1. Major equipment (1) Acetylene generator. Drainage medium pressure type, that is, pressure is 10-100kPa or 10-150kPa. (2) Oxygen cylinders. (3) spray welding. For spray splines, SPH1/h spray guns are used, and SPH2/h spray guns are used for spray splines. (4) A self-made bracket that supports the spline shaft is used to hold the spline shaft with two thimbles. 2. Preparation before spray welding (1) Remove surface oil and rust. (2) Use a vernier caliper to measure the size of the part to be sprayed. If the wear amount is more than 0.3mm, it cannot be sprayed directly. It needs to be welded after welding. When the wear amount is less than 0.3mm, it can be sprayed directly. 3. One-step process (1) welding repair welding. Using φ3.2mm junction 422 electrode, welding current is 90-120A. After welding, the outer circle is processed by a lathe, and the keyway is processed by a grinder or a planer to be processed to a sufficient extent for spray welding. (2) Spray gun inspection. Spray test before spraying to check whether the gun is blocked, whether the switch is sensitive and reliable, and whether the powder delivery is even. (3) adjust the pressure. Adjust the oxygen pressure to 150-250 kPa and adjust the acetylene pressure to 100-150 kPa. (4) spray welding. Adjust the flame to a neutral flame so that the nozzle of the gun is 20-30mm from the workpiece at an included angle of sixty degrees. When the soldering station is heated to about 550-600 degrees Celsius (dark red color), push the powder delivery handle so that the alloy powder is sucked out with the airflow and sprayed onto the surface of the workpiece. Due to the higher preheating of the substrate, the powder that reaches the surface of the workpiece melts immediately and forms a molten solder layer. When the coating layer is melted and the mirror reflection occurs, it indicates that the powder has been remelted. As the gun moves forward, the powder sprays onto the new heated surface and melts again. (5) After spray welding processing. After grinding by spray welding, the surface hardness is HRC45-60. 4. The two-step process (1) welding repair welding, gun inspection and adjusting the pressure and other processes and one-step process is the same. (2) dusting. After adjusting the spray gun to a slight carbonization flame, the torch is moved back and forth on the surface of the workpiece and the surface of the workpiece is warmed by the torch flame. When the workpiece is heated to about 250 degrees Celsius, raise the gun so that the nozzle and the workpiece surface to maintain a distance of 50-100mm, and the flame perpendicular to the surface of the workpiece. Press the powder feed switch at this time to spray the powder onto the surface of the workpiece until the powder has accumulated to a certain thickness and stop powder feeding. In this way, a layer of alloy powder coating is formed on the surface of the workpiece. (3) remelting. Slowly lower the gun and adjust it to a soft neutral flame. Keep the nozzle at a distance of 20-30 mm from the surface of the sprayed coating and the angle between 60 degrees Celsius and 75 degrees Celsius. Remelt until the spray is visible. After the specular reflection occurs on the powder, the gun moves forward again. When remelting, please note that the remelting flame should not be too large or too close to the coating. The faster the remelting speed, the better, otherwise the substrate will overheat and melt. (4) Post-spray processing is the same as one-step process. 5. Alloy powder for spray welding. Spray-welding should use nickel-based alloy powder, which has good wear resistance, and has the characteristics of anti-oxidation, low melting point and so on. In the one-step process, the powder used is finer because of one-shot melting. In the two-step process, the powder used is coarser because of the remelting process. 6. Possible defects and solutions (1) Poor bonding strength. The oil and rust on the spray-welded surface, or the oxidation of the base metal caused by the excessive preheating temperature, will result in the defect that the welding and the base metal are not well-joined. Therefore, be sure to clean the surface of the workpiece before the oil and rust, and grasp the preheating temperature. (2) There is a crack in the spray welding surface. The main reason is that the preheat temperature is not enough or the cooling rate after spray welding is too fast. So be sure to pay attention to the preheat temperature and post-weld cooling rate. Remelt after cracking occurs. The temperature during remelting should be high and the melting should be thorough. (3) The spray layer has pores. The main cause of the generation of pores is the excessively high temperature during remelting, the generation of bubbles due to the burning of metal powder, and the formation of pores. Therefore, the temperature must be mastered during remelting and the remelting should be uniform. (4) There is slag in the spray coating. The main reason is that when the remelting gun advances too fast, the molten slag has not yet floated safely and the molten pool has started to solidify, thus forming slag. Therefore, when the remelting gun forward speed should be properly controlled.
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