GH4169高温合金表面NiCrAlY涂层的单晶刚玉砂轮磨削工艺优化与精度控制OA

To address critical challenges in synchronous grinding of GH4169 superalloy substrates with NiCrAlY thermal barrier coatings—including excessive dimensional deviation,grinding cracks,and coating delamination—a precision grinding process using Single-Crystal Alumina(SCA)wheels was developed.Comparative analysis revealed that SCA wheels can significantly sup-press edge chipping compared to white alumina wheels.Through a three-factor,three-level orthogonal experiment,the significance order of key process parameters affecting dimensional accuracy Δ and surface roughness Ra was determined as wheel feed speed＞wheel rotational speed＞grinding depth and wheel rotational speed＞wheel feed speed＞grinding depth.The optimized process parameter combination was wheel feed speed of 8 mm/min,wheel rotational speed of 2 500 r/min,grinding depth of 3 μm.Post-optimization results demonstrate 42.9％improvement in dimensional accuracy(Δ=1.2 μm),46.3％reduction in surface rough-ness(Ra=0.2 μm),elimination of grinding cracks and coating delamination(validated by microscopic inspection).Batch pro-duction verification confirmed that metallurgical structure was compliance with HB 6702 standard,product qualification rate was increased to 99.2％,providing a high-reliability grinding solution for aero-engine high-temperature component remanufacturing.