CN113798394A - Integrated manufacturing method of high-temperature-resistant thin-wall special-shaped component by laying laminated metal foil strips for blank making - Google Patents
Integrated manufacturing method of high-temperature-resistant thin-wall special-shaped component by laying laminated metal foil strips for blank making Download PDFInfo
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Abstract
A high-temperature-resistant thin-wall special-shaped component integrated manufacturing method adopting a laminated metal foil tape to lay blanks is characterized in that a plastic phase is added in a foil tape form and is overlapped with two base element foil tapes and is rolled and laminated, meanwhile, a granular reinforcing phase can be added between the foil tapes during rolling, the two methods can enable the thin-wall special-shaped component to obtain a reinforcing structure at any axial position, the defect that the thin-wall special-shaped component is cracked due to stress concentration caused by changes of the geometric shape and the external dimension of the cross section is avoided, and the thin-wall special-shaped component can be reinforced at different radial thickness positions to obtain a similar laminated plate structure. The invention utilizes sand and other granular media to transfer pressure to enable the component to complete pre-sintering treatment and internal pressure forming, enables the component to complete low-temperature reaction synthesis under the combined action of pressure and temperature, is beneficial to the efficient proceeding of the following high-temperature reaction synthesis, and simultaneously solves the problem of air leakage caused by the gap between adjacent foil strips when the prefabricated blank is expanded by hot air pressure.
Description
Technical Field
The invention belongs to the technical field of manufacturing of high-temperature-resistant thin-wall special-shaped components, and particularly relates to an integrated manufacturing method of a thin-wall special-shaped component by laying laminated metal foil strips for blank manufacturing.
Background
The new generation of aerospace craft is rapidly developed in the direction of forward high Mach number, high bearing, ultra-long endurance and ultra-long range, and the demand for light high-temperature-resistant thin-wall components is continuously increased. The pneumatic heat generated by the hypersonic aircraft at the ultrahigh cruising speed can enable components such as an air inlet passage of the scramjet engine to generate extremely high temperature, the service temperature of the air inlet passage is as high as 900-1000 ℃, the service temperature of the air inlet passage exceeds the limit service temperature of the common titanium alloy, and the structure of the common nickel-based high-temperature alloy is seriously overweight due to high density. Therefore, it is urgently needed to adopt a novel light high-temperature-resistant material to replace nickel-based high-temperature alloy to manufacture a thin-wall key component. Nowadays, intermetallic compounds such as TiAl and NiAl, which are materials having higher heat resistance temperature, are becoming hot points of research. The service temperature of TiAl is 600-850 ℃, and the service temperature of NiAl is as high as 900-1000 ℃. Besides high heat-resistant temperature, intermetallic compounds such as TiAl, NiAl and the like also have the advantages of low density, high specific strength, high specific stiffness, excellent oxidation resistance and the like, so that the TiAl-NiAl-based alloy material has wide application prospect in the field of aerospace.
The existing manufacturing method of TiAl and NiAl alloy thin-wall components adopts the traditional idea of firstly preparing blanks and then forming the components. The method mainly comprises the steps of firstly preparing a plate blank by adopting processes such as rolling and the like, and then obtaining a final thin-wall component by adopting forming manufacturing technologies such as superplastic forming and hot creep forming. However, due to the intrinsic brittleness of the NiAl/TiAl material, a large-size NiAl/TiAl thin-wall plane slab or tube blank is difficult to prepare, and even if the plane slab or tube blank can be prepared, the plane slab or tube blank is extremely difficult to deform into a complex component at room temperature and in a warm state. In order to solve the problem, the invention patent (application number: 201910444894.6) provides a forming and property control integrated method for a Ni/Al alloy thin-wall pipe fitting, which is characterized in that a laminated foil pipe blank is obtained by alternately stacking, coiling and welding large-size Ni foils and Al foils, and then the laminated foil pipe blank is subjected to gas bulging forming and reaction synthesis in a gas bulging forming die to obtain the NiAl alloy thin-wall pipe fitting. Because the laminated foil pipe prepared by the method is a simple cylinder or a cone, the shape of the laminated foil pipe is greatly different from that of a final component, the laminated foil pipe has large and complex deformation in the process of gas expansion forming, and is easy to have the problems of local thinning, cracking, wrinkling and the like, and in addition, the structure performance of welding materials and parent materials at a welding seam is difficult to regulate and control. In order to reduce the defects, the invention patent (application number: 202010031405.7) provides an integrated manufacturing method of a high-temperature-resistant thin-wall component by laying metal foil tapes for blank making, and the invention patent (application number: 202010811707.6) provides a method for preparing an intermetallic compound curved thin-wall component by winding a core mould by using the metal foil tapes. The two methods are characterized in that two single-layer element metal foil strips are alternately wound and laid out to form the shape of the final part, and then the shape of the final part is reacted and synthesized at high temperature and high pressure to realize material modification, so that the part with the material and the shape meeting the requirements is finally obtained. In the two methods, when a blank is manufactured by adopting a single-layer foil tape laying or winding core die, due to different complexity of geometric characteristics of different areas on the blank, the phenomena of gaps, stacking, even folds and the like can occur between adjacent foil tapes on the same layer, and in the subsequent diffusion synthesis reaction process, an intermediate transition state intermetallic compound can be formed due to incomplete reaction caused by partial lack of certain elements. In addition, the components and the content of the transition intermetallic compound are uncontrollable, the microstructure cannot be regulated, and a thin-wall special-shaped component with good comprehensive mechanical property is difficult to obtain. Meanwhile, the gaps between adjacent foil strips also cause air leakage during subsequent hot-air bulging, and it is difficult to obtain a member with high shape accuracy through bulging.
The method aims to solve the problem that when a single-layer foil tape is laid to manufacture blanks, the laying path limits, the foil tape partially generates stacking or gaps, and diffusion reaction is incomplete to generate transition-state compounds; the phase composition and the content of the microstructure of the TiAl and NiAl intermetallic compound material are difficult to regulate and control; the thin-wall special-shaped component with a reinforcing structure at different positions is difficult to obtain by laying a single-layer foil tape for blank making; and the problem of preform blow-by during hot gas expansion due to the gap between adjacent foil strips, a new manufacturing method is needed.
Disclosure of Invention
In order to solve the problems that a single-layer foil belt is limited by a laying path when being laid to manufacture a blank, the foil belt is partially stacked or gapped to cause incomplete diffusion reaction to generate a transition compound, the phase composition and the content of a microstructure of a TiAl and NiAl intermetallic compound material are difficult to regulate, the single-layer foil belt laid blank is difficult to obtain a thin-wall special-shaped component with a reinforcing structure at different positions, and the gas leakage phenomenon is caused by the gap between adjacent foil belts when a prefabricated blank is expanded by heat, the high-temperature-resistant thin-wall special-shaped component integrated manufacturing method for laying the blank by adopting the laminated metal foil belt is provided.
The technical scheme of the invention is as follows:
an integrated manufacturing method of a high-temperature-resistant thin-wall special-shaped component by laying laminated metal foil strips for blank manufacturing comprises the following steps:
designing a prefabricated blank, preparing a support core mold: performing characteristic analysis on the thin-wall special-shaped component, determining the shape and size of the required thin-wall prefabricated blank by a theoretical calculation or simulation method, and preparing a support core mould by taking the inner wall of the prefabricated blank as a characteristic surface;
determining the layer number proportion, the structure form, the thickness of each layer and the type of the added plastic phase of the laminated foil strip;
firstly, according to the requirement of mechanical property of component, determining integral intermetallic compound AxByIs selected from the group consisting of (a) a,
determining the layer number proportion of the laminated foil strips: determining an integral intermetallic compound A according to the mechanical property requirement of the thin-wall special-shaped componentxByBy combining the calculation method and formula in step three of the invention patent (application No. 202010811707.6) and by using the intermetallic compound AxByCalculating the total thickness ratio of the single-layer matrix element A, B foil tapes according to the atomic number ratio, and adjusting the layer number ratio of the single-layer matrix element foil tapes to be 2:1 or 1: 2;
structural form of the laminated foil strip: stacking in a laminated foil strip A-B-A or B-A-B structure;
principle of addition of plastic phase: 1) the thin-wall special-shaped component is not easy to crack at the position where stress concentration is easy to generate in the axial direction; 2) obtaining plasticized and toughened similar laminated plate structures at different thicknesses; 3) obtaining a net-shaped reinforcing structure; adding a plastic phase C in a foil strip form, selecting an element capable of changing a lattice structure to promote the start of a slip system, realizing plasticization and toughening as the plastic phase C, and determining the thickness and the position of the stack of the plastic phase C according to requirements; stacking the laminated foil strips in structural forms of C-A-B-A or A-C-B-A and the like;
A. the total thickness of the B foil strip is determined by the wall thickness of the thin-wall special-shaped component and the thickness of the support core mold, the thickness of the single-layer element foil strip is obtained by calculating the total thickness ratio of the single-layer base element A, B foil strip and the designed layer number, and the thickness of the plastic phase element foil strip is calculated according to the thickness and the layer number of the plastic layer required by the local position;
thirdly, surface pretreatment of the single-layer foil strip and the support core mold; before the foil tape is laid, cleaning the surface of the foil tape by using an organic solvent and smearing a release agent on the outer surface of a support core mold for solder resist;
step four, rolling and laminating the laminated foil tape and adding a granular reinforcing phase; stacking a single-layer matrix element foil strip and a plastic phase element foil strip together to form a laminated foil strip, entering a hot rolling system, adding a granular reinforcing phase between the foil strips, and forming the laminated foil strip after the laminated foil strip is subjected to hot rolling treatment;
fifthly, laying the laminated foil strips layer by layer to manufacture a prefabricated blank; selecting laminated foil tapes with different structural forms according to different mechanical properties of the axial position or the radial thickness direction of a required part, and laying the laminated foil tapes to manufacture a prefabricated blank by establishing a laying path of the laminated foil tapes;
step six, sintering and shaping the prefabricated blank; placing the laminated prefabricated blank with the supporting core mold in a heating furnace, heating to the temperature higher than the melting point of the metal with lower melting point, and preserving heat to shape the laminated prefabricated blank so as to be convenient for taking out the supporting core mold;
step seven, separating the prefabricated blank, filling sand into the prefabricated blank, extruding, sintering and forming the prefabricated blank; after the support core mold is taken out, the laminated prefabricated blank filled with sand is placed in a mold, the mold is heated, a punch head feeds to extrude the sand in the prefabricated blank, and normal pressure perpendicular to the surface of the blank is provided for the blank by utilizing the sand transfer pressure, so that the thin-wall special-shaped component is subjected to presintering treatment and is formed;
step eight, cooling the prefabricated blank and cleaning sand; cooling and cleaning the sand inside the preform after removing the preform from the mold;
step nine, performing high-temperature reaction synthesis and densification treatment on the prefabricated blank; carrying out diffusion synthesis reaction and densification treatment on the laminated prefabricated blank under the conditions of high temperature and high pressure, and controlling the temperature, the gas pressure and the heat preservation time to obtain a thin-wall special-shaped component with different phase compositions and contents;
step ten, cutting and post-processing the formed part; and cutting off the process section of the formed thin-wall profiled component and processing the end part and the surface.
The invention has the beneficial effects that:
when A, B two element foil tapes with a certain thickness proportion are stacked together to form a laminated foil tape laying blank, the material composition of the local position of a laminated component can be ensured not to be limited by a foil tape laying path, and a single characteristic target material composition can be obtained at any position;
the invention can regulate and control the microstructure phase composition by adjusting the thickness ratio of the foil strips with different elements and the initial thickness of the foil strips, and can design different transition state intermetallic compounds AxByThe layered structure is beneficial to improving the comprehensive mechanical property;
the plastic phase is added in the form of foil strips, and the foil strips are overlapped with A, B two matrix element foil strips and rolled for lamination, so that the composition and the structural form of the laminated foil strips containing the plastic phase are adjusted, meanwhile, a granular reinforcing phase can be added between the foil strips during rolling, both the two methods can ensure that a reinforcing structure is obtained at any axial position of the thin-wall special-shaped component, the defect that the thin-wall special-shaped component is cracked due to stress concentration caused by the change of the geometric shape and the external dimension of the cross section is avoided, the reinforcing can also be realized at different radial thickness positions of the thin-wall special-shaped component, and the similar laminated plate structure is obtained, and the purposes of different mechanical properties at different characteristic positions of the special-shaped component are achieved. In addition, different types of net-shaped reinforcing structures can be obtained according to different laying paths of the foil tapes, so that the problem that a thin-wall special-shaped component with good comprehensive mechanical property is difficult to obtain is solved;
the invention utilizes the granular media such as sand to transfer pressure to enable the component to complete pre-sintering treatment and internal pressure forming, enables the component to complete low-temperature reaction synthesis under the combined action of pressure and temperature, is beneficial to the high-temperature reaction synthesis, and simultaneously solves the problem of gas leakage caused by the gap between adjacent foil strips when the prefabricated blank is expanded by hot air pressure; in addition, the pre-sintering treatment and the internal pressure forming by using granular media such as sand are completed in one set of die, so that the problem of reduction of the size precision caused by the transfer of the thin-wall component is effectively avoided, the working procedures can be reduced, and the production efficiency is effectively improved.
Drawings
FIG. 1 is a schematic diagram of an integrated manufacturing method of a high-temperature-resistant thin-wall special-shaped component by laying laminated metal foil tapes for blank manufacturing.
FIG. 2(a) is a schematic view of a laminated foil tape produced by hot roll pressing,
FIG. 2(b) is a schematic representation of hot rolling to produce a laminated foil tape with the addition of a particulate reinforcing phase.
FIG. 3 is a schematic illustration of the placement of a laminated metal foil strip.
FIG. 4(a) is a schematic diagram of preforms with different mechanical properties obtained by different laying modes of metal foil strips.
FIG. 4(b) is a schematic diagram of preforms with different mechanical properties obtained by different laying modes of metal foil strips.
FIG. 4(c) is a schematic diagram of preforms with different mechanical properties obtained by different laying modes of metal foil strips.
FIG. 5 is a schematic view of the pre-sintering process of the laminated preform and the formation of the particulate media.
FIG. 6 is a schematic view of a high temperature reaction synthesis and densification process of a laminated preform in a hot isostatic press.
FIG. 7 is a schematic view of the hot air bulging of a laminate preform.
Figure 8 is a schematic view of an external sand charging scheme.
In the figure: 1-single layer element foil tape, 2-Cr element foil tape, 3-hot roller, 4-Cr-Ni-Al-Ni form laminated foil tape, 5-TiB2Particle, 6-spraying device, 7-single-layer element foil tape reel, 8-reversing device, 9-hot rolling system, 10-foil tape laying mechanical arm, 11-rolling mechanical arm and 12-rotationPlatform, 13-Ni-Al-Ni form laminated foil strip, 14-support core mould, 15-gas-liquid pressure cylinder, 16-punch head, 17-water cooling plate, 18-heat insulation plate, 19-granular medium forming mould upper mould, 20-heating device, 21-granular medium forming mould lower mould, 22-laminated prefabricated blank, 23-sand, 24-gas cylinder, 25-gas control cabinet, 26-induction coil, 27-temperature measuring device, 28-thermocouple 1 (measuring temperature in heat isostatic pressing device), 29-thermocouple 2 (measuring temperature of laminated prefabricated blank), 30-expanding mould upper mould, 31-gas medium, 32-expanding mould lower mould, 33-pressure device and 34-laminated prefabricated blank with support core mould.
Detailed Description
The following further describes a specific embodiment of the present invention with reference to the drawings and technical solutions.
The first embodiment is as follows: with reference to fig. 1 to 8, the present invention provides an integrated manufacturing method of a thin-walled profiled component by laying laminated metal foil strips, which is performed according to the following steps:
designing a prefabricated blank and preparing a support core mold. Performing characteristic analysis on the thin-wall special-shaped component, simplifying the small characteristics of the complex component by methods such as theoretical calculation or simulation and the like, thereby determining the shape and the size of the required thin-wall prefabricated blank, and preparing a support core mould by taking the inner wall of the prefabricated blank as a characteristic surface;
determining the layer number proportion, the structure form, the thickness of each layer and the type of the added plastic phase of the laminated foil strip;
firstly, according to the requirement of mechanical property of component, determining integral intermetallic compound AxByIs selected from the group consisting of (a) a,
determining the layer number proportion of the laminated foil strips: determining an integral intermetallic compound A according to the mechanical property requirement of the thin-wall special-shaped componentxByBy combining the calculation method and formula in step three of the invention patent (application No. 202010811707.6) and by using the intermetallic compound AxByCalculating the total thickness ratio of the single-layer matrix element A, B foil tapes according to the atomic number ratio, and adjusting the layer number ratio of the single-layer matrix element foil tapes to be 2:1 or 1: 2;
structural form of the laminated foil strip: stacking in a laminated foil strip A-B-A or B-A-B structure;
principle of addition of plastic phase: 1) the thin-wall special-shaped component is not easy to crack at the position where stress concentration is easy to generate in the axial direction; 2) obtaining plasticized and toughened similar laminated plate structures at different thicknesses; 3) obtaining a net-shaped reinforcing structure; adding a plastic phase C in a foil strip form, selecting an element capable of changing a lattice structure to promote the start of a slip system, realizing plasticization and toughening as the plastic phase C, and determining the thickness and the position of the stack of the plastic phase C according to requirements; stacking the laminated foil strips in structural forms of C-A-B-A or A-C-B-A and the like;
A. the total thickness of the B foil strip is determined by the wall thickness of the thin-wall special-shaped component and the thickness of the support core mold, the thickness of the single-layer element foil strip is obtained by calculating the total thickness ratio of the single-layer base element A, B foil strip and the designed layer number, and the thickness of the plastic phase element foil strip is calculated according to the thickness and the layer number of the plastic layer required by the local position;
and step three, pretreating the surfaces of the single-layer foil belt and the support core mold. Before the foil strips are laid, oil stains on the surfaces of the metal foil strips need to be cleaned by alcohol in an ultrasonic cleaning machine, and the surfaces of the metal foil strips need to be dried by alcohol after cleaning; after the outer surface of the supporting core mold is coated with uniform liquid boron nitride, the supporting core mold is dried, so that the subsequent reaction of the foil strip and the supporting core mold is prevented, and the demolding is facilitated;
and step four, rolling and laminating the laminated foil tape and adding the granular reinforcing phase. Stacking a single-layer matrix element foil strip and a plastic phase element foil strip together to form a laminated foil strip, entering a hot rolling system, adding a granular reinforcing phase between the foil strips, and performing hot rolling treatment on the laminated foil strip to form a laminated foil strip;
and fifthly, laying the laminated foil strips layer by layer to manufacture a prefabricated blank. Selecting laminated foil tapes with different structural forms according to different mechanical properties of the axial position or the radial thickness direction of a required part, and laying the laminated foil tapes to manufacture a prefabricated blank by establishing a laying path of the laminated foil tapes;
and step six, sintering and shaping the prefabricated blank. Placing the laminated prefabricated blank with the support core mold in a heating furnace, heating to a temperature higher than the melting point of metal with a lower melting point, and preserving heat for 0.5-1h to shape the laminated prefabricated blank so as to be convenient for taking out the support core mold;
and step seven, separating the prefabricated blank, filling sand into the prefabricated blank, extruding, sintering and forming the prefabricated blank. After the support core mold is taken out, the laminated prefabricated blank filled with sand is placed in a mold, the mold is heated, a punch head feeds to extrude the sand in the prefabricated blank, and normal pressure perpendicular to the surface of the blank is provided for the blank by utilizing the pressure transmitted by the sand, so that the component is subjected to presintering treatment and is formed;
and step eight, cooling the prefabricated blank and cleaning sand. Cooling and cleaning the sand inside the preform after removing the preform from the mold;
step nine, performing high-temperature reaction synthesis and densification treatment on the prefabricated blank. Carrying out diffusion synthesis reaction and densification treatment on the laminated prefabricated blank under the conditions of high temperature and high pressure, and controlling the temperature, the gas pressure and the heat preservation time to obtain a thin-wall special-shaped component with different phase compositions and contents;
and step ten, cutting and post-processing the formed part. The process section of the shaped thin-walled profiled element is cut off and the necessary treatments are applied to the ends and surfaces.
The beneficial effects of the embodiment are as follows: by adopting the integrated manufacturing method of the thin-wall special-shaped component for laying the blank by the laminated metal foil strips, when the laminated foil strip laying blank is formed by stacking A, B two element foil strips according to a certain thickness proportion, the material composition of the local position of the laminated component can be ensured not to be limited by the foil strip laying path, and the single characteristic target material composition can be obtained at any position; the microstructure phase composition can be regulated and controlled by adjusting the thickness ratio of the foil strips with different elements and the initial thickness of the foil strips, and different transition state intermetallic compounds A can be designedxByThe layered structure is beneficial to improving the comprehensive mechanical property; the plastic phase is added in the form of foil strips and is overlapped with A, B two matrix element foil strips and is rolled and laminated, the composition and the structural form of the laminated foil strips containing the plastic phase are adjusted, meanwhile, the granular reinforcing phase can be added between the foil strips during rolling, and the two methods can ensure that the thin-wall special-shaped component obtains a reinforcing structure at any axial position, thereby avoiding the thin-wall special-shaped component from being caused by the geometric shape of the cross sectionThe defect that the stress concentration is caused to generate the fracture due to the change of the shape and the external dimension can be realized, the reinforcement can be realized at the radial different thicknesses of the thin-wall special-shaped component to obtain a similar laminated plate structure, the purpose of different mechanical properties at different characteristic positions of the special-shaped component is achieved, in addition, different types of net-shaped reinforcing structures can be obtained according to the different laying paths, and the problem that the thin-wall special-shaped component with better comprehensive mechanical properties is difficult to obtain is solved; the components are subjected to presintering treatment and internal pressure forming by utilizing pressure transferred by granular media such as sand and the like, and are subjected to low-temperature reaction synthesis under the combined action of pressure and temperature, so that the subsequent high-temperature reaction synthesis can be efficiently carried out, and the problem of gas leakage caused by gaps between adjacent foil strips during hot air pressure bulging of the prefabricated blank is solved; in addition, the pre-sintering treatment and the internal pressure forming by using granular media such as sand are completed in one set of die, so that the problem of reduction of the size precision caused by the transfer of the thin-wall component is effectively avoided, the working procedures can be reduced, and the production efficiency is effectively improved.
The second embodiment is as follows: according to the intermetallic compound A in step twoxByAnd (3) calculating the atomic number ratio of the A atoms to the B atoms, calculating A, B the total thickness ratio of the foil strips, determining the thickness of the single-layer foil strips, and taking the final product as an intermetallic compound NiAl alloy as an example for illustration, if the Ni and Al foil strips are completely reacted to synthesize the NiAl alloy without other transition metal compounds, the thickness ratio of the Ni and Al foil strips is 2: 3. the laminated foil strips can be stacked in a Ni-Al-Ni mode, and Al foil strips with the thickness of 0.15mm and Ni foils with the thickness of 0.05mm are selected. In addition, in order to improve the plasticity and toughness of local positions of the NiAl alloy component, a plastic second phase (such as Cr, Fe and the like) is added in the form of foil strips, the laminated foil strips are stacked in the form of Cr-Ni-Al-Ni or Ni-Cr-Al-Ni, and the structural form of different laminated foil strips can change the position of a plastic layer in the component. The invention is stacked according to the form of Cr-Ni-Al-Ni, an Al foil strip with the thickness of 0.15mm and a Ni foil strip with the thickness of 0.05mm are selected, and then the Cr foil strip with the thickness of 0.01mm is calculated and selected according to the thickness and the layer number of the plastic layer required by the local position.
The beneficial effects of the embodiment are as follows: the laminated foil tape prepared in the form of Ni-Al-Ni can ensure that the material composition of the local position of the laminated component is not limited by the laying path of the foil tape, and a single characteristic target material composition can be obtained at any position; phase components of microstructures can be regulated and controlled by adjusting the thickness ratio of foil strips with different elements, NiAl alloy grains can be refined by reducing the thickness of initial Ni and Al foil materials, in addition, a plastic second phase (such as Cr, Fe and the like) can be effectively introduced into the laminated foil strip in a Cr-Ni-Al-Ni form, the lattice structure is changed to a certain extent, the start of a sliding system is promoted, and the purpose of improving the plasticity and toughness of the material can be realized.
The third concrete implementation mode: in the fourth step, which is described with reference to fig. 2(a), the foil strips of each layer are rolled by a hot roller, so that the gap between the foil strips becomes smaller and the foil strips are bonded to each other. In order to make the thickness of each laminated foil strip on the prefabricated blank the same, the laminated foil strips of the Cr-Ni-Al-Ni form and the Ni-Al-Ni form are formed into the laminated foil strips of the Cr-Ni-Al-Ni form and the Ni-Al-Ni form after hot rolling, the total thickness is controlled to be the same, namely, the thickness of each laminated foil strip of the two different forms is 0.1 mm. Simultaneously, the reinforcing body TiB is sprayed by a spraying device in the hot rolling process2Particles are added on the laminated foil strip as shown in fig. 2 (b);
the beneficial effects of the embodiment are as follows: before the laminated foil is wound on the support core mould, the laminated foil is heated and rolled, so that loose multilayer foils are combined into a whole, the compactness of the laminated foil is improved, and meanwhile, the phenomenon of air leakage caused by gaps between adjacent layers of foils during hot air expansion can be prevented. When two different forms of laminated foil tapes are laid for blank making, the material composition of the local position of the laminated component can be ensured not to be limited by the laying path of the foil tapes, and the single characteristic target material composition can be obtained at any position. In addition, after hot rolling is finished, the thicknesses of the laminated foil strips of different forms are the same, so that the wrinkling defect caused by uneven distribution of local materials due to different thicknesses of the layers during blank laying is avoided;
the fourth concrete implementation mode: the combination of the two types of laminated foil strips can be replaced when the laminated foil strips are laid in the fifth step, as shown in fig. 4(a), the laminated foil strips in the Cr-Ni-Al-Ni form can be laid in the positions which are easy to generate fracture defects in the front, middle and rear positions of the axis of the thin-wall special-shaped component, and the laminated foil strips in the Ni-Al-Ni form can be laid in the other positions; or the thin-wall special-shaped component can be paved at different radial thicknesses by using Cr-Ni-Al-Ni laminated foil tapes, when the thin-wall special-shaped component is paved layer by layer as shown in figure 4(b), the first layer, the third layer and other odd layers are paved by using Cr-Ni-Al-Ni laminated foil tapes, and the second layer, the fourth layer and other even layers are paved by using Ni-Al-Ni laminated foil tapes instead, so that a similar laminated plate structure is obtained; when a laying path of the laminated foil tapes is established, after the laminated foil tapes are laid to one end of the component, the next laminated foil tape is laid in a reverse cross mode, and the two adjacent laminated foil tapes are both laminated foil tapes in a Cr-Ni-Al-Ni form, so that a mesh reinforcing structure can be realized as shown in fig. 4 (c).
The beneficial effects of the embodiment are as follows: the reinforced structure is obtained at any axial position of the thin-wall special-shaped component, the defect that the thin-wall special-shaped component is cracked due to stress concentration caused by changes of the geometric shape and the external dimension of the cross section is avoided, the reinforced structure can also be realized at different radial thickness positions of the thin-wall special-shaped component to obtain a similar laminated plate structure, the purpose of different mechanical properties at different characteristic positions of the special-shaped component is achieved, the comprehensive mechanical property is improved, in addition, different types of net-shaped reinforced structures can also be obtained according to different laying paths, and the problem that the thin-wall special-shaped component with better comprehensive mechanical property is difficult to obtain is solved.
The fifth concrete implementation mode: and (3) explaining the whole low-temperature reaction synthesis process into two parts, namely a pre-sintering treatment and a granular medium forming process in the step seven, after the core die is taken out in the step seven, filling sand in the laminated prefabricated blank, putting the laminated blank filled with the sand in a die, heating the granular medium forming die to 550-650 ℃, providing pressure through a gas-liquid pressure cylinder to push a punch to extrude the sand, so that the sand flows, further transmitting the pressure to the surface of the laminated blank, keeping the pressure at 5-20MPa for 0.5-4 hours under the combined action of the temperature and the pressure until the Al layer completely reacts.
The beneficial effects of the embodiment are as follows: the pre-sintering treatment and the forming of the component are completed by utilizing the pressure transmitted by the particle medium, so that the problem of air leakage caused by the gap between adjacent foil strips when the prefabricated blank is expanded by hot air pressure is solved; in addition, low-temperature reaction synthesis (presintering treatment and internal pressure forming by using granular media such as sand) is completed in a set of die, so that the problem of size precision reduction caused by the transfer of a thin-wall component is effectively avoided, the processes can be reduced, and the production efficiency is effectively improved.
The sixth specific implementation mode: the description is given by combining fig. 6 that in the step ten, the high-temperature reaction synthesis and densification treatment are carried out by placing the component after hot air pressure bulging in a hot isostatic pressing device, wherein the gas pressure during the high-temperature reaction synthesis is 10-50MPa, and the heat preservation and pressure maintaining are carried out for 2-4 h; during densification treatment, the temperature is increased to 1000-1300 ℃, the gas pressure is increased to 50-100MPa, and the heat preservation and pressure maintaining are carried out for 1-5 h.
The beneficial effects of the embodiment are as follows: placing the formed component in a hot isostatic pressing device, accurately controlling three parameters of temperature, gas pressure and heat preservation time to control the degree of high-temperature reaction synthesis, and mixing the residual Ni layer and Ni2Al3Subsequent reaction of the layers takes place to form a homogeneous NiAl alloy and the compactness of the component is improved by means of high pressure.
The seventh embodiment: the scheme of internal sand filling and hot air pressure bulging is described by combining the figure 7, and the seventh step and the eighth step are replaced by the following steps:
1) separating the prefabricated blank and filling sand in the prefabricated blank for pre-sintering treatment. After the core mold is taken out, the preformed blank is placed in a preformed mold, pressure is applied to a punch through a gas-liquid pressure cylinder, so that sand fully extrudes the preformed blank to complete the pre-sintering treatment, the pressure is 5-20MPa, the temperature of the bulging forming mold is 550-650 ℃, and the preformed blank is kept for 0.5-4 hours under the combined action of the temperature and the pressure;
2) sand is cleaned after cooling the preform. Cooling and cleaning the sand inside the preform after removing the preform from the mold;
3) the prefabricated blank is made by hot air pressure bulging and low temperature reaction synthesis. Placing the laminated prefabricated blank into a bulging forming die for hot air pressure bulging, wherein the laminated prefabricated blank is subjected to the gas pressure of 5-20MPa, the temperature of the bulging forming die is 550-650 ℃, and the laminated prefabricated blank is kept to be Al under the combined action of the temperature and the pressure
The layer is completely reacted to complete the low-temperature reaction synthesis preparation.
Other steps are the same as in the first embodiment.
The beneficial effects of the embodiment are as follows: through sand filling and pre-sintering treatment after the pre-forming blank is obtained, the gaps between the laminated foil strips of the same layer and the adjacent layers are reduced and mutually bonded under the combined action of pressure and temperature, the compactness of the laminated foil strips is improved, and the problem of air leakage caused by the gaps between the adjacent foil strips during hot air pressure bulging of the pre-forming blank is solved. In addition, in the internal pressure forming by using granular media such as sand and the like, the pressure transmission of the sand is not uniform, and the hot-air expansion forming process is adopted, so that the forming quality can be effectively ensured, and the precision of a formed component is improved.
The specific implementation mode is eight: the scheme of external pressurization and hot air pressure bulging is described by combining the figure 8, and the seventh step and the eighth step are replaced by the following steps:
1) placing the laminated preform with the support mandrel in an external sand medium;
2) pressurizing sand by a pressurizing device, so that the external part of the laminated prefabricated blank is pressurized, and the internal part of the laminated prefabricated blank is supported by a support core mold, thereby achieving the aim of pre-sintering treatment, wherein the pressure is 5-20MPa, the temperature of the whole device is 550-650 ℃, and the whole device is kept for 0.5-4 hours under the combined action of the temperature and the pressure;
3) cooling the laminated prefabricated support core mold and taking out the support core mold;
4) and (3) placing the laminated prefabricated blank in a bulging forming die for hot air pressure bulging, wherein the air pressure is 5-20MPa, the temperature of the bulging forming die is 550-650 ℃, and the laminated prefabricated blank is kept under the combined action of the temperature and the pressure until the Al layer is completely reacted.
Other steps are the same as in the first embodiment.
The beneficial effects of the embodiment are as follows: the method can also reduce the gaps between the laminated foil strips of the same layer and the adjacent layers to be mutually bonded by utilizing the external pressurization mode of granular media such as sand and the like, improves the compactness of the laminated foil strips, solves the problem of air leakage caused by the gaps between the adjacent foil strips when the preformed blank is subjected to hot air pressure bulging, does not need a preformed die and reduces the production cost.
Claims (1)
1. An integrated manufacturing method of a high-temperature-resistant thin-wall special-shaped component by laying laminated metal foil strips for blank manufacturing is characterized by comprising the following steps:
designing a prefabricated blank, preparing a support core mold: performing characteristic analysis on the thin-wall special-shaped component, determining the shape and size of the required thin-wall prefabricated blank by a theoretical calculation or simulation method, and preparing a support core mould by taking the inner wall of the prefabricated blank as a characteristic surface;
determining the layer number proportion, the structure form, the thickness of each layer and the type of the added plastic phase of the laminated foil strip;
determining the layer number proportion of the laminated foil strips: determining an integral intermetallic compound A according to the mechanical property requirement of the thin-wall special-shaped componentxByBy the kind of intermetallic compound AxByCalculating the total thickness ratio of the single-layer matrix element A, B foil tapes according to the atomic number ratio, and adjusting the layer number ratio of the single-layer matrix element foil tapes to be 2:1 or 1: 2;
structural form of the laminated foil strip: stacking in a laminated foil strip A-B-A or B-A-B structure;
principle of addition of plastic phase: 1) the thin-wall special-shaped component is not easy to crack at the position where stress concentration is easy to generate in the axial direction; 2) obtaining plasticized and toughened similar laminated plate structures at different thicknesses; 3) obtaining a net-shaped reinforcing structure; adding a plastic phase C in a foil strip form, selecting an element capable of changing a lattice structure to promote the start of a slip system, realizing plasticization and toughening as the plastic phase C, and determining the thickness and the position of the stack of the plastic phase C according to requirements;
A. the total thickness of the B foil strip is determined by the wall thickness of the thin-wall special-shaped component and the thickness of the support core mold, the thickness of the single-layer element foil strip is obtained by calculating the total thickness ratio of the single-layer base element A, B foil strip and the designed layer number, and the thickness of the plastic phase element foil strip is calculated according to the thickness and the layer number of the plastic layer required by the local position;
thirdly, surface pretreatment of the single-layer foil strip and the support core mold; before the foil tape is laid, cleaning the surface of the foil tape by using an organic solvent and smearing a release agent on the outer surface of a support core mold for solder resist;
step four, rolling and laminating the laminated foil tape and adding a granular reinforcing phase; stacking a single-layer matrix element foil strip and a plastic phase element foil strip together to form a laminated foil strip, entering a hot rolling system, adding a granular reinforcing phase between the foil strips, and forming the laminated foil strip after the laminated foil strip is subjected to hot rolling treatment;
fifthly, laying the laminated foil strips layer by layer to manufacture a prefabricated blank; selecting laminated foil tapes with different structural forms according to different mechanical properties of the axial position or the radial thickness direction of a required part, and laying the laminated foil tapes to manufacture a prefabricated blank by establishing a laying path of the laminated foil tapes;
step six, sintering and shaping the prefabricated blank; placing the laminated prefabricated blank with the supporting core mold in a heating furnace, heating to the temperature higher than the melting point of the metal with lower melting point, and preserving heat to shape the laminated prefabricated blank so as to be convenient for taking out the supporting core mold;
step seven, separating the prefabricated blank, filling sand into the prefabricated blank, extruding, sintering and forming the prefabricated blank; after the support core mold is taken out, the laminated prefabricated blank filled with sand is placed in a mold, the mold is heated, a punch head feeds to extrude the sand in the prefabricated blank, and normal pressure perpendicular to the surface of the blank is provided for the blank by utilizing the sand transfer pressure, so that the thin-wall special-shaped component is subjected to presintering treatment and is formed;
step eight, cooling the prefabricated blank and cleaning sand; cooling and cleaning the sand inside the preform after removing the preform from the mold;
step nine, performing high-temperature reaction synthesis and densification treatment on the prefabricated blank; carrying out diffusion synthesis reaction and densification treatment on the laminated prefabricated blank under the conditions of high temperature and high pressure, and controlling the temperature, the gas pressure and the heat preservation time to obtain a thin-wall special-shaped component with different phase compositions and contents;
step ten, cutting and post-processing the formed part; and cutting off the process section of the formed thin-wall profiled component and processing the end part and the surface.
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