Research on hybrid remanufacturing process chain of laser cladding, CNC machining and ultrasonic rolling for aero-engine blades

There are high geometric accuracy and mechanical performance requirements in the repair and remanufacturing process for aero-engine blades. Therefore, a synergy of multiple processes is necessary for blade repair. This paper mainly studies the coupling relationship between multiple processes of aero-engine blade repair and the influence and contribution of each process to the final surface integrity of the blade. Firstly, a hybrid remanufacturing process chain of laser cladding, CNC machining and ultrasonic rolling is proposed for the requirements of blade repair. Then, a numerical model of the geometric feature construction and transient thermal and structural behavior in the hybrid remanufacturing process chain for blades is established. Finally, the interaction law among the three processes of laser cladding, CNC machining and ultrasonic rolling is analyzed. The results show that a larger powder feed rate is allowed in the laser cladding process of the hybrid remanufacturing process chain for blades. Thermal deformation and residual stress caused by high powder feed rate and thin-walled structure can be optimized by CNC machining and ultrasonic rolling. In addition, the influence mechanism of the three processes on the final surface integrity is revealed. It is shown that the effects of the hybrid remanufacturing process parameters on the remanufacturing quality are different from that of the traditional process. The feasibility of the hybrid remanufacturing process chain for blades is illustrated by the verification experiment on the damaged blade.