties of the FH group and the as-deposited one

Fig.6 Typical tensile curves in RD and ND direction of single-bead multi-layer additive blocks for the FH group and the as-deposited one

Fig.7 XRD diffraction patterns and main peaks of the FH group and the as-deposited one

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Strength-ductility Synergy Control of Key Overflow Components of Hydro- turbines by Follow-up Hot-hammering-assisted Wire Arc Additive Remanufacturing

随动热锤辅助水轮机关键过流部件电弧增材再制造强塑协同调控

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