Abstract
The centrifugal compressor impeller is widely used in petroleum, chemicals, and other fields and is liable to failure in complicated working environment. Laser cladding as an advanced technology was used to remanufacture the failure impeller. And, remanufacture quality and service safety should be considered. In this paper, simulation and experiments were applied to study the remanufacturing process of failure thin-wall impeller blade. Firstly, a sequentially uncoupled 3D thermo-mechanical finite element (FE) model was developed to calculate temperature distribution and conduct mechanical analysis. Secondly, the impeller blade of repair region quality was studied based on microstructure analysis, microhardness, and tensile property tests. Finally, dynamic-balancing experiment, over-speed test, and dye penetration inspection were used to assess the security of remanufactured impeller. Numerical simulation showed that high temperature (about 1521 °C) and high residual stress (about 300 MPa) were distributed surrounding heat-affected zone (HAZ). And, experiments showed that the deformation of remanufactured impeller was 1.5 mm without no pores, cracks, slag inclusion, and other defects occurred in the remanufactured region.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Sonthipermpoon K, Bohez E, Hasemann H, Rautenberg M (2010) The vibration behavior of impeller blades in the five-axis CNC flank milling process. Int J Adv Manuf Technol 46(9):1171–1177
Wilson JM, Piya C, Shin YC, Zhao F, Ramani K (2014) Remanufacturing of turbine blades by laser direct deposition with its energy and environmental impact analysis. J Clean Prod 80(80):170–178
Egusquiza E, Valero C, Presas A, Huang X, Guardo A, Seidel U (2015) Analysis of the dynamic response of pump-turbine impellers influence of the rotor. Mechanical Systems & Signal Processing 68-69:330–341
Zhang M, Liu Y, Wang W, Wang P, Li J (2016) The fatigue of impellers and blades. Eng Fail Anal 62:208–231
Zhang P, Liu Z (2015) Machinability investigations on turning of Cr-Ni-based stainless steel cladding formed by laser cladding process. Int J Adv Manuf Technol 82:1707–1714
Dong SY, Yan SX, BS X, Wang YJ, Ren WB (2013) Laser cladding remanufacturing technology of cast iron cylinder head and its quality evaluation. Journal of academy of armored force. Engineering 27(1):90–93
Hu YH, Tian YJ, Chen CN, Ruan ZJ, Zhang Z, Zhong QP, Hang BC (2008) Failure analysis on laser cladding repaired GH864 alloy rotating blades of flue gas turbines. Heat Treatment of Metals 5:96–99
Rottwinkel B, Nölke C, Kaierle S, Wesling V (2014) Crack repair of single crystal turbine blades using laser cladding technology. Procedia Cirp 22(1):263–267
Lin CM (2015) Parameter optimization of laser cladding process and resulting microstructure for the repair of tenon on steam turbine blade. Vacuum 115:117–123
Chew YX, Pang JHL, Bi GJ, Song B (2015) Thermo-mechanical model for simulating laser cladding induced residual stresses with single and multiple clad beads. J Mater Process Technol 224:89–101
Jiang WC, Liu Z, Gong JM, Tu ST (2010) Numerical simulation to study the effect of repair width on residual stresses of a stainless steel clad plate. International Journal of Pressure Vessels & Piping 87(8):457–463
Jia WP, Lin X, Tan H, Yang HO, Zhong CW, Huang WD (2007) Numerical simulation for temperature field of TC4 titanium alloy hollow blade during laser rapid forming process. Rare Metal Mater Eng 36(7):1193–1199
Thiago FA, Raphael CC, Paulo RTS, Abraão SS, Sandro G (2016) Analysis of turbo impeller rotor failure. Eng Fail Anal 63:12–20
Chu QL, Zhang M, Li JH (2013) Failure analysis of impeller made of FV520B martensitic precipitated hardening stainless steel. Eng Fail Anal 34(1):501–510
Zhang M, Wang WQ, Wang PF, Yan LIU, Li JF (2014) Fatigue behavior and mechanism of FV520B-I in ultrahigh cycle regime. Procedia. Mater Sci 3:2035–2041
Al-Khairy RT (2011) Thermal wave propagation in a finite medium irradiated by a heat source with Gaussian distribution in both the temporal and spatial domain. Int J Therm Sci 50(8):1369–1373
Kong F, Ma J, Kovacevic R (2011) Numerical and experimental study of thermally induced residual stress in the hybrid laser–GMA welding process. J Mater Process Technol 211(6):1102–1111
Farahmand P, Kovacevic R (2014) An experimental–numerical investigation of heat distribution and stress field in single- and multi-track laser cladding by a high-power direct diode laser. Optics & Laser Technology 63(4):154–168
Xu L, Cao HJ, Shu LS (2016) 3-D modeling and hexahedral mesh generation method based on failure characteristics of remanufactured centrifugal compressor impeller. Journal of Industrial and Production Engineering 33(5):339–347
Liu SJ, Liu C, YW H, Gao SB, Wang YF, Zhang HC (2016) Fatigue life assessment of centrifugal compressor impeller based on FEA. Eng Fail Anal 60:383–390
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Lei, X., Huajun, C., Hailong, L. et al. Study on laser cladding remanufacturing process with FeCrNiCu alloy powder for thin-wall impeller blade. Int J Adv Manuf Technol 90, 1383–1392 (2017). https://doi.org/10.1007/s00170-016-9445-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-016-9445-z