Laser Quenching equipment
Perform phase transformation hardening treatment on the metal surface to improve the hardness, wear ...
Perform phase transformation hardening treatment on the metal surface to improve the hardness, wear ...
Used for surface strengthening, repair, and remanufacturing of components, the coating has high adhe...
Flexible processing of complex curved sheet metal parts, with high cutting accuracy, fast speed, and...
Specially designed for seamless welding of precision plastic components, with a small heat affected ...
In the forging industry, the high temperature and high pressure working environment causes great die loss. I will expand on the principles of mold damage, laser cladding repair technology, repair process, more actual data and industry impact to make the contents more rich and detailed.
Forging dies are subjected to multiple tests such as high temperature, high pressure and high speed impact under severe working conditions. In the forging process, the hot metal blank is extruded with extremely high pressure, the instantaneous temperature of the die surface can reach over 800 ℃, and the local pressure exceeds 2000MPa. Such extreme conditions will lead to serious plastic deformation and thermal fatigue cracks on the surface of the die cavity. At the same time, the fierce friction between the high-temperature metal and the die surface will accelerate the wear of the die, which will reduce the dimensional accuracy of the die cavity and increase the surface roughness, directly affecting the quality of forging products and the service life of the die.
Dow automation laser cladding equipment adopts advanced high-energy laser beam, with a scanning speed of 10-20 meters per second, to melt the special high-performance alloy powder instantaneously and cladding on the surface of the wear mold cavity. Through the self-developed closed-loop control system, the equipment can realize the accurate control of the thickness and shape of the cladding layer in the micrometer level, and ensure that the dimensional accuracy deviation of the repaired mold cavity is ≤ ± 0.02mm, reaching or even exceeding the manufacturing standard of the new mold. At the same time, the cladding layer forms a solid metallurgical combination with the die matrix. After heat treatment, the die hardness returns to the original standard of HRC58-62, significantly improving the wear resistance and thermal fatigue resistance of the die.
Taking a large forging factory as an example, after three months of high-strength use, the wear depth of key parts of the die cavity reaches 0.5mm, resulting in a soaring scrap rate of crankshaft forging to 15%. When the Dow laser cladding equipment is used for repair, the technical team first carries out ultrasonic cleaning and three-dimensional scanning modeling on the mold, and customize the cladding path and alloy formula according to the wear data; Then, the five-axis linkage system of the equipment is used to carry out precise cladding layer by layer for the complex curved surface mold cavity; Finally, laser heat treatment process is used to eliminate the stress in the cladding layer. The repaired mould is put into production again, not only the dimensional accuracy of the forged crankshaft completely meets the standard, but also in subsequent use, the mould produces 80000 qualified products continuously. Through accounting, compared with direct replacement of new moulds of the same specification, the repair cost saved more than 500000 yuan, and the downtime was reduced by 20 days, greatly improving the production efficiency and economic benefits of the enterprise. This successful case also provides a reproducible and efficient solution for die repair in the forging industry, driving the industry towards green and low-cost development.
