CN1939645B - 一种用于制造复合材料的工艺 - Google Patents

一种用于制造复合材料的工艺 Download PDF

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CN1939645B
CN1939645B CN2006101444274A CN200610144427A CN1939645B CN 1939645 B CN1939645 B CN 1939645B CN 2006101444274 A CN2006101444274 A CN 2006101444274A CN 200610144427 A CN200610144427 A CN 200610144427A CN 1939645 B CN1939645 B CN 1939645B
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copper
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welding
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CN1939645A (zh
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B·舍德勒
Th·胡贝尔
Th·弗里德里希
K·沙伊贝尔
D·舍德勒
A·察贝尼格
H-D·弗里德尔
S·迈尔
N·韦尔莱
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    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
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    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/06—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of high energy impulses, e.g. magnetic energy
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    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
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    • B23K2103/00—Materials to be soldered, welded or cut
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Abstract

本发明涉及一种制备复合材料的工艺，该复合材料包含由钢或钛基材料制成的部分和由铜基或铝基材料制成的部分。该复合材料的各部分通过中间件连接。该中间件同样的包括由钢或钛基材料制成的区域和由铜基或铝基材料制成的区域，这两个区域通过爆炸焊连接。该复合材料的各部分与中间件的各同型区域通过熔焊或扩散焊工艺连接。

Description

一种用于制造复合材料的工艺
技术领域
本发明涉及一种制备复合材料的工艺，该复合材料包括由钢或钛基材料制成的部分和由铜基或铝基材料制成的部分。 
背景技术
铜基材料或铝基材料不能通过熔焊工艺与钢或钛基材料直接相连接。在下文的术语“-基材料”在各种情况下，都应理解为基底金属含量大于50wt％的合金。术语钢包括全部的钢系材料。 
包含由钢或钛基材料制成部分和由铜基或铝基材料制成部分的复合材料，其一个重要应用为冷却元件。铜和铝因其具有高导热性而被采用。为了获得足够的结构强度，将铜或铝部分连接到一结构材料，通常为钢或钛材料。 
例如，采用钢/铜复合材料作为聚变反应堆第一层器壁部件的零件。开发第一层器壁部件，尤其是用于诸如分流器、挡板和限制器之类的具有极高能量密度的区域，是代表聚变研究技术实现的关键部件。针对这些材料的粘着性连接已开展了广泛的研究。 
例如，已知下述特别针对钢/铜复合材料的解决方案： 
-在铜基材料和钢之间焊接一Ni接头 
-采用电镀层密封该过渡层 
-扩散焊 
-软钎焊 
软钎焊连接在耐腐蚀性和强度上存在缺陷，通过扩散焊连接的连接件的强度在很多情况下都是不够的。此外，建立所需的工艺稳定性也十分困难。且，这种连接的强度性能多变而很低。正如热负荷测试所证实的，在铜基材料和钢之间的Ni接头的焊接也有其缺点。例如，这种过渡对于Ni接头区域内的局部流动较为敏感。 
发明内容
因此，本发明的目的是提供一种复合材料，其具有足够的功能，尤其是强度、耐热疲劳和耐腐蚀性。 
为实现上述目的，本发明提供一种复合材料，其包含由钢或钛基材料制成的管状部分及由铜基或铝基材料制成的管状部分；其中复合材料的各管状部分通过中间件相连接；中间件由钢或钛基材料制成的区域和铜基或铝基材料制成的区域组成；上述两区域通过爆炸焊进行粘着性连接形成第一连接区域，且将钢或钛基材料制成的管状部分与钢或钛基材料制成的区域进行粘着性连接形成第二连接区域、将铜基或铝基材料制成的管状部分与铜基或铝基材料制成的区域进行粘着性连接形成第三连接区域。 
为实现上述目的，本发明还提供一种用于制造复合材料的工艺，该复合材料包含由钢或钛基材料制成的管状部分及由铜基或铝基材料制成的管状部分；其中由钢或钛基材料制成的金属板和由铜基或铝基材料制成的金属板通过爆炸焊连接并加工成管状断面从而制造出具有钢基或钛基材料制成的区域、铜基或铝基材料制成的区域以及钢基或钛基材料制成的区域和铜基或铝基材料制成的区域通过爆炸焊连接形成的第一连接区域的中间件；且通过熔焊或扩散焊将钢基或钛基材料制成的管状部分与钢基或钛基材料制成的区域连接形成第二连接区域、以及将铜基或铝基材料制成的管状部分与铜基或铝基材料制成的区域连接形成第三连接区域。 
首先，制备一中间件，包括由钢或钛基材料制成的区域和由铜基或铝基材料制成的区域，他们通过爆炸焊接连接。这可以通过采用由所用材料制成的金属薄板/板材简单地完成。由于铜和铝比钢和钛的延展性好，且具有更低的屈服强度，因此优选把铜或铝薄板/板材置于钢或钛薄板/板材上。然后在铜或铝薄板/板材上放置炸药。形成波状、锯齿形的具有高强度的典型爆炸焊接连接区域。可以通过机加工或射线加工将这种方式制造出的复合材料加工成具有适当几何形状的中间件。 
然后，通过熔焊或扩散焊工艺将复合材料的各部分与中间件的相应的区域连接。在本文中，词语“相应的”意味着该复合材料部分和与其相连的中间件区域是由相同类型材料制备的。在本文中，术语“相同类型”应理解为其由相同基体材料构成，即，例如由铜基材料制成的部分和由铜基材料制成的区域，或由钢制成的部分和由钢制成的区域。 
因此，为了制备复合材料，例如，包含钢和铜基材料，首先，应通过爆破焊接制备由钢和铜基材料构成的中间件。然后，通过熔焊或扩散焊将钢部分与中间件的钢区域相连，以及将由铜基材料制成的部分与中间件的由铜基材料制成的区域相连。该中间件的钢与其余复合材料的钢可以有不同的结构和/或成分，或优选为相同的结构和/或成分。铜基材料同样适用类似情况。 
可能以类似方法制备的复合材料包括： 
-钢/铝基材料 
-钛基材料/铜基材料，以及 
-钛基材料/铝基材料。 
如果中间件的各个区域与复合材料的各个部分有相同或相似的组成，那么在本文中的各种情况下都是有利的。尤其是对于具有较宽范围可能微观结构的钢，类似的微观结构也是有利的。 
采用加工硬化的材料制造复合材料也是有利的，如微粒硬化的铜合金(例如：Cu-Cr-Zr)或合金钢(例如：奥氏体钢，如316L)。因此，该中间件(例如：Cu-Cr-Zr/316L)的各个材料区具有足够高的流动屈服值。因此，不存在会因局部流动而失效的低强度过渡区。因而应力导致的延伸可以在更大的区域内被吸收或被复合材料的部分解决。此外，对所有的材料组合而言爆破焊接代表一种经济的既定工艺。可以对该爆破焊接的连接部分进行非破坏性测试。既然中间件各区域与复合材料各部分之间的连接部分在各自情况下由相同类型的材料组成，采用熔焊或扩散焊工艺是可能的。可采用的熔焊工艺的特别实例包括惰性气体保护钨极电弧焊(TIG)、激光和电子束焊。 
对于在第一层器壁方面的应用，进一步的优势在于，由于避免了使用镍，因此可以满足相对磁导率尽可能低的要求。 
对于用作冷却元件的情形，如果将中间件设计为管状断面且将复合材料的各部分设计成管状是有利的。在这种情况下将中间件设计成管状断面与对爆炸焊制造的复合材料板进行机加工的情况是一样的，在该情况中管状断面轴向长度与复合材料板的厚度一致。用钢/铜基材料制成的复合材料已经可能取得特别有利的效果。从较广的钢种范围方面，奥氏体或部分奥氏体钢特别值得一提。微粒硬化铜合金，诸如析出强化铜合金Cu-Cr-Zr，已被证实为合适的铜基材料。本发明工艺用于制造聚变反应堆的第一层器壁部件或第一 层器壁部件的零件尤其具有优势。 
在接下来的描述中，基于由钢/铜基材料组成的复合材料对本发明进行解释。然而，以同样的方式依照本发明制造其它的复合材料也是可能的。 
附图说明
图1所示为一管状复合材料的横剖面。 
具体实施方式
实施例： 
采用Cu-Cr-Zr/316L(奥氏体钢)制造一种管状复合材料1。这种复合材料用作聚变反应堆分流器中的热交换器。 
为达到这种目的，通过爆炸焊将处于固溶退火、淬火状态下的用Cu-Cr-Zr制成的板材与用316L制成的板材连接起来。两块板材各自的表面积为500×500mm2、各自的厚度为15mm。对于爆炸焊而言，Cu-Cr-Zr板材用作“锭壳”。出于这一目的，将炸药置于Cu-Cr-Zr板材的上边并点火，结果形成连接区域7。 
焊接后，对复合板进行超声检验。通过这种途径可以定位已连接和未连接的区域。然后利用喷水切割从板材上已连接区域切割出芯状的中间件4，其中芯的轴与爆炸焊接的连接表面7垂直。芯4的直径为15mm，高度为30mm。钢区域5和Cu-Cr-Zr区域6各自的厚度为15mm。爆炸焊缝7具有该种连接工艺的典型波浪形形状。 
将该芯4的两端进行车削加工形成一个深5mm、直径为12mm的台阶。在接下来装配复合材料的被设计为Φ15×1.5mm的管状的Cu-Cr-Zr部分3时，处于Cu-Cr-Zr区域6内的台阶作为电子束焊的对中手段。316L侧区域5内的台阶也遵照同样的原则。 
将一用316L制成的钢管2定位于区域5的中心，将一Cu-Cr-Zr管3定位于区域6的中心。之后将以这种方式获得的组件通过电子束焊进行粘着性连接，其中外围焊缝9位于Cu-Cr-Zr区域，另一外围焊缝8位于316L区域。接着对焊接后的复合材料进行475℃/3h时效硬化，并机加工成一根外径15mm、壁厚1.5mm的复合材料管1。接下来进行的诸如氦泄漏测试、染色 渗透性测试及X光检验，显示出完整无缺的连接区域。在拉伸试验中，失效发生在Cu-Cr-Zr管部分。这表明爆炸焊缝和电子束焊缝的强度高于Cu-Cr-Zr的强度。 

Claims (7)

1.一种用于制造复合材料(1)的工艺，该复合材料包含由钢基材料制成的管状部分(2)及由铜基材料制成的管状部分(3)；其中由钢基材料制成的金属板和由铜基材料制成的金属板通过爆炸焊连接并加工成管状断面从而制造出具有钢基材料制成的区域(5)、铜基材料制成的区域(6)以及所述钢基材料制成的区域(5)和所述铜基材料制成的区域(6)通过爆炸焊连接形成的第一连接区域(7)的中间件(4)；且通过熔焊或扩散焊将所述钢基材料制成的管状部分(2)与所述钢基材料制成的区域(5)连接形成第二连接区域(8)、以及将所述铜基材料制成的管状部分(3)与所述铜基材料制成的区域(6)连接形成第三连接区域(9)。
2.如权利要求1所述的工艺，其中通过惰性气体保护钨极电弧焊、激光或电子束焊将所述钢基材料制成的管状部分(2)与所述钢基材料制成的区域(5)连接起来，将所述铜基材料制成的管状部分(3)与所述铜基材料制成的区域(6)连接起来。
3.如权利要求1所述的工艺，其中所述钢至少在部分区域具有奥氏体微观组织。
4.如权利要求1所述的工艺，其中铜基材料进行了微粒硬化。
5.如权利要求4所述的工艺，其中铜基材料为Cu-Cr-Zr。
6.如权利要求1-5之一所述的工艺，其中复合材料(1)用作聚变反应堆第一层器壁元件或是第一层器壁元件的部件。
7.如权利要求1所述的工艺，其中所述中间件(4)的两端进行车削加工形成台阶，所述台阶的直径分别对应于所述由钢基材料制成的管状部分(2)和所述由铜基材料制成的管状部分(3)的内径。
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