CN117961441A - Manufacturing method of large liquid rocket secondary engine spray pipe extension section - Google Patents
Manufacturing method of large liquid rocket secondary engine spray pipe extension section Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 29
- 239000007921 spray Substances 0.000 title claims abstract description 28
- 239000007788 liquid Substances 0.000 title claims abstract description 25
- 238000003466 welding Methods 0.000 claims abstract description 99
- 241000219112 Cucumis Species 0.000 claims abstract description 66
- 235000015510 Cucumis melo subsp melo Nutrition 0.000 claims abstract description 66
- FJJCIZWZNKZHII-UHFFFAOYSA-N [4,6-bis(cyanoamino)-1,3,5-triazin-2-yl]cyanamide Chemical compound N#CNC1=NC(NC#N)=NC(NC#N)=N1 FJJCIZWZNKZHII-UHFFFAOYSA-N 0.000 claims abstract description 66
- 238000000034 method Methods 0.000 claims abstract description 49
- 238000012937 correction Methods 0.000 claims abstract description 8
- 238000012545 processing Methods 0.000 claims abstract description 7
- 239000000463 material Substances 0.000 claims description 23
- 239000002994 raw material Substances 0.000 claims description 22
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 18
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 11
- 229910052786 argon Inorganic materials 0.000 claims description 9
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- 238000010438 heat treatment Methods 0.000 claims description 7
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- 230000001681 protective effect Effects 0.000 claims description 4
- IADRPEYPEFONML-UHFFFAOYSA-N [Ce].[W] Chemical compound [Ce].[W] IADRPEYPEFONML-UHFFFAOYSA-N 0.000 claims description 3
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- 229910052751 metal Inorganic materials 0.000 abstract description 7
- 229910045601 alloy Inorganic materials 0.000 description 8
- 239000000956 alloy Substances 0.000 description 8
- 210000001503 joint Anatomy 0.000 description 5
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 4
- 229910001018 Cast iron Inorganic materials 0.000 description 3
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- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 2
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- 239000010937 tungsten Substances 0.000 description 2
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- 238000010146 3D printing Methods 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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Abstract
The invention relates to the technical field of liquid rocket engine jet pipes, and discloses a manufacturing method of a large liquid rocket secondary engine jet pipe extension section, which is characterized in that the extension section is divided into n sections of barrel bodies according to the size of a plate and the extensibility of the plate, and the barrel bodies are uniformly divided into m melon segments and are manufactured in a splice welding mode; the number n of the sections of the cylinder body ensures that the number of circumferential weld joints of the extension section is minimum, and the welding of the circumferential weld joints is avoided to the greatest extent; the cylinder body of the extension section is obtained by performing stress relaxation thermal correction treatment on the preformed cylinder body, and the problem that welding deformation is uncontrollable is solved. The invention solves the problem that the contour tolerance of the inner surface of the extension section of the spray pipe is difficult to ensure due to uncontrollable deformation caused by rebound of sheet metal forming in block welding, improves the welding quality, reduces the rejection rate and the production cost of finished products, improves the production efficiency, has wide application prospect, and can finish processing any large-diameter thin-wall product according to the method.
Description
Technical Field
The invention relates to the technical field of liquid rocket engine spray pipes, in particular to a manufacturing method of a large liquid rocket secondary engine spray pipe extension section.
Background
In a liquid rocket propulsion system, an engine nozzle is a key component of a rocket engine and is an important device for energy conversion, wherein an extension section mainly plays a role in accelerating high-temperature fuel gas and generating thrust and is an important component of the engine nozzle. The shape of the extension section of the spray pipe is a bell jar, the inner profile of the extension section is a parameter curved surface, and the profile of the curved surface is directly related to the vacuum specific impact performance of the engine. The use condition of the secondary engine is a vacuum environment, and when the engine works in vacuum, the larger the area ratio of the spray pipe is, the higher the ratio is, so that the diameter of the large end of the spray pipe extension section of the large liquid rocket secondary engine is generally more than 3000mm, the height is about 3200mm, the wall thickness is generally less than 1mm, and the large liquid rocket secondary engine belongs to large-size and thin-wall parts.
The existing spray pipe extension section processing method mainly comprises two methods, namely, adopting a 3D (three-dimensional) printing technology, taking a digital model file as a basis, and constructing a spray pipe extension section by adopting powdered metal in a layer-by-layer printing mode; secondly, the spray pipe is manufactured by adopting a block welding mode, the spray pipe extension section is split into a plurality of small blocks, each small block is formed by adopting a sheet metal roll bending mode, and then the small blocks are welded integrally into a whole.
The quality control of the secondary rocket is very strict, the integral quality control of the corresponding secondary engine is also very strict, and the temperature of the engine is high when the engine works and can reach 3000 ℃ at most. Therefore, the following problems exist with the 3D stereoscopic printing technique: firstly, alloy powder is used as a raw material, the overall strength is insufficient, the thickness of a spray pipe needs to be increased to ensure enough strength, and the requirement that the wall thickness is lower than 1mm cannot be met; secondly, the 3D printing technology is adopted, and the adhesive is required to be added, so that the high temperature resistance of the jet pipe cannot meet the requirement, cooling is required to be added to the extension section of the jet pipe, the production cost and the energy consumption are increased, and the scheme is suitable for manufacturing the rocket primary engine jet pipe with relatively loose load requirements, and the secondary engine jet pipe is not suitable for use. By adopting the technical scheme of block splice welding, the parts can rebound after sheet metal forming, the splice welding procedure after part forming has the welding of longitudinal seams and circumferential seams, the welding is complex, the welding deformation is difficult to control, the tolerance requirement of the profile of the inner profile is difficult to ensure, the sheet material for manufacturing the extension section of the spray pipe is a high-temperature alloy sheet, and the shape correction is difficult, so that the rejection possibility of the finished product due to the tolerance of the profile of the inner profile of the extension section is very high.
Disclosure of Invention
In view of the above, the invention provides a method for manufacturing a jet pipe extension section of a large liquid rocket secondary engine, which solves the problem that the contour tolerance of the inner surface of the jet pipe extension section is difficult to guarantee due to uncontrollable deformation caused by sheet metal molding rebound in block welding, improves welding quality, reduces finished product rejection rate and production cost, and improves production efficiency.
In order to solve the technical problems, the technical scheme provided by the invention is as follows: a manufacturing method of a large liquid rocket secondary engine spray pipe extension section comprises the following steps:
Step 1, an extension section model is established, the extension section model is divided into n sections of cylinders (n is an integer and is more than or equal to 2) along the axial direction of the model, the cylinders are radially and uniformly scaled down to obtain a preformed cylinder, and the uniformly scaled down scaling is that the cylinder is subjected to preformed cylinder=1: (0.995-0.999); dividing the preformed cylinder into m melon segments (m is an integer and is equal to or more than 2), and expanding the melon segments to obtain a melon segment expanding surface; the number of sections n of the cylinder and the number of blocks m of the melon segments are determined according to the size of the raw material plate, and the number of sections n of the cylinder ensures that the number of circumferential weld joints of the extension section is minimum;
Step 2, cutting a raw material plate according to the melon segment unfolding surface obtained in the step 1 to obtain a melon segment forming base material, and processing the melon segment forming base material according to the size and the cross-section profile of the melon segment obtained in the step 1 to obtain the melon segment obtained in the step 1;
Step3, preparing m melon segments according to the step2, and longitudinally welding the m melon segments to obtain the preformed cylinder in the step 1;
Step 4, performing stress relaxation thermal correction treatment on the preformed cylinder body prepared in the step 3 to obtain the cylinder body in the step 1; the stress relaxation thermal correction treatment comprises the steps of firstly assembling the preformed cylinder prepared in the step 3 onto a bulging die at normal temperature and locking, then placing the preformed cylinder together with the bulging die in a heating furnace, heating to the stress-removing temperature of the raw material plate, preserving heat at the stress-removing temperature, and then cooling to below 200 ℃ along with the furnace for air cooling to obtain a piece; the heat preservation time of the preformed cylinder and the bulging die at the stress-relieving temperature is determined according to the material and the thickness of the raw material plate, for example, the raw material plate used in the embodiment of the invention is a GH3128 high-temperature alloy thin plate, the wall thickness is 0.8mm, and the heat preservation time is 3-4 h;
And 5, preparing n sections of cylinders according to the methods from step 2 to step4, and performing circumferential splice welding on the n sections of cylinders to obtain the spray pipe extension section.
Further, the method for processing the melon flake forming substrate in the step 2 is room temperature stretch forming and water cutting.
Furthermore, in the step 3, the melon segments are welded by adopting an automatic laser welding system, and the welding process is finished by adopting an industrial robot to control movement.
Furthermore, in the step 3, the melon segments are subjected to surface oxide removal treatment and then subjected to splice welding.
The method for removing the surface oxide comprises the steps of firstly cleaning and removing greasy dirt on the surface of the melon petals by using solvents such as acetone or alcohol, then corroding and removing the oxide by using an acidic solution, wherein the temperature of the acidic solution is controlled to be 45-60 ℃, the corrosion time is 90-150 min, flushing by using cold water after corrosion, neutralizing by using an alkaline solution, the temperature of the alkaline solution is less than or equal to 80 ℃, the neutralization time is 1-3 min, flushing by using cold water after neutralization, drying or airing, then carrying out dehydrogenation treatment, and the dehydrogenation temperature is 180-250 ℃ for 120min.
Further, the actual size of the profile of the outer surface of the expansion die after the pre-formed cylinder is assembled in the step 4 is slightly smaller than the size of the cylinder in the step 1, the size difference is the volume expansion difference between the pre-formed cylinder and the expansion die at the stress relief temperature, the difference can be obtained through calculation of the volume expansion coefficients of two materials, and therefore the linear expansion coefficient of the raw material for preparing the expansion die is larger than that of the raw material plate for preparing the pre-formed cylinder, so that the expansion die can be heated and expanded to the theoretical size of the inner surface of the cylinder at the stress relief temperature of the pre-formed cylinder, and the pre-formed cylinder is expanded into the cylinder in the step 1.
Furthermore, in the step 5, the welding of the cylinder is performed by adopting a manual positioning welding combined with an automatic argon arc welding system.
Furthermore, the manual positioning welding method is to symmetrically weld eight positioning points, wherein the eight positioning points are uniformly distributed on the circumference, and the length of the positioning spot welding seam is 10-15 mm.
Furthermore, the automatic laser welding system or the automatic argon arc welding system adopts a mode of not adding welding wires to weld, adopts high-purity argon with the purity more than or equal to 99.99% as protective gas, and adopts cerium tungsten wires as electrodes.
Further, the n sections of cylinders in the step 5 are subjected to turning of circumferential allowance before the splice welding so as to adapt to the circumference of each cylinder.
Compared with the prior art, the manufacturing method of the jet pipe extension section provided by the invention comprehensively considers the plate extensibility according to the maximum size of the plate (the standard plate width of the high-temperature alloy thin plate is 1000mm multiplied by 2200mm and the thickness of the high-temperature alloy thin plate is 0.8 mm) provided by a raw material manufacturer, the extension section is divided into n sections of cylinders, the cylinders are divided into m melon segments, the jet pipe extension section is prepared in a splice welding mode, the problem that the raw material plate size cannot meet the preparation of the jet pipe extension section of a large-scale liquid rocket engine is solved, the number n of the cylinders and the number m of melon segments are determined according to the size of the raw material plate, the number n of the cylinders ensures the number of circumferential welds of the extension section to be the minimum, the welding of the circumferential welds is avoided to the greatest extent, and the welding process difficulty of the circumferential welds is greater than that of the melon segments is the longitudinal welds, and the welding deformation problem of the circumferential welds cannot be avoided, and the longitudinal welds of the melon segments can overcome the welding deformation problem through stress relaxation thermal correction treatment; according to the process method, the problem that welding deformation of direct splice welding forming of a plurality of plates is uncontrollable is solved, the problem of rebound after sheet metal forming is effectively solved by adopting a method of removing stress along with a furnace by adopting a bulging die, and meanwhile, the problem that contour tolerance of the inner surface of an extension section of a spray pipe is difficult to guarantee is solved; the problem of the circumferential allowance turning procedure added after the forming of the extension section cylinder body is effectively solved, so that the circumferential allowance welding adaptation circumference of the extension section cylinder body is controllable, and the circumferential allowance turning procedure can better ensure the circumferential allowance welding quality.
The manufacturing method of the spray pipe extension section provided by the invention adopts the existing equipment and plates to process, the processing method is the existing conventional sheet metal, machining and welding processes, all processing links are controllable, the problem that the contour tolerance of the inner surface of the spray pipe extension section is difficult to guarantee due to uncontrollable deformation caused by sheet metal forming rebound in block welding is solved, the welding quality is improved, the rejection rate and the production cost of finished products are reduced, the production efficiency is improved, the method has wide application prospect, and any large-diameter thin-wall product can be processed according to the method.
Drawings
FIG. 1 is a schematic illustration of the profile of a nozzle extension made in accordance with an embodiment of the present invention;
FIG. 2 is a schematic illustration of a segment of a nozzle extension according to an embodiment of the present invention;
FIG. 3 is a schematic view of a preformed cylinder corresponding to a front-end cylinder according to an embodiment of the present invention;
FIG. 4 is a schematic view of the melon petals of FIG. 3;
fig. 5 is an expanded view of the melon petals of fig. 4.
Legend description:
1-a spray pipe extension section; 11-a front section cylinder; 12-a rear section cylinder; 2-preforming a cylinder; 21-melon pieces; 3-melon petal forming base material.
Detailed Description
In order to make the technical scheme of the present invention better understood by those skilled in the art, the present invention will be further described in detail with reference to the detailed description and the accompanying drawings.
Referring to fig. 1, the external shape of a jet pipe extension section 1 of a large liquid rocket secondary engine is a bell jar, the diameter of the large end of the jet pipe extension section is generally more than 3000mm, the height of the jet pipe extension section is about 3200mm, the wall thickness of the jet pipe extension section is generally less than 1mm, and the jet pipe extension section belongs to large-size and thin-wall parts. The following examples used GH3128 superalloy sheets (sheet material meeting GB/T14996-2010 superalloy cold rolled sheet standard) with solution treated wall thickness of 0.8mm, sheet width 1000mm x 2200mm to prepare jet pipe extension sections (large end diameter 3100mm, height 3200mm, wall thickness 0.8 mm) for large liquid rocket secondary engines.
Examples: a manufacturing method of a large liquid rocket secondary engine spray pipe extension section comprises the following steps:
Step 1, an extension section model is established, the extension section model is divided into n sections of cylinders (n is an integer and is more than or equal to 2) along the axial direction of the model, each section of cylinder is reduced in an equal proportion along the radial direction to obtain a preformed cylinder corresponding to each section of cylinder, the preformed cylinder is uniformly divided into m melon petals (m is an integer and is more than or equal to 2), and the melon petals are unfolded to obtain melon petal unfolding surfaces; the scaling-down ratio of the equal-ratio scaling-down is barrel:preformed barrel=1: (0.995-0.999); the number of sections n of the cylinder and the number of blocks m of the melon segments are determined according to the size of the raw material plate, and the number of sections n of the cylinder ensures that the number of circumferential weld joints of the extension section is minimum;
In this embodiment, referring to fig. 2, the extension section model is divided into two sections of cylinders, including a front section cylinder 11 and a rear section cylinder 12, where the front section cylinder 11 is scaled down in equal proportion according to a scaling-down ratio of 1:0.995 to obtain a corresponding preformed cylinder, and the rear section cylinder 12 is scaled down in equal proportion according to a scaling-down ratio of 1:0.999 to obtain a corresponding preformed cylinder;
Fig. 3 is a schematic structural view of the preform cylinder 2 corresponding to the front-stage cylinder 11, and fig. 3 shows that the preform cylinder 2 is equally divided into ten melon pieces 21, fig. 4 is a schematic outline of the melon pieces, and fig. 5 is a schematic development of the melon pieces.
Step 2, cutting a raw material plate according to the outline (such as shown in fig. 5) of the melon segment expansion surface obtained in the step 1 to obtain a melon segment forming base material, and processing the melon segment forming base material according to the size and the section outline of the melon segment in the step 1 to obtain the melon segment in the step 1, wherein the processing method adopts a room temperature stretch forming process for forming and water cutting to remove the stretch forming blank holder;
In the embodiment, the melon segment forming base material is processed by adopting a room temperature stretch forming process, specifically, the unilateral size of the melon segment forming base material is that the unilateral size of a melon segment unfolding surface is added with a stretch forming blank holder of 30-50 mm, wherein the upper end surface and the lower end surface are respectively added with a vehicle allowance of 30-50 mm, and after the melon segment forming base material is subjected to room temperature stretch forming, the water cutting is performed to remove the stretch forming blank holder to obtain the melon segment.
Step 3, preparing m melon segments according to the step 2, and longitudinally welding the m melon segments to obtain the preformed cylinder in the step 1; preferably, the melon petals are subjected to surface oxide removal prior to tailor welding. In this embodiment, referring to fig. 3 to 5, ten melon petals 21 are longitudinally splice welded to obtain a preformed cylinder 2 corresponding to the anterior cylinder 11.
Step 4, performing stress relaxation thermal correction treatment on the preformed cylinder body prepared in the step 3 to obtain the cylinder body in the step 1; the stress relaxation thermal shaping treatment is that the preformed cylinder body prepared in the step 3 is assembled and locked on a bulging die at normal temperature, then the preformed cylinder body is placed in a heating furnace together with the bulging die, heated to the stress relieving temperature of the raw material plate (the stress relieving temperature of the GH3128 high-temperature alloy sheet is 850+/-10 ℃), kept at the stress relieving temperature for 3-4 hours, cooled to below 200 ℃ along with the furnace, and then air-cooled for taking out.
In this embodiment, the expansion mold is made of the ball-milled cast iron, and the linear expansion coefficient of the raw material (ball-milled cast iron) for making the expansion mold is larger than that of the raw material plate (GH 3128 superalloy thin plate) for making the preformed cylinder, so that the expansion mold can be ensured to be thermally expanded to the theoretical size of the inner profile of the cylinder at the stress-relieving temperature of the preformed cylinder.
And 5, preparing n sections of cylinders according to the methods from step 2 to step 4, and performing circumferential splice welding on the n sections of cylinders to obtain the spray pipe extension section. In this embodiment, referring to fig. 2, the front section cylinder 11 and the rear section cylinder 12 are welded together in the circumferential direction to obtain the nozzle extension shown in fig. 1.
The specific working procedure is as follows:
1. and purchasing the plates meeting the requirements, wherein the plates are subjected to solution treatment.
2. Cutting a plate into a trapezoid plate according to the process requirement size of a corresponding cylinder by adopting laser cutting, wherein the trapezoid plate is a melon petal-shaped base material (the confirmation of the process size of the trapezoid plate is obtained through theoretical calculation, the front-stage cylinder 11 is scaled down according to the scaling of 1:0.995 to obtain a preformed cylinder corresponding to the trapezoid plate, the rear-stage cylinder 12 is scaled down according to the scaling of 1:0.999 to obtain a preformed cylinder corresponding to the preformed cylinder, the deformation of the preformed cylinder is required to be between 5% and 8%, and the ratio of the elongation of the preformed cylinder to raw materials is 12% to 20%).
3. And (3) stretching the trapezoid sheet material by adopting a room temperature stretching forming process, and then cutting the trapezoid sheet material with water to obtain the melon petals by the allowance of edge pressing.
4. Chemically cleaning melon petals to remove oxides on the surface of the alloy; specifically, acetone or alcohol and other solvents are used for cleaning and removing greasy dirt on the surfaces of melon petals, then an acidic solution is used for corrosion and oxide removal, the temperature of the solution is controlled to be 45-60 ℃, the corrosion time is controlled to be 90-150 min (according to the thickness of the plate), cold water is used for washing after corrosion is finished, then an alkaline solution is used for neutralization, the temperature of the solution is 80 ℃ and the neutralization time is 1-3 min, cold water is used for washing after neutralization is finished, and then the melon petals are dried or aired, and then dehydrogenation treatment is carried out, wherein the dehydrogenation temperature is 180-250 ℃ and the dehydrogenation time is 120min.
5. Longitudinally splicing and welding melon petals into preformed cylinders corresponding to each section of cylinder by adopting an automatic laser welding system; specifically, the melon petals are assembled on a longitudinal seam welding tool, the longitudinal seam edges of the melon petals are aligned with the center of a welding leakage backing plate, a butt welding joint is tightly matched, local gaps of the joint are allowed, the gap amount is no more than 0.1mm, the joint is allowed to be locally misplaced, the misplaced amount is required to be no more than 10% of the thickness of a base material, an automatic laser welding system is adopted for welding after the assembly is in place, the welding process is finished by adopting an industrial robot to control movement, and the whole longitudinal seam welding of the preformed cylinder body is finished according to the requirements. The laser power adopted by the invention is 800W, welding is carried out in a mode of not adding welding wires, and high-purity argon (the purity is more than or equal to 99.99%) is adopted as protective gas.
Trimming the welding line to eliminate surface defects; performing 100% X-ray inspection on a longitudinal welding line of the preformed cylinder, wherein the internal quality of the welding line meets the requirements of a QJ 20693-2018I grade welding line; and polishing the inner surface of the preformed cylinder body to ensure that the back rest height of the longitudinal seam of the preformed cylinder body is flush with the base material, and smoothly transiting the edge of the welding seam to the base material, so that the base material is required to be damaged.
6. And assembling and locking the polished preformed cylinder body on a corresponding ball-milling cast iron bulging die, then placing the preformed cylinder body in a heating furnace together with the bulging die, heating to 850+/-10 ℃, preserving heat for 3-4 hours at the temperature, and then cooling to below 200 ℃ along with the furnace to obtain the piece through air cooling. 7. Turning the circumferential allowance of the extension section cylinder, requiring 2 extension section cylinders to be matched and turned, and adapting to the outer circumference;
and after the cylinder is machined, detecting the profile contour and roundness of the butt joint end face in the cylinder by adopting a profile detection template and a laser tracker.
8. Assembling a base and a central shaft of a circular seam welding tool for the extension section of the spray pipe to circular seam automatic welding equipment, wherein the perpendicularity between the central shaft and the base is required to be 0.1mm;
Assembling a circular seam inner support piston ring for assembly welding of the rear section and the front section of the extension section on a central shaft of a welding tool, wherein the perpendicularity of the inner support piston ring and the central shaft is required to be 0.1mm, and the coaxiality of the inner support piston ring and a base is required to be phi 0.1mm;
Placing the inner supporting piston ring in a contracted state, assembling the rear section cylinder of the extension section to a welding tool, and adjusting the position of the inner supporting piston ring to ensure that the welding edge of the rear Duan Tongti of the extension section is placed at the center of a piston ring welding leakage backing plate; assembling a front section internal support framework tool to a central shaft, requiring the perpendicularity of the framework tool and the central shaft to be 0.1mm, and assembling an extension section front section cylinder body to a welding tool;
the inner supporting piston ring is pressurized and spread, the piston ring position is adjusted according to the assembly condition of the front section cylinder body and the rear section cylinder body of the extension section, the butt joint formed by the rear section and the front section of the extension section is tightly matched, the local clearance of the joint is allowed, the clearance is no more than 0.1mm, the local dislocation is allowed, the dislocation height is not allowed to exceed 10% of the thickness of a base material, the total length of the local dislocation is not more than 15% of the total length of a welding line, and the welding external pressure tool is assembled to the butt joint of the two cylinder sections and is pressed.
9. The assembled two-section extension section cylinder body is subjected to manual positioning welding, direct current is adopted as a welding power supply, 8 points are positioned and uniformly distributed on the circumference, the length of a welding line is 10-15 mm, the welding sequence is required to be symmetrically welded, the width and the residual height of the positioning welding line are not more than 75% of the corresponding size of the welding line, HGH3128 high-temperature alloy welding wires (conforming to GJB 2612-1996 standard) are adopted as welding wires for positioning welding, high-purity argon (with purity more than or equal to 99.99%) is adopted as protective gas, cerium tungsten wires are adopted as electrodes, the end parts of tungsten electrodes are ground into flat-head cones, and the flat-head diameter is about 1/3 tungsten electrode diameter.
And carrying out girth welding on the extension section cylinder body subjected to the positioning welding by adopting girth automatic argon arc welding equipment, wherein the girth welding adopts a mode of not adding welding wires.
10. Trimming the welding line to eliminate surface defects; and (3) carrying out 100% X-ray inspection on the circumferential weld of the extension section of the spray pipe, wherein the internal quality of the weld meets the requirements of QJ1842-1990 grade I weld.
11. And polishing the inner surface of the extension section of the spray pipe, ensuring that the back residual height of the girth weld is flush with the base metal, and smoothly transiting the edge of the weld to the base metal, wherein the base metal is required to be not damaged.
12. When the tool and the part are assembled, a laser tracker is adopted to detect the position degree of the tool and the size and position degree of the assembled part, and all the sizes are qualified and can be welded; and after welding, detecting the profile of the inner and outer surfaces under the conditions that the outer pressing tool, the inner supporting framework and the piston ring are detached and kept in a tightly supporting state.
Through detection, the contour tolerance of the inner surface and the outer surface of the spray pipe extension section manufactured by adopting the manufacturing method reach the design requirement.
While the fundamental and principal features of the invention and advantages of the invention have been shown and described, it will be apparent to those skilled in the art that the invention is not limited to the details of the foregoing exemplary embodiments, but may be embodied in other specific forms without departing from the spirit or essential characteristics thereof; the present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (10)
1. A manufacturing method of a large liquid rocket secondary engine spray pipe extension section is characterized by comprising the following steps of: the method comprises the following steps:
Step 1, an extension section model is established, the extension section model is divided into n sections of cylinders (n is an integer and is more than or equal to 2) along the axial direction of the model, the cylinders are radially and uniformly scaled down to obtain a preformed cylinder, and the uniformly scaled down scaling is that the cylinder is subjected to preformed cylinder=1: (0.995-0.999); dividing the preformed cylinder into m melon segments (m is an integer and is equal to or more than 2), and expanding the melon segments to obtain a melon segment expanding surface; the number of sections n of the cylinder and the number of blocks m of the melon segments are determined according to the size of the raw material plate, and the number of sections n of the cylinder ensures that the number of circumferential weld joints of the extension section is minimum;
Step 2, cutting a raw material plate according to the melon segment unfolding surface obtained in the step 1 to obtain a melon segment forming base material, and processing the melon segment forming base material according to the size and the cross-section profile of the melon segment obtained in the step 1 to obtain the melon segment obtained in the step 1;
Step3, preparing m melon segments according to the step2, and longitudinally welding the m melon segments to obtain the preformed cylinder in the step 1;
Step 4, performing stress relaxation thermal correction treatment on the preformed cylinder body prepared in the step 3 to obtain the cylinder body in the step 1; the stress relaxation thermal correction treatment comprises the steps of firstly assembling the preformed cylinder prepared in the step 3 onto a bulging die at normal temperature and locking, then placing the preformed cylinder together with the bulging die in a heating furnace, heating to the stress-removing temperature of the raw material plate, preserving heat at the stress-removing temperature, and then cooling to below 200 ℃ along with the furnace for air cooling to obtain a piece;
And 5, preparing n sections of cylinders according to the methods from step 2 to step4, and performing circumferential splice welding on the n sections of cylinders to obtain the spray pipe extension section.
2. The method for manufacturing the large liquid rocket secondary engine nozzle extension section according to claim 1, wherein the method comprises the following steps: the method for processing the melon petal-shaped base material in the step 2 comprises room temperature stretch forming and water cutting.
3. The method for manufacturing the large liquid rocket secondary engine nozzle extension section according to claim 1, wherein the method comprises the following steps: and in the step 3, the longitudinal splice welding of the m melon segments is performed by adopting an automatic laser welding system.
4. The method for manufacturing the large liquid rocket secondary engine nozzle extension section according to claim 1, wherein the method comprises the following steps: and in the step3, the melon segments are subjected to surface oxide removal treatment and then subjected to splice welding.
5. The method for manufacturing the large liquid rocket secondary engine nozzle extension section according to claim 4, wherein the method comprises the following steps: the method for removing the surface oxide comprises the steps of firstly removing greasy dirt on the surface of melon petals, then corroding and removing the oxide by using an acid solution, controlling the temperature of the acid solution to be 45-60 ℃ and the corrosion time to be 90-150 min, flushing by using cold water after corrosion, neutralizing by using an alkaline solution, wherein the temperature of the alkaline solution is less than or equal to 80 ℃ and the neutralization time is 1-3 min, flushing by using cold water after neutralization, drying or airing, and then carrying out dehydrogenation treatment, wherein the dehydrogenation temperature is 180-250 ℃ and the time is 120min.
6. The method for manufacturing the large liquid rocket secondary engine nozzle extension section according to claim 1, wherein the method comprises the following steps: the linear expansion coefficient of the raw material for preparing the bulging die is larger than that of the raw material plate for preparing the preformed cylinder.
7. The method for manufacturing the large liquid rocket secondary engine nozzle extension section according to claim 1, wherein the method comprises the following steps: in the step 5, the circumferential welding of the n sections of cylinders is performed by adopting a manual positioning welding combined with an automatic argon arc welding system.
8. The method for manufacturing the large liquid rocket secondary engine nozzle extension section according to claim 7, wherein the method comprises the following steps: the manual positioning welding method is to position eight positioning points for symmetrically welding, wherein the eight positioning points are uniformly distributed on the circumference, and the length of a positioning spot welding seam is 10-15 mm.
9. A method of manufacturing a large liquid rocket secondary engine nozzle extension according to claim 3 or 7, wherein: the automatic laser welding system or the automatic argon arc welding system adopts a mode of not adding welding wires to weld, adopts high-purity argon with the purity more than or equal to 99.99% as protective gas, and adopts cerium tungsten wires as electrodes.
10. The method for manufacturing the large liquid rocket secondary engine nozzle extension section according to claim 1, wherein the method comprises the following steps: and (5) turning the circumferential allowance of the n sections of cylinders in the step (5) before welding so as to adapt to the circumference of each cylinder.
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