CN112025212A - Method for processing nondestructive flaw detection surface of powder high-temperature alloy part - Google Patents

Method for processing nondestructive flaw detection surface of powder high-temperature alloy part Download PDF

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CN112025212A
CN112025212A CN202010752839.6A CN202010752839A CN112025212A CN 112025212 A CN112025212 A CN 112025212A CN 202010752839 A CN202010752839 A CN 202010752839A CN 112025212 A CN112025212 A CN 112025212A
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powder
processing
temperature alloy
superalloy
nondestructive inspection
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CN112025212B (en
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郑作赟
韩志宇
瞿宗宏
黄椿森
谭启明
张妍莉
宋嘉明
王庆相
赖运金
梁书锦
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Xi'an Ouzhong Materials Technology Co ltd
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Xi'an Sino Euro Materials Technologies Co ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency

Abstract

The invention discloses a method for processing the nondestructive inspection surface of a powder high-temperature alloy part, which is implemented by the following steps: step 1, preparing high-temperature alloy powder with low oxygen content and high purity by adopting a plasma rotary electrode atomization method, performing sheath packaging treatment on the prepared high-temperature alloy powder, and preparing a powder high-temperature alloy workpiece by a hot isostatic pressing hot consolidation process; step 2, carrying out solution heat treatment on the powder high-temperature alloy part prepared in the step 1; step 3, carrying out rough turning and fine turning processing on the powder superalloy processed in the step 2; and 4, carrying out surface mirror finishing treatment on the powder superalloy workpiece treated in the step 3.

Description

Method for processing nondestructive flaw detection surface of powder high-temperature alloy part
Technical Field
The invention belongs to the technical field of powder metallurgy, and particularly relates to a method for processing a nondestructive inspection surface of a powder high-temperature alloy workpiece.
Background
Superalloy turbine disks are one of the important hot end components of aircraft engines. The working conditions of the turbine disk are very harsh, the turbine disk bears the superposition effect of the cyclic mechanical stress and the thermal stress caused by temperature difference during flying, and the fatigue fracture of the turbine disk is easy to generate. On the other hand, the high temperature alloy belongs to gamma' phase precipitation strengthening type alloy, because the strengthening alloy elements are increased, the hot working performance is deteriorated due to serious segregation, the low cycle fatigue performance is reduced, the crack propagation capacity is reduced, and the feeding ratio is more than 19: 1. The powder superalloy turbine disc is prepared by a powder metallurgy process, has uniform structure, fine crystal grains, no obvious segregation, high alloying degree, high yield strength resistance and good fatigue resistance, can greatly improve the utilization rate of metal materials, and is a preferred material for parts such as a high-thrust-ratio engine turbine disc and the like.
The powder superalloy turbine disc has three common defects, namely original particle boundaries, thermally induced holes and non-metallic inclusions, wherein the non-metallic inclusions cannot be completely eliminated through the existing powder manufacturing and processing technology, so that the powder superalloy turbine disc needs to be subjected to nondestructive inspection by adopting an ultrasonic water immersion nondestructive inspection technology. In the ultrasonic water immersion nondestructive inspection technology, the surface quality of a workpiece has a decisive influence on the inspection process, when the ultrasonic detection frequency is fixed, the height of multiple echoes is only related to the surface roughness of a test piece, the attenuation of sound energy is correspondingly intensified by the increase of the roughness, and finally, the nondestructive detection cannot be carried out, so that the control of the surface roughness (< Ra0.8) of the powder high-temperature alloy is a necessary condition for carrying out nondestructive inspection. But with the continuous addition of high alloying elements in the powder superalloy, the difficulty of the mechanical processing process is increased. The cutting processability of the powder high-temperature alloy workpiece is poor, the workpiece can be processed at low speed generally, a common cutter is fast in abrasion and serious in passivation, the surface roughness (more than Ra1.6) of the workpiece after the workpiece is processed is difficult to ensure, and repeated mechanical reworking caused by the defect surface not reaching the standard before nondestructive inspection is easily caused; or the surface roughness process is improved through the polishing and grinding process, which causes huge waste in the aspects of production cycle and production cost.
FGH4097 is a precipitation strengthening type nickel-base superalloy, mainly takes a gamma 'phase as a precipitation strengthening phase, and the quantity, size, form and distribution of the gamma' phase have great influence on the structure and performance of FGH 4097. After FGH4097 is formed by hot isostatic pressing and hot consolidation, the gamma 'phase in the alloy can be dissolved by' long-time 'solution treatment, the precipitation content of the gamma' phase is reduced, the hardness of FGH4097 is reduced, and better machining performance is obtained. The solid solution time of GH4097 is generally 6-8 h, and the solid solution time in the invention is 9-12 h, so that the precipitation content of gamma' phase can be effectively reduced, and the hardness of FGH4097 is reduced by 24%. The higher and higher alloying degree causes the problems of poor thermal conductivity, serious work hardening phenomenon and the like of the powder superalloy in the machining process, and has severe requirements on the cutter material used in the machining process. Therefore, when the cutter is selected, the cutter has the advantages of high strength, high red hardness, good wear resistance, good toughness, high thermal conductivity and strong anti-bonding capability, the sharpness of the cutting edge is kept, and the chip removal is smooth. The mirror surface processing technology utilizes the cold plasticity characteristic of metal materials at normal temperature to carry out high-frequency and high-focusing energy impact on the surface of a workpiece for tens of thousands of times per second, so that processing traces such as turning, grinding, milling and the like are extended, and the mirror surface effect is finally achieved. The mirror surface processing is a novel processing technology, does not remove materials, does not influence the dimensional accuracy and form and position tolerance of workpieces, can greatly improve the surface roughness (can reach less than Ra0.4) of workpieces, effectively reduces the production period and the production cost, and achieves the purposes of cost reduction and efficiency improvement.
Disclosure of Invention
The invention aims to provide a method for processing the nondestructive inspection surface of a powder high-temperature alloy part, which aims to solve the problems that the surface roughness of the machined part cannot meet the nondestructive inspection requirement and the production period and the production cost are easily increased due to higher hardness and poorer machining performance of the powder high-temperature alloy part in the nondestructive inspection process of the powder high-temperature alloy part at present.
In order to achieve the purpose, the invention adopts the technical scheme that: a processing method for the nondestructive inspection surface of a powder superalloy workpiece is implemented according to the following steps:
step 1, preparing high-temperature alloy powder with low oxygen content and high purity by adopting a plasma rotary electrode atomization method, performing sheath packaging treatment on the prepared high-temperature alloy powder, and preparing a powder high-temperature alloy workpiece by a hot isostatic pressing hot consolidation process;
step 2, carrying out solution heat treatment on the powder high-temperature alloy part prepared in the step 1;
step 3, carrying out rough turning and fine turning processing on the powder superalloy processed in the step 2;
and 4, carrying out surface mirror finishing treatment on the powder superalloy workpiece treated in the step 3.
The technical scheme of the invention also has the following characteristics:
in the step 1, the high-temperature alloy powder is FGH4097 alloy powder with the grain diameter of 50 um-150 um.
In the step 1, the sheath is made of carbon steel or stainless steel, and the packaging vacuum degree is less than or equal to 4 x 10-3Pa, the leakage rate is less than or equal to 0.03Pa/min, the degassing temperature is 400-450 ℃, and sealing welding treatment is carried out by adopting electron beams in a vacuum chamber.
In the step 1, the hot isostatic pressing hot consolidation process specifically comprises the following steps: the heat preservation pressure is 120Mpa +/-10 Mpa, the heat preservation temperature is 1180 +/-10 ℃, and the heat preservation time is 2-3 h.
In the step 2, the solution heat treatment specifically includes: charging at 800 +/-10 ℃, heating to 1180 +/-10 ℃ after 4-6 hours, keeping the temperature for 9-12 hours, discharging and air cooling.
In the step 3, in the processes of numerical control rough turning and finish turning, the used cutter is a Cubic Boron Nitride (CBN) superhard cutter, and the surface roughness of the powder high-temperature alloy workpiece after finish turning is Ra1.6.
In the step 4, the surface mirror finishing specifically includes: the cutter adopts the ultrahigh vibration frequency of 23000 +/-200/s, the processing linear speed of 50 +/-5 mm/min, the feed amount of 0.1 +/-0.02 mm/r, and the surface roughness of a finished piece after the mirror surface processing is Ra0.4.
The invention has the beneficial effects that: compared with traditional mechanical processing means such as polishing, grinding and the like, the invention provides a 'long-time' solution treatment, rough/finish turning and surface mirror surface processing 'powder high-temperature alloy workpiece nondestructive flaw detection surface processing method, the' long-time 'solution treatment is carried out successively to control the precipitation behavior of a precipitation strengthening phase gamma' phase of the alloy, so that the alloy hardness is reduced by 24% to obtain better cold processing performance; and then the surface roughness of the workpiece meets the requirements of nondestructive inspection by the rough/fine turning machining of a superhard Cubic Boron Nitride (CBN) cutter and the mirror surface machining of an ultrahigh frequency surface. The surface roughness of the powder high-temperature alloy workpiece treated by the method can reach Ra0.4, so that the problems of production cycle and production cost waste caused by unqualified surface roughness in the nondestructive testing process are favorably controlled: the production period is reduced by 60 percent, and the production cost is reduced by 50 percent. The method can also be used for solving the problem that the surface roughness of the nondestructive inspection of other metal materials difficult to process does not reach the standard, and has wide industrial application value.
Detailed Description
The technical solution of the present invention will be further described in detail with reference to the following specific examples.
The invention relates to a method for processing the nondestructive inspection surface of a powder high-temperature alloy workpiece, which is implemented by the following steps:
step 1, preparing high-temperature alloy powder with low oxygen content and high purity by adopting a plasma rotary electrode atomization method, performing sheath packaging treatment on the prepared high-temperature alloy powder, and preparing a powder high-temperature alloy workpiece by a hot isostatic pressing hot consolidation process; in step 1: the high-temperature alloy powder is FGH4097 alloy powder with the grain diameter of 50 um-150 um; the sheath is made of carbon steel or stainless steel, and the packaging vacuum degree is less than or equal to 4 x 10-3Pa, the leakage rate is less than or equal to 0.03Pa/min, the degassing temperature is 400-450 ℃, and sealing welding treatment is carried out by adopting electron beams in a vacuum chamber; the hot isostatic pressing hot consolidation process comprises the following specific steps: the heat preservation pressure is 120Mpa +/-10 Mpa, and the heat preservation is carried outThe temperature is 1180 +/-10 ℃, and the heat preservation time is 2-3 h;
step 2, carrying out solution heat treatment on the powder high-temperature alloy part prepared in the step 1; the solution heat treatment specifically comprises: charging at 800 +/-10 ℃, heating to 1180 +/-10 ℃ after 4-6 hours, keeping the temperature for 9-12 hours, discharging from the furnace and air cooling;
step 3, carrying out rough turning and fine turning processing on the powder superalloy processed in the step 2; in the numerical control rough turning and finish turning machining processes, the used cutter is a Cubic Boron Nitride (CBN) superhard cutter, and the surface roughness of a powder high-temperature alloy workpiece after finish turning machining is Ra1.6
Step 4, carrying out surface mirror processing on the powder superalloy workpiece treated in the step 3; the surface mirror finishing specifically comprises the following steps: the cutter adopts the ultrahigh vibration frequency of 23000 +/-200/s, the processing linear speed of 50 +/-5 mm/min, the feed amount of 0.1 +/-0.02 mm/r, and the surface roughness of a finished piece after the mirror surface processing is Ra0.4.
Compared with traditional mechanical processing means such as polishing, grinding and the like, the invention provides a 'long-time' solution treatment, rough/finish turning and surface mirror surface processing 'powder high-temperature alloy workpiece nondestructive flaw detection surface processing method, the' long-time 'solution treatment is carried out successively to control the precipitation behavior of a precipitation strengthening phase gamma' phase of the alloy, so that the alloy hardness is reduced by 24% to obtain better cold processing performance; and then the surface roughness of the workpiece meets the requirements of nondestructive inspection by the rough/fine turning machining of a superhard Cubic Boron Nitride (CBN) cutter and the mirror surface machining of an ultrahigh frequency surface. The surface roughness of the powder high-temperature alloy workpiece treated by the method can reach Ra0.4, so that the problems of production cycle and production cost waste caused by unqualified surface roughness in the nondestructive testing process are favorably controlled: the production period is reduced by 60 percent, and the production cost is reduced by 50 percent. The method can also be used for solving the problem that the surface roughness of the nondestructive inspection of other metal materials difficult to process does not reach the standard, and has wide industrial application value.
Example 1
The invention relates to a method for processing the nondestructive inspection surface of a powder high-temperature alloy workpiece, which is implemented by the following steps:
step 1Preparing high-temperature alloy powder with low oxygen content and high purity by adopting a plasma rotary electrode atomization method, performing sheath packaging treatment on the prepared high-temperature alloy powder, and preparing a powder high-temperature alloy part by a hot isostatic pressing hot consolidation process; in step 1: the high-temperature alloy powder is FGH4097 alloy powder with the grain diameter of 50 um; the sheath is made of carbon steel or stainless steel, and the packaging vacuum degree is less than or equal to 4 x 10-3Pa, the leakage rate is less than or equal to 0.03Pa/min, the degassing temperature is 400 ℃, and sealing welding treatment is carried out by adopting an electron beam in a vacuum chamber; the hot isostatic pressing hot consolidation process comprises the following specific steps: the heat preservation pressure is 110Mpa, the heat preservation temperature is 1170 ℃, and the heat preservation time is 2 hours;
step 2, carrying out solution heat treatment on the powder high-temperature alloy part prepared in the step 1; the solution heat treatment specifically comprises: charging at 790 ℃, heating to 1170 ℃ after 4h, keeping the temperature for 9h, discharging and air cooling;
step 3, carrying out rough turning and fine turning processing on the powder superalloy processed in the step 2; in the numerical control rough turning and finish turning machining processes, the used cutter is a Cubic Boron Nitride (CBN) superhard cutter, and the surface roughness of a powder high-temperature alloy workpiece after finish turning machining is Ra1.6
Step 4, carrying out surface mirror processing on the powder superalloy workpiece treated in the step 3; the surface mirror finishing specifically comprises the following steps: the cutter adopts the ultrahigh vibration frequency of 22800/s, the processing linear speed of 45mm/min, the feed amount of 0.08mm/r, and the surface roughness of a finished piece after the mirror surface processing is Ra0.4.
Example 2
The invention relates to a method for processing the nondestructive inspection surface of a powder high-temperature alloy workpiece, which is implemented by the following steps:
step 1, preparing high-temperature alloy powder with low oxygen content and high purity by adopting a plasma rotary electrode atomization method, performing sheath packaging treatment on the prepared high-temperature alloy powder, and preparing a powder high-temperature alloy workpiece by a hot isostatic pressing hot consolidation process; in step 1: the high-temperature alloy powder is FGH4097 alloy powder with the grain diameter of 100 um; the sheath is made of carbon steel or stainless steel, and the packaging vacuum degree is less than or equal to 4 x 10-3Pa, leakage rate less than or equal to 0.03Pa/min, degassing temperature 425 ℃, and sealing and welding positions by adopting electron beams in a vacuum chamberC, processing; the hot isostatic pressing hot consolidation process comprises the following specific steps: the heat preservation pressure is 120Mpa, the heat preservation temperature is 1180 ℃, and the heat preservation time is 2.5 hours;
step 2, carrying out solution heat treatment on the powder high-temperature alloy part prepared in the step 1; the solution heat treatment specifically comprises: charging at 800 ℃, heating to 1180 ℃ after 5 hours, keeping the temperature for 10.5 hours, discharging from the furnace and air cooling;
step 3, carrying out rough turning and fine turning processing on the powder superalloy processed in the step 2; in the numerical control rough turning and finish turning machining processes, the used cutter is a Cubic Boron Nitride (CBN) superhard cutter, and the surface roughness of a powder high-temperature alloy workpiece after finish turning machining is Ra1.6
Step 4, carrying out surface mirror processing on the powder superalloy workpiece treated in the step 3; the surface mirror finishing specifically comprises the following steps: the cutter adopts the ultrahigh vibration frequency of 23000/s, the processing linear speed is 50mm/min, the feed amount is 0.1mm/r, and the surface roughness of a finished piece is Ra0.4 after the mirror surface processing is finished.
Example 3
The invention relates to a method for processing the nondestructive inspection surface of a powder high-temperature alloy workpiece, which is implemented by the following steps:
step 1, preparing high-temperature alloy powder with low oxygen content and high purity by adopting a plasma rotary electrode atomization method, performing sheath packaging treatment on the prepared high-temperature alloy powder, and preparing a powder high-temperature alloy workpiece by a hot isostatic pressing hot consolidation process; in step 1: the high-temperature alloy powder is FGH4097 alloy powder with the grain diameter of 150 um; the sheath is made of carbon steel or stainless steel, and the packaging vacuum degree is less than or equal to 4 x 10-3Pa, the leakage rate is less than or equal to 0.03Pa/min, the degassing temperature is 450 ℃, and sealing welding treatment is carried out by adopting an electron beam in a vacuum chamber; the hot isostatic pressing hot consolidation process comprises the following specific steps: keeping the temperature at the pressure of 130Mpa and the temperature of 1190 ℃ for 3 h;
step 2, carrying out solution heat treatment on the powder high-temperature alloy part prepared in the step 1; the solution heat treatment specifically comprises: charging at 810 ℃, heating to 1190 ℃ after 6 hours, keeping the temperature for 12 hours, discharging from the furnace and air cooling;
step 3, carrying out rough turning and fine turning processing on the powder superalloy processed in the step 2; in the numerical control rough turning and finish turning machining processes, the used cutter is a Cubic Boron Nitride (CBN) superhard cutter, and the surface roughness of a powder high-temperature alloy workpiece after finish turning machining is Ra1.6
Step 4, carrying out surface mirror processing on the powder superalloy workpiece treated in the step 3; the surface mirror finishing specifically comprises the following steps: the cutter adopts ultrahigh vibration frequency 23200/s, processing linear speed 55mm/min, feed amount 0.12mm/r, and the surface roughness of the finished piece after mirror finishing is Ra0.4.

Claims (7)

1. The method for processing the nondestructive inspection surface of the powder superalloy workpiece is characterized by comprising the following steps:
step 1, preparing high-temperature alloy powder with low oxygen content and high purity by adopting a plasma rotary electrode atomization method, performing sheath packaging treatment on the prepared high-temperature alloy powder, and preparing a powder high-temperature alloy workpiece by a hot isostatic pressing hot consolidation process;
step 2, carrying out solution heat treatment on the powder high-temperature alloy part prepared in the step 1;
step 3, carrying out rough turning and fine turning processing on the powder superalloy processed in the step 2;
and 4, carrying out surface mirror finishing treatment on the powder superalloy workpiece treated in the step 3.
2. The method for processing the nondestructive inspection surface of the powder superalloy part according to claim 1, wherein in the step 1, the powder of the superalloy is FGH4097 alloy powder having a particle size of 50 to 150 um.
3. The method for processing the nondestructive inspection surface of the powder superalloy workpiece according to claim 1, wherein in the step 1, the sheath is made of carbon steel or stainless steel, and the packaging vacuum degree is less than or equal to 4 x 10-3Pa, the leakage rate is less than or equal to 0.03Pa/min, the degassing temperature is 400-450 ℃, and sealing welding treatment is carried out by adopting electron beams in a vacuum chamber.
4. The method for processing the nondestructive inspection surface of the powder superalloy workpiece according to claim 1, wherein in the step 1, the hot isostatic pressing hot consolidation process is specifically: the heat preservation pressure is 120Mpa +/-10 Mpa, the heat preservation temperature is 1180 +/-10 ℃, and the heat preservation time is 2-3 h.
5. The method for processing the nondestructive inspection surface of the powder superalloy article according to claim 1, wherein in the step 2, the solution heat treatment is specifically: charging at 800 +/-10 ℃, heating to 1180 +/-10 ℃ after 4-6 hours, keeping the temperature for 9-12 hours, discharging and air cooling.
6. The method for processing the nondestructive inspection surface of the powder superalloy workpiece according to claim 1, wherein in the step 3, a cutter used in the numerical control rough turning and finish turning process is a Cubic Boron Nitride (CBN) superhard cutter, and the surface roughness of the powder superalloy workpiece after finish turning is Ra1.6.
7. The method for processing the nondestructive inspection surface of the powder superalloy workpiece according to claim 1, wherein in the step 4, the surface mirror processing is specifically: the cutter adopts the ultrahigh vibration frequency of 23000 +/-200/s, the processing linear speed of 50 +/-5 mm/min, the feed amount of 0.1 +/-0.02 mm/r, and the surface roughness of a finished piece after the mirror surface processing is Ra0.4.
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