Abstract
Abstract. Additive remanufacturing height and matching cooling parameters are the key factors affecting blade repair quality. First, the mathematical model of the single additive remanufacturing repair height and wire-feeding speed was established, the solution method was proposed and the numerical solution was obtained, and the validity of the model was verified by experiments. Then, based on the calculation results of a single additive remanufacturing repair, the geometric morphology of the cross section under double additive remanufacturing repair was analyzed, and the mathematical model was established. Second, based on the optimal parameters obtained by numerical analysis and the mathematical model, the fluid structure coupling heat transfer model of “blade fixture” for base channel cooling was established. The cooling effect of the typical section under different initial temperatures and different flow rates was calculated, and the coupled heat transfer in the process of blade remanufacturing was explained by the mechanism. Third, through the comparative analysis of the cooling effect, optimal cooling parameters of double additive remanufacturing repair were obtained, and the model of coupled heat flow was verified by experiment. The results showed that the mathematical model of additive remanufacturing height is effective for studying the thermal cycle and cooling effect of welding, and the cooling parameters obtained by numerical analysis can effectively guarantee the quality of double additive remanufacturing of blade repair.
Highlights
Due to a long time of working in a high pressure and high temperature environment, coupled with grinding and impact with dust in the air, the compressor blades of aircraft engines are usually damaged to different degrees
According to the experimental parameters obtained from previous studies (Gong et al, 2019; Dai et al, 2020a), the cross section morphology of the additive zone of two kinds of wire-feeding speeds (6 in min−1 (2.54 mm s−1) and 8 in min−1 (3.39 mm s−1)) was measured by software
The results show that, the cross sectional morphology is inclined to a certain extent, the roundness of the additive morphology of the two wire-feeding speeds is good, which is consistent with the theoretical model
Summary
Due to a long time of working in a high pressure and high temperature environment, coupled with grinding and impact with dust in the air, the compressor blades of aircraft engines are usually damaged to different degrees. Due to the ultrathin blade tip and poor thermal conductivity, the matching of increased ARM-repair height and the cooling parameters is a technical challenge in blade additive remanufacturing, which seriously affects the blade repair quality. M. Gong et al.: Modeling of additive height and numerical analysis of cooling parameters directly affects the weld seam quality (Zhao et al, 2011; Shen et al, 2020). A compressor blade is a kind of ultrathin alloy which has higher requirements for temperature control and cooling of the molten pool, and the repair process is more complicated. The thermal cycle of the molten pool, which are the key factors affecting the repair quality of ultrathin alloy blades. The study can provide scientific theoretical support for blade ARM-repair height and related cooling parameters and positively improve blade repair technology
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