再制造产品性能调控中的基础科学问题

Not only is the standard that the qualities of remanufactured products are superior to the new products, but also it is an important basic proposition which must be solved by remanufacturing engineering. .The mechanism that remanufactured products possess superior properties will be proclaimed from the perspective of material science, mechanics and informatics, respectively.The target products of the project are crankshaft and cylinder head which are two key components of heavy load motor..In terms of materials science, the problem of materials compatibility and the micro adhesive mechanism of the heterogeneous material interface between remanufacturing semi-finished products/repairing layers composed of multiple elements during the process of the formation of the repairing layers will be researched, so that the forms and properties of the interfaces can be controlled..From the angle of mechanics, the problem of the evolution law of defects and structural integrity of repairing layers in complex stresses conditions, which are still uncertain to characterize, will be explored. .From the aspect of informatics, with the problem of the incomplete trace and the insufficient excavation of the change rule of the huge data which reflect the whole lifecycle of remanufactured products, the foundation of information tracking and data mining will be researched, and the model of themain control factor of remanufactured products will be established. .Ultimately, the important scientific purpose why the remanufactured products possess more excellent properties compared with new products will be attained, and the essential mechanism will be elaborated accurately and comprehensively in scientific ways.

再制造产品性能优于原型新品，这是再制造必须坚持的质量标准，也是再制造必须正面回答却仍未得到回答的一个重大基础命题。本项目以重载发动机关键零件曲轴和缸盖为研究载体，针对涂覆层多元异质材料成形匹配设计不当的难题，研究再制造毛坯/涂敷层成形界面的“形、性”调控行为，阐述异质材料结合的微观机制，实现对再制造产品性能优于原型新品的材料学基础的揭示；针对涂覆层应力诱导缺陷演变规律把握不准的难题，阐述复杂应力状态下的涂覆层结构完整性演变规律，实现对再制造产品性能优于原型新品的力学基础的揭示；针对再制造产品全生命周期中庞大数据痕迹追踪不足、变化规律未得到挖掘提炼的难题，研究再制造产品全生命周期信息追踪与数据挖掘基础，建立再制造产品质量主控因子的表达模型，实现对再制造产品性能优于原型新品的信息学基础的揭示。最终实现用科学的语言阐述再制造产品性能优于原型新品本质规律的重大科学目的。

再制造产品性能优于原型新品，这是再制造必须坚持的质量标准，也是本项目研究力图解决的重大科学问题。本项目以重载发动机关键零件为研究载体，提出面向服役需求逆向设计强韧匹配再制造涂层新材料方法，建立了涂覆层界面热力学模型，设计了添加CNTs的强韧性陶瓷基等离子喷涂粉体新材料，实现对再制造产品性能优于原型新品的材料学基础的揭示；阐明了喷涂层与基体之间界面嵌合的微观机制，通过基体表面织构设计实现了喷涂层界面结合强度的显著提升。发明了柔性旋转内孔喷涂技术，设计超音速喷嘴，提出随动冷却和负压降尘新方法，实现了等离子射流垂直于工件内壁喷涂，解决了加速距离短、粒子铺展不充分和粉尘聚集污染、热量过度累积造成的大深径比内孔零件增材再制造涂层难结合的瓶颈难题，实现强约束条件下局限空间再制造形性调控；针对涂覆层应力诱导缺陷演变规律把握不准的难题，揭示了喷丸、渗氮等表面强化工艺对再制造毛坯表、界面残余应力重分布行为的作用机制，明确了诱发残余压应力松弛的条件。阐明了再制造毛坯表界面特性与裂纹扩展的耦合作用，涂层厚度影响裂纹萌生的法向应力及切向应力大小，实现了对再制造产品性能优于原型新品的力学基础的揭示；建立了基于光-热效应和声-热效应的再制造喷涂层质量评价方法，依据传热学理论，揭示了热灯脉冲激励下喷涂层表面热波相位特征与涂层厚度之间的映射关系，实现了喷涂层厚度及界面脱粘缺陷的定量表征，提高了缺陷边缘提取和尺寸定量表征的精度。提出了一种基于射频识别的再制造产品全生命周期信息追踪方法，揭示了RFID传感标签的抗金属机制，设计了一种以微带结构标签为原型的抗金属传感标签，突破了复杂金属构件对传感标签布设的限制，建立了表面裂纹深度与标签特征信号间的映射关系，实现了金属表面裂纹深度定量表征。最终实现用科学的语言阐明了再制造产品性能优于原型新品本质内涵。