CN109822248B - Hot isostatic pressing-brazing composite forming method for thin-wall structure - Google Patents
Hot isostatic pressing-brazing composite forming method for thin-wall structure Download PDFInfo
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Abstract
The invention belongs to the field of hot isostatic pressing forming and welding, and discloses a hot isostatic pressing-brazing composite forming method for a thin-wall structure. The method comprises the following steps: (a) processing the thin-wall structure according to the shape of the part to form a lower cover plate and an upper cover plate with a micro-channel and an air exhaust port; (b) cleaning, grinding and polishing the surfaces to be connected of the upper cover plate and the lower cover plate; (c) filling a core material into the microchannels; (d) placing brazing filler metal between the surfaces to be connected of the upper cover plate and the lower cover plate, fixing and then packaging; (e) carrying out hot isostatic pressing on the upper cover plate and the lower cover plate after packaging; (f) and removing peripheral welding parts of the upper cover plate and the lower cover plate, and removing the core material to obtain the thin-walled component. By the invention, the connection between the thin-wall structural member and the core is realized at low temperature, the structure of the connection part is uniform, and the macrosegregation is less.
Description
Technical Field
The invention belongs to the field of hot isostatic pressing forming and welding, and particularly relates to a hot isostatic pressing-brazing composite forming method for a thin-wall structure.
Background
With the rapid development of aerospace technology, the requirements on materials at some key parts are more and more strict, and the materials are required to have good high-temperature strength and fatigue performance to ensure the safety and stability of aerospace equipment due to long-term work in a high-temperature environment.
The aerospace engine is the heart of the rocket, and the turbine, the casing and other key parts of the aerospace engine have complex structures and are difficult to process, so that the forming and manufacturing difficulty is high. With the continuous development of aerospace technology, the requirement on the thrust-weight ratio of the engine is continuously improved, and the requirement on materials is further improved. The engine is mainly composed of a turbine, a propellant delivery pump and a combustion chamber. The turbine material mainly comprises nickel-based alloy, cobalt-based alloy and titanium alloy. Compared with a turbine and a propellant delivery pump, the environment of the combustion chamber is more severe, and the indoor combustion temperature can reach more than 3000 ℃. Under such high temperature conditions, any material will soften or melt and only cooling of the combustion chamber and the gas outlet will ensure the necessary strength of the material. For liquid fuel engines, a porous flow passage structure material is often used as a mounting plate, and low-temperature liquid fuel is used to increase the cooling effect. In addition, the outer skin and the nozzle pipe of some aircraft also adopt the structure, and the key parts are generally of a multilayer structure, have complex flow passages inside and have larger sizes. When the parts are machined and formed, processes such as laser welding, vacuum brazing and the like are usually adopted, but for the parts, the precision requirements of machining and assembly by adopting the two types of welding are high, for example, vacuum brazing requires that the welding gap is about 0.1mm, the welding quality is difficult to ensure for complex and large-scale structures, the defects of welding beading, slag inclusion and the like are often generated, and the space of the complex structure also cannot meet the process requirements.
In order to solve the above existing problems, a process using hot isostatic pressing-BRAZING composite (HIP-BRAZING) forming has been proposed. Hot isostatic pressing was used for the earliest densification of castings, by which defects and porosity in the castings were effectively eliminated. The diffusion bonding by using the hot isostatic pressing is also another important application of the hot isostatic pressing, and under the action of high temperature and high pressure, surface atoms of two different materials such as metal-metal, metal-nonmetal and nonmetal-nonmetal move rapidly and are locally subjected to plastic deformation to form a new diffusion layer at an interface, so that reliable connection is realized. However, the temperature required for diffusion bonding directly using hot isostatic pressing is high, which affects the material of the matrix itself, and therefore, the application thereof is limited, and the processing method of the present invention is proposed in order to reduce the temperature required for diffusion bonding and obtain a good bonding interface.
Disclosure of Invention
In response to the above-identified deficiencies in the art or needs for improvement, the present invention provides a method for hot isostatic pressing-brazing composite forming of thin-walled structures, used for connecting the same or different materials to form a part with a multi-layer thin-wall structure with an internal complex flow passage and excellent welding position performance, wherein, the plate with the internal complex runner structure is subjected to diffusion connection by utilizing the conditions of high temperature and high pressure of hot isostatic pressing, and in order to reduce the influence of the hot isostatic pressing temperature on the structure and the performance of the plate with the thin-walled structure, filling brazing filler metal with lower melting point between the thin-wall structure and the core, performing hot isostatic pressing at lower temperature under certain pressure to fully diffuse atoms between the thin-wall structure and the core and the brazing filler metal, thereby realizing the connection between the thin-wall structures and solving the technical problems that the thin-wall structures are difficult to connect and the hot isostatic pressing temperature is high during the connection.
To achieve the above object, according to the present invention, there is provided a hot isostatic pressing-brazing composite forming method for thin-walled structures, comprising the steps of:
(a) processing the thin-wall structure according to the shape of the part, and processing a lower cover plate and an upper cover plate with a micro-channel and an air exhaust port, wherein the thin-wall structure is made of a titanium alloy or a nickel-based high-temperature alloy material;
(b) cleaning, grinding and polishing the surfaces to be connected of the upper cover plate and the lower cover plate;
(c) preparing a core material into a colloid according to a certain proportion, and filling the colloid into the micro-channels of the upper cover plate, wherein the core material is a water-soluble calcium oxide-based composite material;
(d) placing brazing filler metal between to-be-connected surfaces of an upper cover plate and a lower cover plate filled with the core material, fixing the upper cover plate and the lower cover plate by using positioning pins, and then welding along a gap between the upper cover plate and the lower cover plate; welding an exhaust pipe to an exhaust opening of the upper cover plate, firstly exhausting at room temperature, heating the upper cover plate and the lower cover plate when the vacuum degree reaches below 0.1Pa, wherein the heating temperature is 300-400 ℃, and the vacuum degree reaches 10-3Pa～10-4Sealing and welding the exhaust pipe by Pa;
(e) performing hot isostatic pressing on the upper cover plate and the lower cover plate after packaging, wherein when the material of the thin-wall structure is nickel-based high-temperature alloy, the heat preservation temperature of the hot isostatic pressing is 950-1100 ℃, and the pressure is 10-40MPa, and when the material of the thin-wall structure is titanium alloy, the heat preservation temperature of the hot isostatic pressing is 800-950 ℃, and the pressure is 10-40 MPa;
(f) removing peripheral welding parts of the upper cover plate and the lower cover plate by using a wire cutting method, and cleaning the upper cover plate and the lower cover plate by using water or dilute acid to remove core materials, thereby obtaining the thin-walled member.
Further preferably, when the material of the thin-wall structure is a titanium alloy, the material of the brazing filler metal is Al-Mn, Ti-Zr-Cu-Ni or Ti-Zr-Cu, and the thickness is 50 μm to 100 μm; when the material of the thin-wall structure is nickel-based superalloy, the brazing filler metal is Ti-Cu-Ni, Ti-Zr-Be or nickel foil, and the thickness of the brazing filler metal is 50-100 mu m.
In general, compared with the prior art, the above technical solution contemplated by the present invention can achieve the following beneficial effects:
1. according to the invention, the thin-wall structure and the core are connected in a hot isostatic pressing manner, in the process, under the high-temperature and high-pressure coupling action, the thin-wall structure and the core are respectively in diffusion connection with atoms of brazing filler metal, and metallurgical bonding is generated, so that the obtained welding head has uniform structure and good connection performance, and meanwhile, under higher temperature and pressure, the defects that the quality of the connecting head is influenced by the generation of air holes and the like at the connecting part are avoided, and the quality of the finally obtained part product is ensured;
2. the invention adopts a metal material system which is easy to process or an oxide system with higher melting point as the core, so that the core can be conveniently removed in the later period;
3. according to the invention, different hot isostatic pressing temperatures are selected according to different materials of the selected thin-wall structure, but the temperature of the whole hot isostatic pressing is lower, so that the influence on the thin-wall structure material and the structure of the core is small, and compared with the traditional welding process, the structure obtained by the forming method is more uniform and has less macro segregation.
Drawings
FIG. 1 is a schematic structural diagram of a thin-walled structure constructed in accordance with a preferred embodiment of the present invention;
FIG. 2 is a schematic illustration of a stack-up of thin-walled structures, brazing filler metal, and cores constructed in accordance with a preferred embodiment of the present invention;
fig. 3 is a diagram of a hot isostatic pressing process constructed in accordance with a preferred embodiment of the present invention.
The same reference numbers will be used throughout the drawings to refer to the same or like elements or structures, wherein:
1-positioning pin, 2-upper cover plate, 3-microchannel, 4-air exhaust port, 5-lower cover plate and 6-brazing filler metal.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
The invention discloses a hot isostatic pressing and brazing composite forming process with a multilayer thin-wall structure, which is characterized by comprising the following steps of:
1. according to the shape of the part, the thin plate material adopted in this embodiment is, as shown in fig. 1, a base material of the thin plate material, which is a titanium alloy or a nickel-based superalloy material, such as: TC4, Inconel718, FGH97, and the like.
2. And designing a corresponding core by using three-dimensional modeling software according to the thin-wall structure to be formed.
For parts with complex structures, reasonable structure optimization and core design are very important, the structure of parts which are easy to generate defects is optimally designed to improve the quality of part products, and simulation optimization is often performed by adopting software such as Pro/E, SolidWorks and the like, so that the core design period is greatly shortened.
Selection of core material system:
for a titanium alloy base material, the temperature for diffusion bonding is 650-850 ℃, and in order to facilitate subsequent core removal, a water-soluble calcium oxide-based composite material can be selected, wherein the specific components of the composite material are calcium oxide (CaO), sodium chloride (NaCl), polyvinylpyrrolidone (PVP) and glycerol (C3H 8O 3); the CaO has a melting point of 2580 ℃, has certain strength at the hot isostatic pressing diffusion bonding temperature, can provide a certain shape control effect for a workpiece, has a NaCl melting point of 801 ℃, can be used as a bonding agent for CaO at a high temperature at the diffusion bonding temperature, is soluble in water, is beneficial to subsequent removal, and has the effect of PVP and glycerol that mixed powder of NaCl and CaO can form viscous slurry at normal temperature, so that the mixed powder can be conveniently filled in a cavity; PVP and C3H8O3 are decomposed under the action of high temperature in the air exhaust process and are discharged out of the workpiece;
for a nickel-based high-temperature alloy base material system, the temperature for diffusion bonding is 900-1100 ℃, a water-soluble calcium oxide-based composite material can still be selected, and NaCl is completely melted in the temperature range, so that diffusion bonding between the base material and the brazing filler metal is not facilitated. At this time, the concrete components of the core material are calcium oxide (CaO), iron powder and graphite powder, polyvinylpyrrolidone (PVP) and glycerol (C3H 8O 3).
3. A suitable brazing filler metal is selected. The invention adopts lamellar solid brazing filler metal, and the thickness is selected to be 50-100 mu m.
In diffusion bonding, the hot isostatic pressing temperature can be reduced by using the brazing filler metal with the low melting point, so that the influence of the hot isostatic pressing temperature on the structure and the performance of a matrix material can be reduced under the condition of ensuring the quality of a connecting head. Meanwhile, in the aspect of selecting a brazing filler metal material system, a material with elements similar to those of a base material is selected so as to reduce the influence of element content change on the uniformity and stability of the structure at the joint.
Selection of a brazing filler metal material system:
for titanium alloy base materials, the temperature for diffusion bonding is 650-850 ℃, and aluminum-based or titanium-based solders such as Al-Mn, Ti-Zr-Cu-Ni, and Ti-Zr-Cu can be used.
For a nickel-based high-temperature alloy matrix material system, the temperature for diffusion bonding is 900-1100 ℃, and a titanium-based brazing filler metal or a brazing filler metal with high nickel content, such as Ti-Cu-Ni, Ti-Zr-Be or a nickel foil, can Be used.
4. The thin-walled structure, brazing filler metal and core are assembled as shown in fig. 2.
Because the diffusion bonding has high requirements on the surface quality of the parts, the surfaces of the parts are polished before assembly to remove surface oxide layers and impurities, and the surfaces are cleaned by absolute ethyl alcohol or acetone to improve the diffusion bonding quality.
5. And welding the upper cover plate and the lower cover plate by using TIG welding, performing air extraction treatment on the workpieces, simultaneously performing heating treatment to remove residual gas between the workpieces, and performing sealing welding treatment after the vacuum degree in the sheath reaches a certain degree.
Specifically, after brazing filler metal and core materials are assembled on an upper cover plate and a lower cover plate through positioning pins, the upper cover plate and the lower cover plate are fixed and compacted, and the upper cover plate and the lower cover plate are welded along gaps of the upper cover plate and the lower cover plate; welding an exhaust tube to an exhaust opening of the workpiece so as to facilitate the exhaust of the workpiece; and (3) performing air extraction treatment on the workpiece, firstly performing air extraction at room temperature, heating the workpiece when the vacuum degree reaches below 0.1Pa, wherein the heating temperature is 300-400 ℃, so as to remove residual gas among powder particles as far as possible, and sealing and welding the air extraction pipe when the vacuum degree reaches a certain degree (the vacuum degree is 10 < -3 > to 10 < -4 > Pa).
6. And carrying out hot isostatic pressing treatment on the packaged workpiece by adopting a hot isostatic pressing treatment process for simultaneously raising temperature and boosting pressure. As shown in fig. 3, the low melting point brazing material provides an advantage for the bonding between the substrates during the hiping process, where the atoms diffuse and bond tightly.
The temperature used for diffusion bonding by hot isostatic pressing is determined according to a material system of a matrix, and if the matrix alloy is a nickel-based high-temperature alloy, the heat preservation temperature is 950-1100 ℃, and the pressure is 10-40 MPa; if the base alloy is titanium alloy, the heat preservation temperature is 800-950 ℃, and the pressure is 10-40 MPa.
7. The edge part of the workpiece is cut off by adopting a machining method, and the core is removed by adopting water or dilute acid for vibration cleaning.
The present invention will be further illustrated with reference to specific examples.
Example 1
The TC4 alloy material is adopted as the base material in the embodiment, and the titanium alloy has excellent performance and is widely applied to the aerospace field and the civil field. The temperature of the phase transformation point of TC4 is 950-990 ℃, the brazing filler metal system is Ti-Zr-Cu-N, the melting temperature is 770-820 ℃, the hot isostatic pressing diffusion bonding temperature is 800 ℃, and the pressure is 20 Mpa. And forming the flat thin-wall part with the micro flow channels by using the method according to the parameters. The method comprises the following specific steps:
1. the corresponding hot isostatic pressing process scheme is designed according to the structure of the part to be formed, and the material matrix can be used as a sheath for transmitting pressure and temperature due to the adoption of hot isostatic pressing for diffusion connection. Processing the plates needing diffusion connection according to the structure of the part;
2. cleaning, grinding and polishing the diffusion connection surface;
3. calcium oxide (CaO), sodium chloride (NaCl), polyvinylpyrrolidone (PVP), glycerol (C)3H8O3) Preparing a colloid according to a certain proportion, and filling the colloid into the cavity of the material processed in the step 1;
4. using Ti-Zr-Cu system solder, uniformly spreading the solder between two surfaces needing diffusion connection, and welding;
5. heating and vacuumizing the assembled parts until the vacuum degree reaches 10-3Packaging when Pa is needed;
6. performing hot isostatic pressing, wherein the heat preservation temperature is 800-950 ℃, the pressure is 10-40MPa, and the heat preservation time is 1 h;
7. and removing the welding part on the periphery of the workpiece by using a wire cutting method, and cleaning the workpiece by using water or dilute hydrochloric acid to remove the core material.
Example 2
With the development of aerospace technology, the thrust-weight ratio of an aero-engine is larger and larger, and the inlet temperature of the aero-engine is increased. Nickel-based alloys are excellent as superalloys, modern dayOver 50% of the materials of the gas turbine engine are made of high-temperature alloy, wherein the nickel-based material accounts for about 40%. The nickel-based alloy has excellent comprehensive performance under medium and high temperature conditions as a material of a hot end part of a common engine. The combustion chamber is used as a power source of an engine, the working environment is the most harsh, the environmental temperature is high, effective cooling is particularly important, and the cooling effect can be improved by adopting a thin-wall material with a pipeline structure as the inner wall of the combustion chamber. In the embodiment, the Inconel718 high-temperature nickel-based alloy is used, the hot isostatic pressing diffusion bonding temperature is 1000 ℃ due to the high melting point of the nickel-based high-temperature alloy, the pure nickel foil with the thickness of 25 mu m is adopted as a brazing filler metal system, and calcium oxide (CaO), iron powder, graphite powder, polyvinylpyrrolidone (PVP) and glycerol (C) are adopted as core material systems3H8O3) The hot isostatic pressing heat preservation and pressure maintaining time is 1h, and the forming is carried out by utilizing the invention according to the parameters, and the specific steps are as follows:
1. carrying out corresponding processing treatment on the nickel-based high-temperature alloy plate according to a structure required to be processed and formed;
2. cleaning, grinding and polishing the diffusion connection surface;
3. preparing calcium oxide (CaO), iron powder, graphite powder, polyvinylpyrrolidone (PVP), glycerol (C3H 8O 3) into a colloid according to a certain proportion, and filling the colloid into the cavity of the material processed in the step (1);
4. spreading the pure nickel foil between two surfaces needing diffusion connection, and welding;
5. heating and vacuumizing the assembled parts until the vacuum degree reaches 10-3Packaging when Pa is needed;
6. performing hot isostatic pressing, wherein the heat preservation temperature is 950-1100 ℃, the pressure is 10-40MPa, and the heat preservation time is 1 h;
7. and removing the welding part on the periphery of the workpiece by using a linear cutting method, and cleaning the workpiece by using dilute sulfuric acid to remove the core material.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (2)
1. A method of hot isostatic pressing-brazing composite forming for thin-walled structures, the method comprising the steps of:
(a) processing the thin-wall structure according to the shape of the part, and processing a lower cover plate and an upper cover plate with a micro-channel and an air exhaust port, wherein the thin-wall structure is made of a titanium alloy or a nickel-based high-temperature alloy material;
(b) cleaning, grinding and polishing the surfaces to be connected of the upper cover plate and the lower cover plate;
(c) preparing a core material into a colloid according to a certain proportion, and filling the colloid into the micro-channels of the upper cover plate, wherein the core material is a water-soluble calcium oxide-based composite material;
(d) placing brazing filler metal between to-be-connected surfaces of an upper cover plate and a lower cover plate filled with the core material, fixing the upper cover plate and the lower cover plate by using positioning pins, and then welding along a gap between the upper cover plate and the lower cover plate; welding an exhaust pipe to an exhaust opening of the upper cover plate, firstly exhausting at room temperature, heating the upper cover plate and the lower cover plate when the vacuum degree reaches below 0.1Pa, wherein the heating temperature is 300-400 ℃, and the vacuum degree reaches 10-3Pa～10-4Sealing and welding the exhaust pipe by Pa;
(e) performing hot isostatic pressing on the upper cover plate and the lower cover plate after packaging, wherein when the material of the thin-wall structure is nickel-based high-temperature alloy, the heat preservation temperature of the hot isostatic pressing is 950-1100 ℃, and the pressure is 10-40MPa, and when the material of the thin-wall structure is titanium alloy, the heat preservation temperature of the hot isostatic pressing is 800-950 ℃, and the pressure is 10-40 MPa;
(f) removing peripheral welding parts of the upper cover plate and the lower cover plate by using a wire cutting method, and cleaning the upper cover plate and the lower cover plate by using water or dilute acid to remove core materials, thereby obtaining the thin-walled member.
2. The hot isostatic pressing-brazing composite forming method for thin-walled structures according to claim 1, wherein when the material of the thin-walled structure is a titanium alloy, the brazing filler metal is made of Al-Mn, Ti-Zr-Cu-Ni or Ti-Zr-Cu and has a thickness of 50 μm to 100 μm; when the material of the thin-wall structure is nickel-based superalloy, the brazing filler metal is Ti-Cu-Ni, Ti-Zr-Be or nickel foil, and the thickness of the brazing filler metal is 50-100 mu m.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201910151826.0A CN109822248B (en) | 2019-02-28 | 2019-02-28 | Hot isostatic pressing-brazing composite forming method for thin-wall structure |
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| CN113043648B (en) * | 2021-03-08 | 2024-01-26 | 洛阳航辉新材料有限公司 | Hot isostatic pressing method of flat plate castings |
| CN114734106B (en) * | 2022-03-30 | 2024-06-04 | 西安航天发动机有限公司 | Brazing method of copper steel brazing piece with small holes and throat on inner wall |
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