DOI：10.3969/j.issn.1672-3872.2026.03.032
基金项目：宁德职业技术学院科技计划项目“电机压铸模具失效修复再制造技术研究”（WT2016ZR01）
作 者：魏 炜 ，何 彬 ，王彦军（宁德职业技术学院，福建 宁德 355000）
摘 要：作为精密零部件制造的核心装备，电机压铸模具在高能耗制造过程与服役中面临热疲劳裂纹、冲蚀磨损等复合失效问题，导致资源浪费与寿命缩短。文章聚焦这一技术瓶颈，突破传统修复技术的局限性，构建失效机理导向的再制造工艺体系，实现模具性能恢复与寿命延长。通过多模态无损检测技术量化损伤特征，结合激光熔覆制备梯度功能涂层修复裂纹，采用超音速火焰喷涂碳化铬涂层提升抗冲蚀性，并设计微锻造与矫形工装矫正塑性变形。研究结果表明：优化后的激光熔覆工艺使修复层硬度提升至1 350 HV，裂纹密度降至0；多模态检测分辨率达10 μm，裂纹检出率提升至99.9%；超音速喷涂涂层冲蚀率降至0.2 mg/cm2 ；塑性变形矫正精度达±5 μm，模具寿命延长3倍以上。研究证实，融合数字孪生与智能调控的再制造工艺可恢复模具原始性能并实现材料利用率85%以上，制造成本降低60%~70%。该成果可为高价值模具的绿色再制造提供技术范式，推动制造业低碳转型与循环经济发展，具有显著的经济效益与环保价值。
关键词：电机压铸模具；再制造工艺；激光熔覆；超音速火焰喷涂；数字孪生
Optimization and Application Analysis of Remanufacturing Process for Motor Die-Casting Molds
Author: Wei Wei, He Bin, Wang Yanjun (Ningde Vocational and Technical College, Ningde 355000, China)
Abstract: As a core equipment for manufacturing precision components, die-casting molds for motors face complex failure issues such as thermal fatigue cracks and erosion wear during their high-energy consumption manufacturing process and service life, leading to resource waste and reduced lifespan. This article focuses on these technical bottlenecks, breaks through the limitations of traditional repair technologies, and establishes a failure-mechanism-guided remanufacturing process system to restore mold performance and extend service life. By utilizing multi-modal non-destructive testing (NDT) technology to quantify damage characteristics and combining laser cladding to create gradient functional coatings for crack repair, the study employs supersonic flame spraying of chromium carbide coatings to enhance erosion resistance. Additionally, micro-forging and correction tools are designed to address plastic deformation. The research results show that the optimized laser cladding process increases the hardness of the repair layer to 1 350 HV, with crack density reduced to zero. The resolution of multi-modal testing reaches 10 μm, with crack detection rate increased to 99.9%. The erosion rate of the supersonic flame-sprayed coating is reduced to 0.2 mg/cm2 , and the plastic deformation correction accuracy is ±5 μm, resulting in a mold life extension of more than three times. The study confirms that the remanufacturing process, integrating digital twins and intelligent control, restores the mold’s original performance and achieves a material utilization rate of over 85%, with manufacturing costs reduced by 60% to 70%. This achievement provides a technological paradigm for green remanufacturing of high-value molds, promoting the low-carbon transformation and circular economy development of the manufacturing industry, with significant economic and environmental benefits.
Keywords: motor die-casting molds; remanufacturing process; laser cladding; supersonic flame spraying; digital twin
引文信息：[1]魏炜，何彬，王彦军.电机压铸模具再制造工艺优化与应用分析[J].南方农机，2026，57(3)：122-125.
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