CN117182449A - Integrated welding method for repairing deep hole defects of aluminum alloy thick plate - Google Patents
Integrated welding method for repairing deep hole defects of aluminum alloy thick plate Download PDFInfo
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- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 48
- 238000003756 stirring Methods 0.000 claims abstract description 91
- 230000008439 repair process Effects 0.000 claims abstract description 53
- 230000008569 process Effects 0.000 claims abstract description 42
- 238000010288 cold spraying Methods 0.000 claims abstract description 21
- 238000003754 machining Methods 0.000 claims abstract description 12
- 238000004140 cleaning Methods 0.000 claims abstract description 7
- 238000005507 spraying Methods 0.000 claims description 65
- 239000000463 material Substances 0.000 claims description 62
- 238000011049 filling Methods 0.000 claims description 17
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 16
- 238000005498 polishing Methods 0.000 claims description 16
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- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 8
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 5
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- IADRPEYPEFONML-UHFFFAOYSA-N [Ce].[W] Chemical compound [Ce].[W] IADRPEYPEFONML-UHFFFAOYSA-N 0.000 claims description 4
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Abstract
The application provides an integrated welding method for repairing deep hole defects of an aluminum alloy thick plate, which comprises the following steps: cold spraying is carried out on the defect of the deep hole; performing TIG positioning spot welding of the cold spraying area and the parent metal connecting area, and cleaning the surface; and finally, performing formal repair welding by adopting a cold spraying-friction stir integrated welding mode, wherein secondary welding of welding seams can be performed in the repair process. The application is applied to the field of deep hole defect repair and welding of large-scale thick plate structures of aluminum alloy, and can rapidly realize high-reliability repair aiming at deep hole and crack defects generated by breaking pins or unqualified raw material preparation in the friction stir welding process, and prepare a repaired secondary welding joint with high strength and small deformation. The application makes up the technical situation that the deep hole defect of the aluminum alloy super-thick plate structure can be removed or scrapped only by machining, and lays a technological foundation for researching the butt welding and deep hole defect repair technology of the aluminum alloy super-thick plate.
Description
Technical Field
The application belongs to the field of deep hole repair and welding of ultra-thick plates, and particularly relates to an integrated welding method for repairing defects of deep holes of an aluminum alloy thick plate. In particular to an integrated welding method for repairing deep hole defects of an aluminum alloy ultra-thick plate.
Background
The aluminum alloy super-thick plate is a large structural member and has wide application in the raw material preparation in the field of anti-service equipment and the production process of part of structural members at present.
The air defense missile war chariot is extremely important defending equipment, and has extremely high requirements on aluminum alloy plates with different thicknesses in the development and production process, and large structural parts such as auxiliary frames, cabins and the like relate to the preparation and processing of ultra-thick plate raw materials. In the actual use process, the preparation link of the ultra-thick plate has the problems of loose materials, breaking of a stirring tool in the friction stir welding link of the ultra-thick plate, and the like, and deep hole defects can be generated. In the model development and production process, a machining mode is generally adopted to remove the defective area of the aluminum alloy, and if the machining allowance of the plate is not reserved, the plate is scrapped and re-thrown. Because of the lack of a reasonable and stable repair treatment scheme for the deep hole defects of the aluminum alloy, the engineering applicability of the ultra-thick plate is poor.
Deep hole defects relate to various forms and specifications, and lack a general repairing method. From a macroscopic physical perspective, the deep hole repair process generally comprises two processes of deep hole material filling and filling material densification. In the actual production process, the inconsistent specifications of deep holes bring great difficulty to the material filling link, the material filling is difficult to realize due to the penetrating type through hole structure, and the binding force between the spraying material and the section is lower due to the defects of burrs, oxide films and the like in the section area of the deep holes, so that the filling area is loose and the like.
Cold spraying is a novel aerodynamic coating technology, and compressed air is used as an accelerating medium to drive spray powder to flow at a high speed in a solid state and strike a substrate, so that severe plastic deformation is generated to deposit and form a coating. The cold spraying deposition temperature is low, the thermal influence on the coating and the matrix is small, and the selection space of the base material is enlarged. The types of materials that can be deposited by cold spraying are numerous, and spraying can be generally performed as long as the particle size meets the requirements. The porosity of the cold spray deposition layer is low, the bonding strength with a matrix is high, the density can reach more than 98%, the cold spray deposition layer can be used for preparing some coatings with high thermal conductivity, high electrical conductivity, corrosion resistance and the like, the deposition of the coating is realized at a low temperature, the residual stress in the coating is low, the residual stress is compressive stress, and the coating with large thickness can be prepared.
The cold spraying-stirring friction integrated welding technology adopts a double-machine parallel mode to repair deep holes, is an integrated processing technology, and specifically comprises a spraying tool at the front end of equipment and stirring friction equipment at the rear, wherein the equipment realizes qualified repair of deep hole defects of an aluminum alloy super-thick plate by controlling the pose of a double machine head, the spraying speed of the spraying equipment, the rotating speed of the stirring tool, the penetration depth and the equipment travelling speed. The repair process is reliable and stable, deep hole repair of various forms and specifications can be realized, the base metal is not melted in the repair process, the deformation of the base metal is small, and the repair efficiency is high.
Compared with a simple spraying technology and a simple integration technology, the technology system performs full-period optimization on the basis of a cold spraying-stirring friction integrated welding technology, can realize compact forming of a base material in a repairing area, and avoids incomplete combination of a spraying material and a matrix and loosening of a filling material.
Disclosure of Invention
Aiming at the defects in the prior art, the application aims to provide an integrated welding method for repairing deep hole defects of an aluminum alloy thick plate.
The application provides an integrated welding method for repairing deep hole defects of an aluminum alloy thick plate, which comprises the following steps:
step S1: polishing the deep hole defect area, and blowing off surplus materials by using compressed air, wherein the flat surface of the hole is required to be smooth, and the surplus materials are not generated; the deep hole defects comprise hole defects and cracks in the interval of 30-100mm; the thickness interval of the thick aluminum alloy plate is 30-100mm;
step S2: carrying out cold spraying treatment on the deep hole defect area after finishing polishing and cleaning;
step S3: positioning the surface of the plate at the junction of the spraying repair area and the base metal by adopting TIG welding;
step S4: spraying the to-be-repaired area and the welding area of the deep hole of the plate by adopting front side cold spraying equipment, and simultaneously welding by adopting rear side friction stir welding equipment; and after welding, removing burrs, and finishing deep hole repair and weld forming.
Preferably, for the defects caused by broken pins of the stirring pin in the friction stir welding process, the broken pins are confirmed through the magnet, the discharging and digging are carried out, and the polishing treatment is carried out on the deep hole defect area after the stirring pin is discharged.
Preferably, in said step S2:
firstly spraying the bottom of a deep hole, then carrying out multilayer and multi-channel spraying, after the spraying is finished, adopting a vernier caliper to measure the thickness, and continuing spraying if the thickness is less than 2 mm; if the thickness exceeds 4mm, polishing to a required range; after finishing, polishing the spraying area by adopting sand paper, cleaning redundant substances by adopting HT-2 degreasing agent, and waiting for welding; the interface area of the cold spraying and the base material is in a pre-connected state, and the spraying material is in a loose state in the state, so that densification is realized by means of subsequent procedures.
Preferably, in said step S2:
pure aluminum powder is used as a spraying medium, and the powder feeding speed is controlled to be 5kg/h until deep holes are sprayed to be 2-4mm higher than the plate in the thickness direction.
Preferably, in said step S3:
and carrying out the positioning welding of at least 3 positions with the diameter of the deep hole smaller than 30mm, carrying out the positioning welding of at least 4 positions with the diameter of the deep hole between 30mm and 60mm, and carrying out the positioning welding of at least 5 positions with the diameter of the deep hole exceeding 60mm, thereby realizing the preheating and the pre-connection of the spraying material.
Preferably, in said step S3:
an external heat source is applied by adopting positioning welding, so that the deep hole spraying material is preheated, and the bottom area of the deep hole spraying material is heated to form a temperature gradient;
polishing the surface of the welding spot after the welding is finished, and repairing the surface defect of the welding spot;
in the TIG welding process, the purity of argon and helium is not less than 99.99%, the residual pressure of bottled gas is not less than 0.5MPa, a tungsten electrode adopts a cerium tungsten electrode with the diameter of 1.6mm, and the height of the end part of the tungsten electrode from the outer surface of a to-be-welded part of a workpiece is 0.5-1 mm.
Preferably, in said step S4:
the filling material is completely subjected to the stirring friction effect, the stirring width covers the defect width, only one stirring is carried out, and the repairing process needs to carry out gas cooling in the whole process; removing burrs on the surface of the plate, and flattening the protruding surface from the central area to two sides until the thickness of the base material is consistent;
filling of deep holes and welding line materials is achieved through front side cold spraying equipment, and densification of filling materials is achieved through rear side friction stir welding equipment.
Preferably, the deep hole defect is repaired by one side when the depth is smaller than 50mm, and the deep hole defect is repaired by two sides when the depth is 50-100mm, namely, one side operation is performed and then the other side operation is performed.
Preferably, a back-drawing stirring tool or a fixed stirring tool is used;
the back-drawing stirring tool is suitable for the plate size without allowance, and a surface keyhole is not left on the plate in the repairing process;
the fixed stirring tool is suitable for plates with allowance, key holes generated in the repairing process are led to an area with allowance, and machining is adopted to finish removal.
Preferably, the method further comprises:
step S5: and after the spraying and stirring friction are finished, machining to remove the keyhole area, and finishing the repair.
Compared with the prior art, the application has the following beneficial effects:
1. the application integrates cold spraying and friction stir welding technologies, establishes a deep hole repairing flow, adopts a pre-cold spraying device to perform base metal pretreatment and defect material increase, and adopts a stirring head to synchronously perform defect repairing and weld forming. The equipment adopts a double-head working mode to synchronously carry out material adding and welding, and the friction stir welding process is divided into two processes of penetration and advancing.
2. The application is applied to the field of deep hole defect repair and welding of large-scale thick plate structures of aluminum alloy, and can rapidly realize high-reliability repair aiming at deep hole and crack defects generated by breaking pins or unqualified raw material preparation in the friction stir welding process, and prepare a repaired secondary welding joint with high strength and small deformation.
3. The application can realize the high-efficiency and compact forming of the multi-form deep hole defects of the aluminum alloy, simultaneously realize the forming of the secondary welding joint with high strength and small deformation of the repaired rear super-thick plate, make up the technical situation that the deep hole defects of the structure of the aluminum alloy super-thick plate can only be removed or scrapped by machining, and lay a technological foundation for the research of butt joint welding of the aluminum alloy super-thick plate and deep hole defect repairing technology.
Drawings
Other features, objects and advantages of the present application will become more apparent upon reading of the detailed description of non-limiting embodiments, given with reference to the accompanying drawings in which:
FIG. 1 is a schematic diagram of a comparison of an integrated stirring tool and a back-suction stirring tool.
FIG. 2 is a schematic diagram of deep hole defects.
FIG. 3 is a schematic view of deep hole defect area cold spray and pre-connectorization.
Fig. 4 is a schematic diagram of a deep hole formal dual repair.
Detailed Description
The present application will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the present application, but are not intended to limit the application in any way. It should be noted that variations and modifications could be made by those skilled in the art without departing from the inventive concept. These are all within the scope of the present application.
The application provides an integrated welding method for repairing deep hole defects of an aluminum alloy thick plate, which can cause defects of deep holes and cracks of the thick plate due to broken pins in the friction stir welding process or unqualified raw material preparation. The application can repair deep hole defects of the aluminum alloy thick plate and realize high-strength and small-deformation forming of welding seams. Embodiments of the present application are described in conjunction with fig. 1, 2, 3 and 4. The specific technical process of the embodiment of the application specifically comprises the following steps:
(1) In the embodiment, the thickness of the 5A06 aluminum alloy plate is 60mm, the depth of the deep hole defect is 42mm, a single-sided repair mode is adopted, and the diameter of the actually measured deep hole is 30mm and is in a conical structure. The example is that two 5A06 aluminum alloy thick plates with the thickness of 60mm are broken by a stirring pin in the friction stir welding process, and the aluminum alloy plate in the example has a allowance of 100mm in the repairing direction, so that a fixed stirring tool is used for repairing, the edge of the plate of the spoon Kong Liuzai is subjected to the edge removal by a machining mode.
(2) And (3) polishing the deep hole defect area by adopting an angle grinder or a drill bit, and blowing off the surplus substances by using compressed air, wherein the flat surface of the hole is required to be smooth, and the surplus substances such as burrs, metal scraps and the like are avoided. Aiming at the defects caused by broken needle of the stirring needle in the friction stir welding process, the broken needle position is confirmed through the magnet, the discharging and digging are carried out, and the deep hole is polished after the stirring needle is discharged.
(3) And (3) carrying out cold spraying treatment on the cleaned deep hole defect area, adopting pure aluminum powder as a spraying medium aiming at the aluminum alloy thick plate, and controlling the powder feeding speed to be 5kg/h until the deep hole is sprayed to be 2-4mm higher than the plate in the thickness direction. Firstly spraying the bottom, then carrying out multilayer multi-channel spraying, after the spraying is finished, adopting a vernier caliper to measure the thickness, and continuing spraying if the thickness is less than 2mm, so that the defect that the repaired deep hole is loose due to insufficient added materials is avoided; if the thickness exceeds 4mm, the grinding is carried out to the required range, so that the defects that the stirring tool is damaged due to excessive spraying materials, slag inclusion is generated and the like are avoided.
Wherein, the powder feeding speed is controlled to be 5kg/h for deep hole defects with different depths, the bottom is sprayed firstly, then the multi-layer multi-channel spraying is carried out, after the spraying is finished, the vernier caliper is adopted for thickness measurement, and the requirement is 2-4mm higher than the plate. If the thickness is less than 2mm, spraying is continued, so that the defect that the repaired deep hole is loose and the like due to insufficient added materials is avoided; if the thickness exceeds 4mm, the grinding is carried out to the required range, so that the defects that the stirring tool is damaged due to excessive spraying materials, slag inclusion is generated and the like are avoided.
And after the process is finished, polishing the spraying area by adopting sand paper, cleaning redundant substances by adopting HT-2 degreasing agent, and waiting for welding. The interface area of the cold spraying and the base material is in a pre-connected state, and the spraying material is in a loose state in the state, so that densification is realized by means of subsequent procedures.
(4) Positioning the surface of the plate at the junction of the spraying repair area and the base metal by adopting TIG welding, and positioning welding spots at least at 3 or 4 positions; and generally, the diameter of the deep hole is smaller than 30mm, at least 3 positions are subjected to positioning welding, the diameter of the deep hole is 30mm-60mm, at least 4 positions are subjected to positioning welding, and at least 5 positions are required to be subjected to positioning welding when the diameter of the deep hole exceeds 60mm, so that preheating and pre-connection of spraying materials are realized. And an external heat source is applied by adopting positioning welding, so that the deep hole spraying material is preheated, the bottom area of the deep hole spraying material is heated, a temperature gradient is formed, and the follow-up procedure is facilitated. The pre-connection of the spraying material can be realized by the positioning welding, the situations that the spraying material is lost and the joint is formed incompact in the subsequent stirring friction process are avoided, the surface of the welded joint is polished after the welding is finished, the surface defect of the welded joint is repaired, and the slag inclusion defect is avoided in the subsequent stirring process. In the TIG welding process, the purity of argon and helium is not less than 99.99%, the residual pressure of bottled gas is not less than 0.5MPa, a tungsten electrode adopts a cerium tungsten electrode with the diameter of 1.6mm, and the height of the end part of the tungsten electrode from the outer surface of a to-be-welded part of a workpiece is 0.5-1 mm. The welding piece should be cleaned chemically or mechanically before welding to remove oxide film, greasy dirt, foreign matter, etc. on the joint butt joint surface and the inner and outer surfaces of the area around the welding area (the center of the welding line is +20 mm-30 mm). Argon is adopted for protection during welding, the air flow (10-12) L/min is protected, argon is pre-introduced before welding, the pre-introducing time is not less than 10s, the gas stopping is delayed after welding, and the delay time is not less than 10s.
(5) Spraying the deep hole to be repaired and the welding area of the plate by adopting a double-head parallel process and adopting a preposed cold spraying device, simultaneously welding by adopting a stirring head at the rear side, controlling the pressing-in amount to be 0.1-0.3mm, and welding by adopting a stirring tool at a welding dip angle of 3 degrees. According to different plate thicknesses, corresponding stirring tools and welding parameters are selected, and a back suction and fixed stirring friction mode is selected according to the specifications of the deep hole to be repaired. And after welding, removing burrs, and finishing deep hole repair and weld forming. The length of the stirring tool needle is 42.5mm, the rotation direction is clockwise, the rotation speed of the stirring tool is 250-350r/min, the welding speed is 40-60mm/min, the pressing-in amount is controlled to be 0.1-0.3mm, the stirring tool carries out stirring friction at an inclination angle of 3 degrees, the depth is 42mm, and single-sided repair is adopted. The spraying equipment controls the powder feeding rate to be 5kg/h, the pose inclination angle of the spraying tool to be 10 degrees, and the stirring inclination angle to be 3 degrees (the included angle with the vertical direction). In the repairing process, the filling material is completely subjected to the stirring friction effect, the stirring width can cover the defect width, only 1 stirring is carried out, and the repairing process needs to carry out gas cooling in the whole process. And removing burrs on the surface of the plate, and flattening the protruding surface from the central area to two sides until the thickness of the base material is consistent.
More specifically, the welding is realized by parallel operation of double-head equipment, the deep hole and welding seam materials are mainly filled by front-side equipment, the densification of the filling materials is realized by rear-side equipment, and the functions are realized by adjusting the pose and the advancing speed of the head. The double-sided repair and the single-sided repair are dependent on the hole depth to be repaired, the single-sided repair is adopted when the depth is smaller than 50mm, and the double-sided repair is adopted when the depth is 50-100mm, namely one side operation is carried out and then the other side operation is carried out. The spraying equipment controls the powder feeding speed to be 5kg/h, and the aluminum alloy plate adopts pure aluminum medium. The back-drawing type stirring tool and the fixed type stirring tool are selected according to the product requirement, the back-drawing type stirring tool is suitable for plates with no allowance in size, surface key holes cannot be left on the plates in the repairing process, the fixed type stirring tool is suitable for plates with allowance in size, the key holes generated in the repairing process are led to an area with allowance, and machining is adopted to finish removal.
(6) And after the spraying and stirring friction are finished, the keyhole area is machined and removed, and then the repair can be finished.
Wherein the thickness interval of the thick aluminum alloy plate is 30-100mm, and the deep hole and crack defects are hole defects and cracks with any form in the interval of 30-100 mm. When the thickness of the thick aluminum alloy plate and the depth of the deep hole are within the range of 30-50mm, a single-sided repairing mode can be adopted, and only the problem surface of the thick aluminum alloy plate needs to be repaired; when the thickness of the thick aluminum alloy plate and the depth of the deep hole are in the range of 50-100mm, a double-sided repairing mode is needed, and at the moment, the repairing of the two sides is needed to be completed respectively.
The machine head pose in the repairing process is that the spray tool dip angle is 10 degrees, and the stirring dip angle is 3 degrees (the included angle with the vertical direction). In the deep hole formal repair process, the distance between the stirring tool and the deep hole to be repaired is not less than 200mm, the fixed and back-pumping stirring tools are shown in fig. 1, the length of a specific stirring tool is determined according to the depth of the deep hole, and the depth of the hole is normal. If a fixed stirring tool is adopted, the rotation direction of the stirring head is clockwise (the screw thread is left-handed and the screw thread is right-handed, the rotation direction is reverse), the rotation speed of the stirring tool is 250-350r/min, the welding speed is 40-60mm/min, and the pressing-in amount is controlled to be 0.1-0.3mm. If a back-pumping type stirring tool is adopted, the rotation direction of the stirring head is anticlockwise (the screw thread is right-left-handed, the screw thread is left-handed, the rotation direction is reverse), the rotation speed of the stirring tool is 250-370r/min, the welding speed is 40-70mm/min, the pressing-in amount is controlled to be 0.1-0.3mm, back pumping is carried out after the deep hole is repaired, and the back pumping speed is 2mm/min. In the formal repair process of the deep hole, the filling material is required to be ensured to be completely subjected to the stirring friction, if the width of the deep hole is wider, multiple stirring friction can be carried out, and the repair process is required to be carried out gas cooling in the whole process. And removing burrs on the surface of the plate, and flattening the protruding surface from the central area to two sides until the thickness of the base material is consistent.
The present application will be described in more detail below with reference to one of the variations and preferred embodiments of the above embodiment.
The present embodiment is described with reference to fig. 1, 2, 3 and 4, and the specific process of the present embodiment is as follows, and specifically includes the following steps:
(1) In the embodiment, the thickness of the 5A06 aluminum alloy plate is 60mm, the depth of the deep hole defect is 33mm, a single-sided repair mode is adopted, and the diameter of the actually measured deep hole is 26mm and is in a conical structure. In the example, the aluminum alloy plate 5A06 has internal loose defects, the depth of the defect position in the example is 33mm, and machining allowance does not exist, so that the repair is carried out by adopting a back-pumping type stirring tool, and a machined keyhole cannot be generated in the repair process.
(2) And polishing the plane of the area to be repaired by adopting an angle grinder, and blowing off the surplus substances by using compressed air, wherein the plane is required to be flat, and the surplus substances such as burrs, metal scraps and the like are avoided. And (3) carrying out cold spraying treatment on the cleaned area, adopting pure aluminum powder as a spraying medium aiming at the aluminum alloy thick plate, and controlling the powder feeding speed to be 5kg/h until the spraying thickness direction is 2-4mm higher than the plane.
And after the process is finished, polishing the spraying area by adopting sand paper, cleaning redundant substances by adopting HT-2 degreasing agent, and waiting for welding. The interface area of the cold spraying and the base material is in a pre-connected state, and the spraying material is in a loose state in the state, so that densification is realized by means of subsequent procedures.
(4) And positioning the surface of the plate at the junction of the spraying repair area and the base metal by adopting TIG welding, and carrying out positioning welding at least at 3 positions. In the TIG welding process, the purity of argon and helium is not less than 99.99%, the residual pressure of bottled gas is not less than 0.5MPa, a tungsten electrode adopts a cerium tungsten electrode with the diameter of 1.6mm, and the height of the end part of the tungsten electrode from the outer surface of a to-be-welded part of a workpiece is 0.5-1 mm. The welding piece should be cleaned chemically or mechanically before welding to remove oxide film, greasy dirt, foreign matter, etc. on the joint butt joint surface and the inner and outer surfaces of the area around the welding area (the center of the welding line is +20 mm-30 mm). Argon is adopted for protection during welding, the air flow (10-12) L/min is protected, argon is pre-introduced before welding, the pre-introducing time is not less than 10s, the gas stopping is delayed after welding, and the delay time is not less than 10s.
(5) Spraying the deep hole to be repaired and the welding area of the plate by adopting a double-head parallel process, adopting a preposed cold spraying device, welding by adopting a stirring head at the rear side, wherein the length of a stirring tool needle is 33.5mm, adopting a back-pumping type stirring tool, wherein the rotation direction of the stirring head is anticlockwise (the screw thread is right-handed and the screw thread is left-handed and vice versa), the rotation speed of the stirring tool is 250-370r/min, the welding speed is 40-70mm/min, the pressing-in amount is controlled to be 0.1-0.3mm, and back pumping is performed after the deep hole is repaired, and the back pumping speed is 2mm/min. In the repairing process, the filling material is completely subjected to the stirring friction effect, the stirring width can cover the defect width, only 1 stirring is carried out, and the repairing process needs to carry out gas cooling in the whole process. And removing burrs on the surface of the plate, and flattening the protruding surface from the central area to two sides until the thickness of the base material is consistent.
The application realizes the integrated welding method for repairing the deep hole defects of the aluminum alloy super-thick plate, realizes the repair of the deep hole defects of the aluminum alloy thick plate and realizes the high-strength and small-deformation forming of welding lines by an integrated spraying and stirring friction technology. And (3) carrying out mechanical property test on the base material in the repair area, wherein the strength of the base material in the repair area is uniform, the tensile strength of the core part and the interface area exceeds 315MPa, and the base material area is broken. Analysis of fracture morphology shows that the enrichment of the ductile cast and the fracture stepped edges is generated in the fracture area, which shows that the bonding strength of the repair area is excellent. That is, the application can realize the reliable repair of deep hole defects with various forms of the aluminum alloy super-thick plate, the melting of the base metal is not generated in the repair process, the deformation of the base metal is small, and the repair efficiency is higher.
The application fills the blank of deep hole defect repairing technology of ultra-thick plate at present, compared with simple spraying technology, the cold spraying-stirring friction integrated welding technology can realize compact molding of base material in repairing area, and avoids incomplete combination of spraying material and matrix and loosening of filling material. The method can be specially used for repairing the deep holes of the ultra-thick plates in the actual engineering application process, avoids material waste caused by the original machining defect area, and can reserve more abundant engineering allowance.
In the description of the present application, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are merely for convenience in describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the present application.
The foregoing describes specific embodiments of the present application. It is to be understood that the application is not limited to the particular embodiments described above, and that various changes or modifications may be made by those skilled in the art within the scope of the appended claims without affecting the spirit of the application. The embodiments of the application and the features of the embodiments may be combined with each other arbitrarily without conflict.
Claims (10)
1. The integrated welding method for repairing the deep hole defects of the aluminum alloy thick plate is characterized by comprising the following steps of:
step S1: polishing the deep hole defect area, and blowing off surplus materials by using compressed air, wherein the flat surface of the hole is required to be smooth, and the surplus materials are not generated; the deep hole defects comprise hole defects and cracks in the interval of 30-100mm; the thickness interval of the thick aluminum alloy plate is 30-100mm;
step S2: carrying out cold spraying treatment on the deep hole defect area after finishing polishing and cleaning;
step S3: positioning the surface of the plate at the junction of the spraying repair area and the base metal by adopting TIG welding;
step S4: spraying the to-be-repaired area and the welding area of the deep hole of the plate by adopting front side cold spraying equipment, and simultaneously welding by adopting rear side friction stir welding equipment; and after welding, removing burrs, and finishing deep hole repair and weld forming.
2. The integrated welding method for repairing deep hole defects of an aluminum alloy thick plate according to claim 1, wherein regarding defects caused by broken pins of a stirring pin in the friction stir welding process, broken pins are confirmed through a magnet, excavation is carried out, and polishing treatment is carried out on a deep hole defect area after the stirring pin is excavated.
3. The aluminum alloy thick plate deep hole defect repair integrated welding method according to claim 2, wherein in the step S2:
firstly spraying the bottom of a deep hole, then carrying out multilayer and multi-channel spraying, after the spraying is finished, adopting a vernier caliper to measure the thickness, and continuing spraying if the thickness is less than 2 mm; if the thickness exceeds 4mm, polishing to a required range; after finishing, polishing the spraying area by adopting sand paper, cleaning redundant substances by adopting HT-2 degreasing agent, and waiting for welding; the interface area of the cold spraying and the base material is in a pre-connected state, and the spraying material is in a loose state in the state, so that densification is realized by means of subsequent procedures.
4. The aluminum alloy thick plate deep hole defect repair integrated welding method according to claim 1, wherein in the step S2:
pure aluminum powder is used as a spraying medium, and the powder feeding speed is controlled to be 5kg/h until deep holes are sprayed to be 2-4mm higher than the plate in the thickness direction.
5. The aluminum alloy thick plate deep hole defect repair integrated welding method according to claim 1, wherein in the step S3:
and carrying out the positioning welding of at least 3 positions with the diameter of the deep hole smaller than 30mm, carrying out the positioning welding of at least 4 positions with the diameter of the deep hole between 30mm and 60mm, and carrying out the positioning welding of at least 5 positions with the diameter of the deep hole exceeding 60mm, thereby realizing the preheating and the pre-connection of the spraying material.
6. The aluminum alloy thick plate deep hole defect repair integrated welding method according to claim 1, wherein in the step S3:
an external heat source is applied by adopting positioning welding, so that the deep hole spraying material is preheated, and the bottom area of the deep hole spraying material is heated to form a temperature gradient;
polishing the surface of the welding spot after the welding is finished, and repairing the surface defect of the welding spot;
in the TIG welding process, the purity of argon and helium is not less than 99.99%, the residual pressure of bottled gas is not less than 0.5MPa, a tungsten electrode adopts a cerium tungsten electrode with the diameter of 1.6mm, and the height of the end part of the tungsten electrode from the outer surface of a to-be-welded part of a workpiece is 0.5-1 mm.
7. The aluminum alloy thick plate deep hole defect repair integrated welding method according to claim 1, wherein in the step S4:
the filling material is completely subjected to the stirring friction effect, the stirring width covers the defect width, only one stirring is carried out, and the repairing process needs to carry out gas cooling in the whole process; removing burrs on the surface of the plate, and flattening the protruding surface from the central area to two sides until the thickness of the base material is consistent;
filling of deep holes and welding line materials is achieved through front side cold spraying equipment, and densification of filling materials is achieved through rear side friction stir welding equipment.
8. The integrated welding method for repairing deep hole defects of an aluminum alloy thick plate according to claim 1, wherein the deep hole defects are repaired by a single surface when the depth of the deep hole defects is smaller than 50mm, and the deep hole defects are repaired by a double surface when the depth of the deep hole defects is 50-100mm, namely one surface operation is performed and then the other surface operation is performed.
9. The integrated welding method for repairing deep hole defects of an aluminum alloy thick plate according to claim 1, wherein a back-pumping type stirring tool or a fixed type stirring tool is adopted;
the back-drawing stirring tool is suitable for the plate size without allowance, and a surface keyhole is not left on the plate in the repairing process;
the fixed stirring tool is suitable for plates with allowance, key holes generated in the repairing process are led to an area with allowance, and machining is adopted to finish removal.
10. The aluminum alloy thick plate deep hole defect repair integrated welding method according to claim 1, further comprising:
step S5: and after the spraying and stirring friction are finished, machining to remove the keyhole area, and finishing the repair.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117840590A (en) * | 2024-03-07 | 2024-04-09 | 成都天成电科科技有限公司 | Method for protecting inner cavity chip during laser re-welding and laser re-welding system |
| CN117840590B (en) * | 2024-03-07 | 2024-06-04 | 成都天成电科科技有限公司 | Method for protecting inner cavity chip during laser re-welding and laser re-welding system |
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2023
- 2023-10-26 CN CN202311404152.3A patent/CN117182449A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117840590A (en) * | 2024-03-07 | 2024-04-09 | 成都天成电科科技有限公司 | Method for protecting inner cavity chip during laser re-welding and laser re-welding system |
| CN117840590B (en) * | 2024-03-07 | 2024-06-04 | 成都天成电科科技有限公司 | Method for protecting inner cavity chip during laser re-welding and laser re-welding system |
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