Research On Continual Local Induction Cladding Proccess For Non-uniform Thickness Pre-coated Layer

The parts such as automobile cover forming molds are complex in structure and bulky,and they are operated under complex heavy load conditions for a long period of time,the quality of the surface is required to be high.The general size recovery technology can not meet the long life and precision remanufacturing requirements.The continual local induction cladding method integrates inductor into a five-axis linkage CNC machine tool,and performs three-sizeal motion along the part-plane failure path to be repaired under the traction,realized the continual induction cladding repair of large complex structure parts surface.In order to ensure the quality of repaired parts,in this paper,the differences in wear of various parts of the failed parts were considered,study the process of continual local induction cladding under the condition of non-uniform thickness pre-coated layer,the main research contents are as follows:Firstly,according to the principle of magnetic field superposition,a double aligned turns inductor that can obtain local high temperature rapidly was designed.Through electromagnetic theory analysis,finite element simulation and experimental research,three methods were used to verify the heating performance,and the temperature uniformity was calculated.The problem that the temperature of continual local induction cladding process is hardly to melt the alloy powder has solved.Secondly,the influence of binder content and preheating process on the surface morphology of cladding layer was studied by experiment,the preparation process and distribution ratios of pre-coated layer were formulated.The formability problem of continual local induction cladding was solved and high quality cladding layer was obtained.In further studies,the influence law of the moving speed of inductor,the thickness of pre-coated layer,the gap between inductor and pre-coated layer on the geometry size and microstructure of cladding layer was revealed by designing orthogonal experiment and single factor experiment respectively.Then,using APDL language of ANSYS software programming to carry out secondary development,the finite element model of continual local induction cladding for non-uniform thickness pre-coated layer was established,and the reliability of simulation model was verified by experiments.The temperature field distribution and regularity of the surface of pre-coated layer and substrate material was studied.Finally,the wear interregional experiment of non-uniform thickness pre-coated layer induction cladding process was designed,obtained the data differences of geometrical size and microstructure index caused by the differences of pre-coated layer thickness,the interregional which worn parts can be repaired was estimated with the microhardness of cladding layer as the evaluation basis.Based on the above research,this study has the practical significance of repairing the failure surface of large complex structure parts with high quality and high-performance size recovery.