Technical News

As an important piece of equipment in industrial production, the wear of the core component of the booster pump, the piston, directly affects the service life and operational efficiency of the equipment. Traditional repair methods such as electroplating and thermal spraying have drawbacks like insufficient bonding force and limited thickness. However, laser cladding technology, with its advantages of high precision, low thermal impact and metallurgical bonding, is gradually becoming the mainstream solution in the field of movable column repair.

I. Principles and Process Breakthroughs of Laser Cladding Technology

Laser cladding is an advanced technology that forms a molten pool on the surface of the substrate through a high-energy laser beam and simultaneously feeds alloy powder to achieve metallurgical bonding with the substrate. According to the analysis of Guosheng Laser Technology, this technology has three core advantages: Firstly, the heat-affected zone is only 0.1-0.3mm, avoiding the deformation problem caused by traditional welding; Secondly, the cladding layer forms an atomic-level bond with the substrate, and the bonding strength can reach over 350MPa. Furthermore, the performance indicators of the cladding layer, such as hardness (HRC20-62) and wear resistance, can be freely regulated through the powder ratio.

In the repair of the booster pump's live column, the key technological breakthroughs are reflected in:

Adaptive path planning: By using 3D scanning reverse modeling technology, the worn area is reconstructed with a precision of 0.05mm in 3D, automatically generating the optimal cladding path. This technology increases the repair efficiency by 40%.

2. Composite powder system: The composite powder of nickel-based alloys (such as Ni60) and tungsten carbide (WC) can enhance wear resistance by 3 to 8 times, making it particularly suitable for the repair of live columns under high-pressure conditions.

3. Online quality control: The temperature of the molten pool is monitored in real time by an infrared thermal imager (with fluctuations controlled within ±15℃), and in combination with a CCD vision system, the thickness tolerance of the cladding layer is ensured to be ±0.1mm.

Ii. Detailed Explanation of the Process Flow for Laser Cladding Repair of Booster Pump Pistons

1. Pretreatment stage

The surface oxide layer was removed by sandblasting treatment (Sa3 grade cleanliness), and the roughness was controlled at Ra6.3-12.5μm

After ultrasonic cleaning, use a laser degreasing device to ensure that the residual oil on the surface is less than 20mg/m²

2. Cladding processing stage

A 5000W fiber laser is selected, with the spot diameter adjustable from 1.5 to 3mm

The powder feeding system adopts carrier gas protection (argon purity 99.99%), and the powder conveying rate is 20-50g/min

The interlayer temperature should be controlled below 150℃ to prevent thermal accumulation deformation

3. Post-processing procedures

The CNC grinding machine is used for precision machining to a dimensional tolerance of IT6 grade

Laser micro-melting treatment eliminates surface micro-cracks and increases fatigue life by more than 30%

Iii. Industry Development Prospects

The development prospects of laser cladding technology in the field of industrial repair are broad. On the one hand, with the popularization of the "remanufacturing" concept and the development of the circular economy, the demand for the repair of high value-added equipment will continue to grow. On the other hand, the popularization and cost reduction of laser technology will make laser cladding repair technology more competitive in the market. It can be foreseen that laser cladding technology will become an important means for the maintenance and upkeep of key equipment such as booster pumps, providing a strong guarantee for the long-term stable operation of industrial equipment.

Of course, the promotion and application of laser cladding repair technology also face some challenges, such as high technical barriers, large initial investment, and a shortage of professional talents. This requires the joint efforts of equipment manufacturers, user enterprises and research institutions to promote the popularization and application of this technology through technical training, experience sharing, industry-university-research cooperation and other means. Meanwhile, the establishment and improvement of relevant standards will also provide norms and guidance for the development of the industry.

Overall, laser cladding repair technology offers an efficient and reliable solution to the problem of wear on the piston of the booster pump. It can not only restore the geometric dimensions and functional performance of parts, but also significantly enhance the service life and reliability of parts, presenting remarkable technical and economic benefits. With the continuous maturation of technology and the deepening of application, laser cladding technology is bound to play an increasingly important role in the field of industrial equipment maintenance and contribute to the sustainable development of the manufacturing industry.