WO2020103217A1 - 一种铝合金异形管件超低温介质压力成形方法 - Google Patents

一种铝合金异形管件超低温介质压力成形方法

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Publication number
WO2020103217A1
WO2020103217A1 PCT/CN2018/120012 CN2018120012W WO2020103217A1 WO 2020103217 A1 WO2020103217 A1 WO 2020103217A1 CN 2018120012 W CN2018120012 W CN 2018120012W WO 2020103217 A1 WO2020103217 A1 WO 2020103217A1
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WO
WIPO (PCT)
Prior art keywords
pipe
ultra
low temperature
temperature medium
mold
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CN2018/120012
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English (en)
French (fr)
Inventor
苑世剑
凡晓波
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Dalian University of Technology
Original Assignee
Dalian University of Technology
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dalian University of Technology filed Critical Dalian University of Technology
Priority to US16/499,993 priority Critical patent/US10960452B2/en
Publication of WO2020103217A1 publication Critical patent/WO2020103217A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B21D26/041—Means for controlling fluid parameters, e.g. pressure or temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/033—Deforming tubular bodies
    • B21D26/045—Closing or sealing means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/053—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure characterised by the material of the blanks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D37/00—Tools as parts of machines covered by this subclass
    • B21D37/16—Heating or cooling
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/10—Alloys based on aluminium with zinc as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent

Definitions

  • the invention relates to the technical field of pipe fitting forming, in particular to an ultra-low temperature medium pressure forming method for aluminum alloy shaped pipe fittings.
  • aluminum alloy As a lightweight material, aluminum alloy has high specific strength and good corrosion resistance, and is widely used in aviation, aerospace and automotive fields. With the further improvement of high reliability, long life and light weight requirements of the new generation of launch vehicles, aircraft and new energy vehicles, the overall structure is replacing the multi-piece split welded structure.
  • aircraft shaped air intakes, electric vehicle chassis components and body frames These components are complex shaped tubes with complex cross-sectional shapes, large cross-section differences, and local small fillets. These geometric features are difficult to deform with high-strength aluminum alloys. The coupling makes it extremely difficult to form such special-shaped pipes.
  • internal high pressure forming is a relatively advanced and mature technology for manufacturing hollow variable-section special-shaped pipes. It has been widely used in the aerospace and automotive industries, and is suitable for materials with good room temperature plasticity, such as low carbon steel and stainless steel. .
  • internal high pressure forming is also gradually applied, such as automobile instrument panel brackets.
  • high-strength aluminum alloys with a tensile strength greater than 400 MPa are limited by their low formability and are prone to orange peel.
  • complex processes such as multi-pass preforming and intermediate annealing are required to form. There are problems of low yield and poor quality of finished products; for complex shape integral pipe fittings, when the section difference is large and the radius radius to thickness ratio is less than 3, the limit of high-pressure forming in high-strength aluminum alloy is exceeded.
  • the purpose of the present invention is to provide an ultra-low temperature medium pressure forming method for aluminum alloy shaped pipes to solve the problems in the prior art mentioned above, greatly improve the forming performance of the weld area of aluminum alloy pipes and friction stir welded pipes, and facilitate complex deformed deformation
  • the forming of cross-section pipe fittings realizes the smooth forming of aluminum alloy pipe fittings with large cross-section difference, and avoids the cracking of the welds of large-diameter aluminum alloy shaped pipe fittings.
  • the present invention provides the following solutions:
  • the invention provides an ultra-low temperature medium pressure forming method for aluminum alloy shaped pipe fittings, which utilizes the characteristics of aluminum alloy pipes to greatly improve their forming performance under ultra-low temperature conditions.
  • the specific steps are as follows:
  • Step 1 Put the pipe into the mold, close the mold, and the left and right punches block the ends of the pipe to achieve effective sealing of the pipe;
  • Step 2 Fill the inside of the pipe with ultra-low temperature medium to cool the pipe to a setting temperature lower than 123K;
  • Step three increase the pressure of the ultra-low temperature medium inside the pipe, so that the pipe is formed against the mold under the pressure of the ultra-low temperature medium;
  • Step four Open the mold, exit the left punch and the right punch, recover the ultra-low temperature medium inside the pipe, and take out the shaped special-shaped pipe.
  • the mold is cooled to a set temperature lower than 123K.
  • the mold includes an upper mold and a lower mold.
  • the upper mold and the lower mold are provided with a circulation passage for circulating an ultra-low temperature medium. The mold cools down through the circulation path.
  • the pipe is first cooled to a set temperature lower than 123K, and then the pipe is placed in the mold.
  • the set temperature range of the pipe and the mold is 3K-123K.
  • the right punch is provided with a channel that communicates with the inside of the tube, and the channel communicates with a low-temperature pressurizer, and the low-temperature pressurizer injects an ultra-low temperature medium into the tube through the channel.
  • the ultra-low temperature medium is injected into the inside of the pipe and the cavity of the mold at the same time, so that the pipe is cooled more uniformly and quickly to the set temperature.
  • the tube is an extruded tube or a tailor-welded tube, and the tube diameter is not greater than 2000 mm and the wall thickness is 0.2-50 mm.
  • the tube is formed against the mold under the combined action of the pressure of the ultra-low temperature medium and the axial feed according to a given process curve, and the pressure is set to not more than 200 MPa.
  • the ultra-low temperature medium is liquid argon, liquid nitrogen or liquid helium.
  • the material of the pipe material is Al-Cu alloy, Al-Mg-Si alloy, Al-Zn-Mg-Cu alloy or Al-Li alloy.
  • the ultra-low temperature medium in the ultra-low temperature medium pressure forming method of the aluminum alloy shaped pipe fittings of the present invention is not only used for cooling the mold and the pipe, but also used for pressurization, to realize the flexible loading of the pipe under the ultra-low temperature condition, which is beneficial to forming complex shaped deformed cross-section pipe fittings; use aluminum
  • the forming performance of alloy pipes is greatly improved under ultra-low temperature conditions.
  • the pipes are formed into complex shaped pipes at ultra-low temperatures.
  • the pipes are deformed under ultra-low temperature conditions, and the forming performance is significantly improved to avoid large cross-section differences.
  • FIG. 1 is a schematic structural view 1 of the ultra-low temperature medium pressure forming method of aluminum alloy shaped pipe fittings of the present invention
  • FIG. 2 is a second structural schematic diagram of the ultra-low temperature medium pressure forming method of the aluminum alloy shaped pipe fitting of the present invention
  • Figure 3 is a schematic cross-sectional view of A-A in Figure 2;
  • FIG. 4 is a schematic structural view 1 of aluminum alloy shaped pipe fittings in the present invention.
  • FIG. 5 is a schematic structural view 2 of die-forming of aluminum alloy shaped pipe fittings in the present invention.
  • FIG. 6 is a schematic structural view of a shaped tube shaped in the present invention.
  • Embodiment 7 is a structural schematic diagram 1 of Embodiment 4 of the ultra-low temperature medium pressure forming method for aluminum alloy shaped pipes of the present invention.
  • FIG. 8 is a schematic cross-sectional view of B-B in FIG. 7;
  • FIG. 9 is a schematic cross-sectional view of C-C in FIG. 7;
  • FIG. 10 is a second structural diagram of Embodiment 4 of the ultra-low temperature medium pressure forming method for aluminum alloy shaped pipes of the present invention.
  • Example 11 is a schematic structural view of a shaped tube shaped in Example 4 of the present invention.
  • 1-upper die 2-left punch; 3-lower die; 4-circulation path; 5-ultra-low temperature medium; 6-pipe; 7-right punch; 8-low temperature pressurizer; 9-low temperature container; 10-shaped tube; 11-cavity; 12-weld.
  • the purpose of the present invention is to provide an ultra-low temperature medium pressure forming method for aluminum alloy shaped pipes to solve the problems in the prior art, and greatly improve the forming performance of the weld area of aluminum alloy pipes and friction stir welded pipes, which is beneficial to complex deformed cross sections
  • the forming of the pipe fittings realizes the smooth forming of the aluminum alloy pipe fittings with large cross-section difference, and avoids the cracking of the welds of the large-diameter aluminum alloy shaped pipe fittings.
  • this embodiment provides an ultra-low temperature medium pressure forming method for aluminum alloy shaped pipe fittings, which utilizes the characteristics of aluminum alloy pipes to greatly improve the forming performance under ultra-low temperature conditions.
  • the tube 6 Cooling and pressurizing, the tube 6 is formed into a special-shaped tube 10 at an ultra-low temperature.
  • the tube 6 is an extruded tube or a tailor-welded tube.
  • the tube 6 has a diameter not greater than 2000 mm and a wall thickness of 0.2-50 mm;
  • the ultra-low temperature medium 5 is liquid argon, Liquid nitrogen or liquid helium.
  • the material of the tube 6 is an aluminum alloy material, preferably an Al-Cu alloy, Al-Mg-Si alloy, Al-Zn-Mg-Cu alloy or Al-Li alloy.
  • Step 1 Put the tube 6 into the mold, close the mold, the left punch 2 and the right punch 7 block the ends of the tube 6 to achieve effective sealing of the tube 6; the right punch is provided with a channel that connects the inside of the tube 6 The channel communicates with the low-temperature pressurizer 8, and the low-temperature pressurizer 8 injects the ultra-low temperature medium 5 into the pipe 6 through the channel.
  • the mold can be cooled to a set temperature lower than 123K.
  • the mold includes an upper mold and a lower mold.
  • the upper mold 1 and the lower mold 3 are provided with a circulation passage 4 for circulating the ultra-low temperature medium 5.
  • the mold passes the circulation passage 4 Cool down.
  • the set temperature range of the pipe 6 and the mold is 3K-123K. It is also possible to first cool the pipe 6 to a set temperature lower than 123K, and then put the pipe into the mold to cool the mold and the pipe 6 together.
  • the ultra-low temperature medium 5 is filled into the pipe 6 to cool the pipe 6 to a setting temperature lower than 123K.
  • the ultra-low temperature medium 5 is injected into the inside of the pipe 6 and the cavity 11 of the mold at the same time, so that the pipe 6 is cooled more uniformly and quickly to the set temperature.
  • step three the pressure of the ultra-low temperature medium 5 inside the pipe 6 is increased by the low-temperature pressurizer 8, so that the pipe 6 is formed against the mold under the pressure of the ultra-low temperature medium 5.
  • the pipe 6 is formed against the mold under the combined effect of the pressure of the ultra-low temperature medium 5 and the axial feed according to the given process curve, and the pressure is set to not more than 200 MPa.
  • Step 4 Open the mold, exit the left punch 2 and the right punch 7, recover the ultra-low temperature medium 5 inside the pipe 6 into the low-temperature container 9, and take out the shaped special-shaped pipe 10.
  • the cross-section of the cavity 11 in this embodiment may also be a combination of one or more of a round cross-section, a square cross-section, or other cross-sections, to achieve filling of a round cross-section, a square cross-section, or a special-shaped cross-section.
  • the ultra-low temperature medium 5 is used to cool the aluminum alloy pipe 6 to an ultra-low temperature, so that the pipe 6 is deformed under ultra-low temperature conditions, and the forming performance is significantly improved, avoiding the problem of hydroforming of complex-shaped aluminum alloy shaped pipes; ultra-low temperature medium 5 pressure forming Method, the forming performance of the friction stir welded pipe base material and the weld 12 are greatly improved, and the plasticity coefficient is similar, which avoids the problem of cracking in the weld area 12 of the large-sized aluminum alloy shaped pipe fittings; placing the natural pipe 6 into the cold mold will cause A frozen lubricating layer is formed on the surface of the tube 6 to reduce the frictional resistance of the flow of the tube 6 to achieve axial feeding and improve the uniformity of the wall thickness; the ultra-low temperature medium 5 is not only used to cool the mold and the tube 6, but also used to pressurize the tube 6 at an ultra-low temperature Flexible loading under conditions is conducive to forming complex deformed cross-section pipe fittings; it is possible to cool only the
  • the tube 6 in this embodiment is a 6061 aluminum alloy tube in a solid solution state, with a thickness of 4.5 mm and a diameter of 140 mm; the cross-sections of the cavity 11 of the upper mold 1 and the lower mold 3 are shaped cross-sections , The maximum equivalent outer diameter is 190mm, and the corresponding section difference of the pipe 6 is 35.7%. Specific steps are as follows:
  • the first step using liquid nitrogen as the ultra-low temperature medium 5 to simultaneously cool the upper die 1, the lower die 3, the left punch 2 and the right punch 7 to a temperature lower than 123K; the upper die 1 and the lower die 3 are provided for circulation
  • the circulation path 4 of the ultra-low temperature medium 5 is cooled by the mold through the circulation path 4.
  • Step 2 Put the room temperature pipe 6 after decontamination treatment into the mold, close the upper mold 1 and the lower mold 3, the left punch 2 and the right punch 7 advance simultaneously, and the pipe 6 is blocked.
  • Step 3 Fill the inside of the pipe with the ultra-low temperature medium 5 through the low-temperature pressurizer 8, so that the pipe 6 is cooled to a temperature lower than 123K under the joint action of the ultra-low temperature medium 5 and the cold mold.
  • the fourth step pressurize the ultra-low temperature medium 5 inside the tube 6 by the low-temperature pressurizer 8 and apply a unit pressure of 100 MPa to cause the tube 6 to swell and deform under the pressure of the ultra-low temperature medium 5 and gradually lean against the mold to complete the deformation.
  • Step 5 Remove the internal pressure of the pipe 6, the left punch 2 and the right punch 7 retreat, recover the ultra-low temperature medium 5 into the low-temperature container 9, open the mold to take out the pipe, and complete the ultra-low temperature medium pressure forming of the shaped pipe 10. After that, the shaped tube 10 is subjected to artificial aging treatment.
  • the cross-section of the cavity 11 may also be a round cross-section, a square cross-section, or a combination of several types of cross-sections, to achieve filling of a round cross-section, a square cross-section, or a special-shaped cross-section.
  • liquid nitrogen can be replaced with liquid argon or liquid helium.
  • the ultra-low temperature medium 5 of this embodiment is not only used to cool the mold and the pipe 6, but also used to pressurize to achieve the flexible loading of the pipe 6 under ultra-low temperature conditions, which is beneficial to forming complex deformed cross-section pipe fittings; After cooling to ultra-low temperature, the tube 6 is deformed under ultra-low temperature conditions, and the forming performance is significantly improved, which avoids the problem of hydroforming of aluminum alloy shaped pipes with large cross-section differences.
  • the tube 6 in this embodiment is a T4 2024 aluminum alloy tube with a thickness of 2.0 mm and a diameter of 60 mm; the cross-section of the cavity 11 of the upper mold 1 and the lower mold 3 is a special-shaped cross-section.
  • the radius of the local small fillet is 4.0 mm, the maximum equivalent outer diameter is 92 mm, and the corresponding cross-sectional difference is 53.3%.
  • the first step use liquid nitrogen as the ultra-low temperature medium 5 to cool the upper die 1, the lower die 3, the left punch 2 and the right punch 7 to a temperature lower than 123K at the same time; the upper die 1 and the lower die 3 are provided for circulation
  • the circulation path 4 of the ultra-low temperature medium 5 is cooled by the mold through the circulation path 4.
  • Step 2 Put the room temperature pipe 6 after the decontamination treatment into the mold, close the upper mold 1 and the lower mold 3, and move the left punch 2 and the right punch 7 simultaneously to block the pipe 6.
  • Step 3 Fill the inside of the pipe 6 with the ultra-low temperature medium 5 through the low-temperature pressurizer 8, so that the pipe 6 is cooled to a temperature lower than 123K under the joint action of the ultra-low temperature medium 5 and the cold mold.
  • the fourth step pressurize the ultra-low temperature medium 5 inside the pipe 6 through the low-temperature pressurizer 8 and apply a unit pressure of 120 MPa, so that the pipe 6 gradually abuts against the mold under the combined action of the ultra-low temperature medium 5 pressure and the axial feed of the punch until the deformation is completed .
  • Step 5 Remove the pressure inside the pipe 6, the left punch 2 and the right punch 7 retreat, open the mold to take out the pipe fittings, recover the ultra-low temperature medium 5 into the low-temperature container 9, and complete the ultra-low temperature medium pressure forming of the shaped pipe 10.
  • the ultra-low temperature medium 5 of this embodiment is not only used to cool the mold and the pipe 6, but also used to pressurize to achieve the flexible loading of the pipe 6 under ultra-low temperature conditions, which is beneficial to forming complex deformed cross-section pipe fittings;
  • the tube 6 is deformed under ultra-low temperature conditions, and the forming performance is significantly improved, avoiding the problem of hydroforming of aluminum alloy shaped pipes with large cross-section differences;
  • the tube 6 is under the combined action of ultra-low temperature medium 5 pressure and punch axial feed Gradually deformed against the mold, which is conducive to the formation of larger shaped cross-section pipes (> 50%).
  • Putting the naturally placed pipe 6 into the cold mold will form a frozen lubricating layer on the surface of the pipe 6 to reduce the flow of the pipe 6 Friction resistance makes it easier to achieve axial feeding and improve the uniformity of wall thickness.
  • the tube 6 in this embodiment is an annealed 7075 aluminum alloy tube with a thickness of 1.0 mm and a diameter of 60 mm; the cross-section of the cavity 11 of the upper mold 1 and the lower mold 3 is a special-shaped cross-section.
  • the radius of the local small fillet is 2.0 mm, the equivalent outer diameter is 80 mm at maximum, and the corresponding cross-sectional difference is 33.3%.
  • the mold of this embodiment does not perform cooling treatment and only cools the aluminum alloy pipe 6 to a temperature lower than 123K. Specific steps are as follows:
  • Step 1 Put the pipe 6 after the decontamination treatment into the mold, close the upper mold 1 and the lower mold 3, the left punch 2 and the right punch 7 advance simultaneously, and the pipe 6 is blocked.
  • the second step quickly fill the inside of the pipe 6 with the ultra-low temperature medium 5 through the low-temperature pressurizer 8, so that the pipe 6 is cooled to a temperature lower than 123K under the action of the circulating ultra-low temperature medium 5.
  • the third step pressurize the ultra-low temperature medium 5 inside the tube 6 by the low-temperature pressurizer 8 and apply a unit pressure of 100 MPa to cause the tube 6 to swell and deform under the pressure of the ultra-low temperature medium 5 until it completely abuts the mold.
  • Step 4 Relieve the internal pressure of the tube 6, recover the ultra-low temperature medium 5 into the low-temperature container 9, the left punch 2 and the right punch 7 retreat, open the mold to take out the pipe fittings, and complete the ultra-low temperature medium pressure forming of the aluminum alloy shaped pipe fittings.
  • the tube 6 of this embodiment has a thin wall thickness, and the ultra-low temperature medium 5 only quickly cools the tube 6 without cooling the mold, which can not only achieve flexible loading under ultra-low temperature conditions, but also achieve efficient forming of complex shaped and deformed cross-section pipes; Deformation occurs under ultra-low temperature conditions, and the forming performance is significantly improved, avoiding the problem of hydroforming of aluminum alloy shaped pipes with large cross-section differences; through ultra-low temperature medium 5 can directly cool thin-walled aluminum alloy pipes to ultra-low temperatures below 123K, the mold can be omitted
  • the cooling treatment is beneficial to improve the forming efficiency of thin-walled special-shaped cross-section pipe fittings.
  • the tube 6 in this embodiment is a solid-solution 2195 aluminum-lithium alloy friction stir welded welded tube with a thickness of 4.0 mm and a diameter of 600 mm; the cavity of the upper mold 1 and the lower mold 3
  • the 11 cross-section is a special-shaped cross-section, the maximum equivalent outer diameter is 760 mm, and the corresponding cross-section difference is 26.7%. Specific steps are as follows:
  • Step 1 Put the pipe 6 after decontamination treatment into the mold, close the upper mold 1 and the lower mold 3, the left punch 2 and the right punch 7 advance at the same time, and the pipe 6 is blocked and sealed.
  • the second step quickly fill the inside of the pipe 6 and the mold cavity 11 with the ultra-low temperature medium 5 through the low-temperature pressurizer 8 to cool the friction stir welded pipe to a temperature lower than 123K under the action of the ultra-low temperature medium 5 on the inside and outside.
  • the third step pressurize the ultra-low temperature medium 5 inside the tube 6 by the low-temperature pressurizer 8 and apply a unit pressure of 80 MPa to cause the tube 6 to swell under the pressure of the ultra-low temperature medium 5 until it gradually contacts the mold to complete the deformation.
  • Step 4 Relieve the internal pressure of the tube 6, recover the ultra-low temperature medium 5 into the low-temperature container 9, the left punch 2 and the right punch 7 retreat, open the mold to take out the pipe fittings, and complete the pressure forming of the ultra-low temperature medium 5 of the aluminum alloy shaped pipe fittings. After that, the shaped tube 10 can be artificially aged to increase the strength of the part.
  • the ultra-low temperature medium 5 of this embodiment is not only used to cool the pipe 6, but also used to pressurize to achieve the flexible loading of the pipe 6 under ultra-low temperature conditions, which is beneficial to forming complex deformed cross-section pipe fittings; the ultra-low temperature medium is passed inside and outside the pipe 6 5. Not only is it easy to achieve more uniform and rapid cooling of the tailor-made welded pipe base material and weld 12 to ultra-low temperature, but also avoid the problem of difficult cooling of large-size molds; the pipe 6 deforms under ultra-low temperature conditions, and the friction stir welded pipe base material and weld 12 The forming performance is greatly improved, and the plasticity coefficient is similar, which avoids the problem of cracking in the weld area 12 of the aluminum alloy shaped pipe fittings.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

一种铝合金异形管件超低温介质压力成形方法，利用铝合金管材在超低温条件下成形性能大幅提高的特性，在模具（1、3）内通过超低温介质（5）对管材（6）进行冷却和加压，使管材在超低温下成形出异形管件（10）。铝合金异形管件超低温介质压力成形方法中超低温介质用于冷却模具和管材，同时增压实现管材的柔性加载，有利于成形复杂异形变截面管件；利用铝合金管材在超低温条件下成形性能大幅提高的特性，通过超低温介质冷却加压，管材在超低温条件下发生变形，成形性能显著提高，解决了大截面差的铝合金异形管件液压成形时开裂的难题；拼焊管焊缝区域和母材成形性能均大幅提高，塑性系数相近，解决了大直径铝合金异形管件焊缝区域开裂的难题。

Description

一种铝合金异形管件超低温介质压力成形方法 技术领域
本发明涉及管件成形的技术领域，特别是涉及一种铝合金异形管件超低温介质压力成形方法。
背景技术
铝合金作为一种轻量化材料，具有比强度高和良好的耐腐蚀性能，广泛应用于航空、航天和汽车领域。随着新一代运载火箭、飞机和新能源汽车等运载装备对高可靠、长寿命、轻量化要求的进一步提高，整体结构代替多块分体拼焊结构的需求越来越多。例如：飞机异形进气道、电动汽车底盘构件和车身框架，这类构件为复杂异形管件，其截面形状复杂、截面差大，还存在局部小圆角，这些几何特征与高强铝合金难变形相互耦合，使得这类异形管件成形难度极大。
目前，内高压成形(或液压成形)是制造空心变截面异形管件较为先进的成熟技术，已在航空航天、汽车行业得到广泛应用，适用于具有良好室温塑性的材料，如低碳钢、不锈钢等。对于简单形状的铝合金异形管件，内高压成形也逐渐得到应用，如汽车仪表盘支架等。然而，抗拉强度大于400MPa的高强铝合金由于受到其成形性能低、易产生橘皮等问题的限制，对于形状相对简单的构件需要多道次预成形和中间退火等复杂工艺才能形成，而又存在成品率低、成品质量差的问题；对于复杂形状整体管件，当截面差大和圆角半径与厚度比小于3时，就超过了高强铝合金内高压成形的极限。
因挤压工艺无法制得大直径薄壁无缝铝合金管坯，对于大直径的铝合金薄壁整体管件内高压成形时，需要通过板材卷焊来获得预制管坯。例如，飞机异形进气道管坯直径超过1米，而壁厚仅为几毫米，需要通过薄板卷曲和搅拌摩擦焊来获得预制管坯。然而，拼焊接头强度和塑性相对母材通常要降低，搅拌摩擦焊管焊缝强度系数小于0.8，在内高压成形时极易引起焊缝区开裂，导致成形无法完成，限制了大直径铝合金异形管件的应用。
而研究发现，高强铝合金母材和搅拌摩擦焊缝在超低温条件下成形性能均大幅提高，且焊缝塑性与母材相近。例如：2219铝合金在77K超低温条件下的成形性能比室温提高了70％。在超低温条件下，铝合金及焊缝成形性能提高，有利于成形复杂形状异形管件。
发明内容
本发明的目的是提供一种铝合金异形管件超低温介质压力成形方法，以解决上述现有技术存在的问题，使铝合金管材、搅拌摩擦焊管的焊缝区域成形性能大幅提高，有利于复杂异形变截面管件的成形，实现大截面差铝合金管件顺利成形，避免大直径铝合金异形管件焊缝开裂。
为实现上述目的，本发明提供了如下方案：
本发明提供了一种铝合金异形管件超低温介质压力成形方法，利用铝合金管材在超低温条件下成形性能大幅提高的特性，在模具内通过超低温介质对管材进行冷却和加压，使管材在超低温下成形出异形管件，具体步骤如下：
步骤一，将管材放入模具，闭合模具，左冲头、右冲头对管材两端进行封堵，实现管材的有效密封；
步骤二，向管材内部填充超低温介质，使管材冷却至低于123K的设定温度；
步骤三，增加管材内部超低温介质的压力，使管材在超低温介质的压力作用下，贴靠模具进行成形；
步骤四，打开模具，退出所述左冲头和所述右冲头，回收管材内部的超低温介质，取出成形好的异形管件。
优选的，实施步骤一之前将模具冷却至低于123K的设定温度，所述模具包括上模具和下模具，所述上模具和所述下模具上设置有用于循环超低温介质的循环通路，所述模具通过所述循环通路冷却降温。
优选的，先将所述管材冷却至低于123K的设定温度，再将所述管材放入所述模具。
优选的，所述管材和所述模具的设定温度范围为3K-123K。
优选的，所述右冲头上设置有连通管材内部的通道，所述通道连通低 温加压器，所述低温加压器通过通道向管材内部注入超低温介质。
优选的，所述步骤二中，在所述管材内部和所述模具的型腔内同时注入超低温介质，使管材更均匀、快速冷却至设定温度。
优选的，所述管材为挤压管或拼焊管，所述管材直径不大于2000mm且壁厚为0.2～50mm。
优选的，所述步骤三中，所述管材按照给定的工艺曲线在超低温介质的压力和轴向进给共同作用下贴靠模具成形，所述压力设置为不大于200MPa。
优选的，所述的超低温介质为液氩、液氮或液氦。
优选的，所述管材的材质为Al-Cu合金、Al-Mg-Si合金、Al-Zn-Mg-Cu合金或Al-Li合金。
本发明相对于现有技术取得了以下技术效果：
本发明的铝合金异形管件超低温介质压力成形方法中超低温介质不仅用于冷却模具和管材，还用于增压，实现管材在超低温条件下的柔性加载，有利于成形复杂异形变截面管件；利用铝合金管材在超低温条件下成形性能大幅提高的特性，通过超低温介质冷却加压，使管材在超低温下成形出复杂异形管件，管材在超低温条件下发生变形，成形性能显著提高，避免了大截面差的铝合金异形管件液压成形时开裂的难题；搅拌摩擦焊管焊缝和母材成形性能均大幅提高，且塑性系数相近，避免了大直径的铝合金异形管件焊缝区域开裂的难题。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本发明铝合金异形管件超低温介质压力成形方法的结构示意图一；
图2为本发明铝合金异形管件超低温介质压力成形方法的结构示意图二；
图3为图2中A-A的截面示意图；
图4为本发明中铝合金异形管件贴模成形的结构示意图一；
图5为本发明中铝合金异形管件贴模成形的结构示意图二；
图6为本发明中成形的异形管件的结构示意图；
图7为本发明铝合金异形管件超低温介质压力成形方法实施例4的结构示意图一；
图8为图7中B-B的截面示意图；
图9为图7中C-C的截面示意图；
图10为本发明铝合金异形管件超低温介质压力成形方法实施例4的结构示意图二；
图11为本发明实施例4中成形的异形管件的结构示意图；
其中：1-上模具；2-左冲头；3-下模具；4-循环通路；5-超低温介质；6-管材；7-右冲头；8-低温加压器；9-低温容器；10-异形管件；11-型腔；12-焊缝。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有付出创造性劳动的前提下所获得的所有其他实施例，都属于本发明保护的范围。
本发明的目的是提供一种铝合金异形管件超低温介质压力成形方法，以解决现有技术存在的问题，使铝合金管材、搅拌摩擦焊管的焊缝区域成形性能大幅提高，有利于复杂异形变截面管件的成形，实现大截面差铝合金管件顺利成形，避免大直径铝合金异形管件焊缝开裂。
为使本发明的上述目的、特征和优点能够更加明显易懂，下面结合附图和具体实施方式对本发明作进一步详细的说明。
如图1至图11所示，本实施例提供了一种铝合金异形管件超低温介质压力成形方法，利用铝合金管材在超低温条件下成形性能大幅提高的特性，在模具内通过超低温介质5对管材6进行冷却和加压，使管材6在超低温 下成形出异形管件10，管材6为挤压管或拼焊管，管材6直径不大于2000mm且壁厚为0.2～50mm；超低温介质5为液氩、液氮或液氦。管材6的材质为铝合金材质，优选为Al-Cu合金、Al-Mg-Si合金、Al-Zn-Mg-Cu合金或Al-Li合金。
具体步骤如下：
步骤一，将管材6放入模具，闭合模具，左冲头2、右冲头7对管材6两端进行封堵，实现管材6有效的密封；右冲头上设置有连通管材6内部的通道，通道连通低温加压器8，低温加压器8通过通道向管材6内部注入超低温介质5。实施步骤一之前可以将模具冷却至低于123K的设定温度，模具包括上模具和下模具，上模具1和下模具3上设置有用于循环超低温介质5的循环通路4，模具通过循环通路4冷却降温。管材6和模具的设定温度范围为3K-123K。还可以先将管材6冷却至低于123K的设定温度，再将管材放入模具，将模具和管材6一起冷却。
步骤二，向管材6内部填充超低温介质5，使管材6冷却至低于123K的设定温度。优选的，步骤二中，在管材6内部和模具的型腔11内同时注入超低温介质5，使管材6更均匀、快速冷却至设定温度。
步骤三，通过低温加压器8增加管材6内部超低温介质5的压力，使管材6在超低温介质5的压力作用下，贴靠模具进行成形。优选的，步骤三中，管材6按照给定的工艺曲线在超低温介质5的压力和轴向进给共同作用下贴靠模具成形，压力设置为不大于200MPa。
步骤四，打开模具，退出左冲头2和右冲头7，回收管材6内部的超低温介质5至低温容器9中，取出成形好的异形管件10。
本实施例中的型腔11截面还可以为圆截面、方截面或其他截面中一种或者几种的结合，实现圆截面、方截面、异形截面充填。
本实施例通过超低温介质5将铝合金管材6冷却至超低温，使管材6在超低温条件下发生变形，成形性能显著提高，避免了复杂形状铝合金异形管件液压成形开裂的难题；超低温介质5压力成形方法，使搅拌摩擦焊管母材 和焊缝12成形性能大幅提高、塑性系数相近，避免了大尺寸铝合金异形管件焊缝12区域开裂的难题；将自然放置管材6放入冷态模具，会在管材6表面形成冰冻润滑层，降低管材6流动的摩擦阻力，实现轴向补料，提高壁厚均匀性；超低温介质5不仅用于冷却模具和管材6，还用于增压实现管材6在超低温条件下的柔性加载，利于成形复杂异形变截面管件；可以通过在管材6内部和外部同时通入超低温介质5以仅对管材6进行冷却，不仅易于实现拼焊管母材和焊缝12更均匀、快速冷却至超低温，还避免了大尺寸模具冷却困难的问题。
实施例1
如图1至图6所示：本实施例中的管材6为固溶态6061铝合金管，其厚度为4.5mm、直径为140mm；上模具1和下模具3型腔11的截面为异形截面，当量外径最大为190mm，相应的管材6截面差为35.7％。具体步骤如下：
第一步：用液氮作为超低温介质5同时将上模具1、下模具3、左冲头2和右冲头7冷却至低于123K的温度；上模具1和下模具3上设置有用于循环超低温介质5的循环通路4，模具通过循环通路4冷却降温。
第二步：将进行除污处理后的室温管材6放入模具，闭合上模具1和下模具3，左冲头2、右冲头7同时前进，对管材6进行封堵。
第三步：通过低温加压器8向管材内部充填超低温介质5，使管材6在超低温介质5和冷态模具的共同作用下冷却至低于123K的温度。
第四步：通过低温加压器8将管材6内部超低温介质5增压，施加100MPa单位压力，使管材6在超低温介质5的压力作用下发生胀形变形，逐渐贴靠模具完成变形。
第五步：卸掉管材6内部压力，左冲头2、右冲头7后退，将超低温介质5回收至低温容器9中，开模取出管件，完成异形管件10的超低温介质压力成形。之后，将异形管件10进行人工时效处理。
本实施例中型腔11截面还可以为圆截面、方截面或其他截面中一种或者几种的结合，实现圆截面、方截面、异形截面充填。本实施例中液氮可以用液氩或液氦替代。
本实施例的超低温介质5不仅用于冷却模具和管材6，还用于增压实现管材6在超低温条件下的柔性加载，有利于成形复杂异形变截面管件；通过超低温介质5将铝合金管材6冷却至超低温，管材6在超低温条件下发生变形，成形性能显著提高，避免了大截面差铝合金异形管件液压成形开裂的难题。
实施例2
如图1至图6所示，本实施例中的管材6为T4态2024铝合金管，其厚度为2.0mm、直径为60mm；上模具1和下模具3的型腔11截面为异形截面，局部小圆角半径为4.0mm，当量外径最大为92mm、相应的截面差为53.3％。具体步骤如下：
第一步：用液氮作为超低温介质5将上模具1、下模具3、左冲头2和右冲头7同时冷却至低于123K的温度；上模具1和下模具3上设置有用于循环超低温介质5的循环通路4，模具通过循环通路4冷却降温。
第二步：将进行除污处理后的室温管材6放入模具中，闭合上模具1和下模具3，左冲头2、右冲头7同时前进，对管材6进行封堵。
第三步：通过低温加压器8向管材6内部充填超低温介质5，使管材6在超低温介质5和冷态模具的共同作用下冷却至低于123K的温度。
第四步：通过低温加压器8将管材6内部超低温介质5增压，施加120MPa单位压力，使管材6在超低温介质5压力和冲头轴向进给共同作用下逐渐贴靠模具直至完成变形。
第五步：卸掉管材6内部的压力，左冲头2、右冲头7后退，开模取出管件，将超低温介质5回收至低温容器9中，完成异形管件10的超低温介质压力成形。
本实施例的超低温介质5不仅用于冷却模具和管材6，还用于增压实现管材6在超低温条件下的柔性加载，有利于成形复杂异形变截面管件；通过超低温介质5将铝合金管材6冷却至超低温，管材6在超低温条件下发生变形，成形性能显著提高，避免了大截面差铝合金异形管件液压成形开裂的难题；管材6在超低温介质5压力和冲头轴向进给共同作用下逐渐贴靠模具发生变形，有利于实现更大大截面差(>50％)异形管件10成形； 将自然放置管材6放入冷态模具，会在管材6表面形成冰冻润滑层，降低管材6流动的摩擦阻力，更容易实现轴向补料，提高壁厚均匀性。
实施例3
如图1至图6所示，本实施例中的管材6为退火态7075铝合金管，其厚度为1.0mm、直径为60mm；上模具1和下模具3的型腔11截面为异形截面，局部小圆角半径为2.0mm，当量外径最大为80mm、相应的截面差为33.3％。不同于实施例1的是，本实施例的模具不做冷却处理而仅将铝合金管材6冷却至低于123K的温度。具体步骤如下：
第一步：将进行除污处理后的管材6放入模具，闭合上模具1和下模具3，左冲头2、右冲头7同时前进，对管材6进行封堵。
第二步：通过低温加压器8向管材6内部快速充填超低温介质5，使管材6在循环流通的超低温介质5作用下冷却至低于123K的温度。
第三步：通过低温加压器8将管材6内部超低温介质5增压，施加100MPa单位压力，使管材6在超低温介质5压力作用下发生胀形变形直至完全贴靠模具。
第四步：卸掉管材6内部压力，将超低温介质5回收至低温容器9中，左冲头2、右冲头7后退，开模取出管件，完成铝合金异形管件超低温介质压力成形。
本实施例的管材6壁厚较薄，超低温介质5仅对管材6进行快速冷却，模具不作冷却，不仅可以实现超低温条件下的柔性加载，还可以实现复杂异形变截面管件高效成形；管材6在超低温条件下发生变形，成形性能显著提高，避免了大截面差铝合金异形管件液压成形开裂的难题；通过超低温介质5可以直接将薄壁铝合金管材冷却至低于123K的超低温，模具可以不做冷却处理，有利于提高薄壁异形截面管件的成形效率。
实施例4
如图7至图11所示，本实施例中的管材6为固溶态2195铝锂合金搅拌摩擦焊拼焊管，其厚度为4.0mm、直径为600mm；上模具1和下模具3的型腔11截面为异形截面，当量外径最大为760mm、相应的截面差为26.7％。具体步骤如下：
第一步：将进行除污处理后的管材6放入模具，闭合上模具1和下模具3，左冲头2、右冲头7同时前进，对管材6进行封堵和密封。
第二步：通过低温加压器8向管材6内部和模具型腔11内同时快速充填超低温介质5，使搅拌摩擦焊管在内外侧超低温介质5作用下冷却至低于123K的温度。
第三步：通过低温加压器8将管材6内部超低温介质5增压，施加80MPa单位压力，使管材6在超低温介质5压力作用下发生胀形直至逐渐贴靠模具完成变形。
第四步：卸掉管材6内部压力，将超低温介质5回收至低温容器9中，左冲头2、右冲头7后退，开模取出管件，完成铝合金异形管件超低温介质5压力成形。之后，可以将异形管件10进行人工时效处理，以提高零件强度。
本实施例的超低温介质5不仅用于冷却管材6，还用于增压实现管材6在超低温条件下的柔性加载，有利于成形复杂异形变截面管件；在管材6内部和外部同时通入超低温介质5，不仅易于实现拼焊管母材和焊缝12更均匀、快速冷却至超低温，还避免了大尺寸模具冷却困难的问题；管材6在超低温条件下发生变形，搅拌摩擦焊管母材和焊缝12成形性能大幅提高、塑性系数相近，避免了铝合金异形管件焊缝12区域开裂的难题。
本说明书中应用了具体个例对本发明的原理及实施方式进行了阐述，以上实施例的说明只是用于帮助理解本发明的方法及其核心思想；同时，对于本领域的一般技术人员，依据本发明的思想，在具体实施方式及应用范围上均会有改变之处。综上所述，本说明书内容不应理解为对本发明的限制。

Claims (10)

  1. 一种铝合金异形管件超低温介质压力成形方法，其特征在于：利用铝合金管材在超低温条件下成形性能大幅提高的特性，在模具内通过超低温介质对管材进行冷却和加压，使管材在超低温下成形出异形管件，具体步骤如下：
    步骤一，将管材放入模具，闭合模具，左冲头、右冲头对管材两端进行封堵，实现管材的有效密封；
    步骤二，向管材内部填充超低温介质，使管材冷却至低于123K的设定温度；
    步骤三，增加管材内部超低温介质的压力，使管材在超低温介质的压力作用下，贴靠模具进行成形；
    步骤四，打开模具，退出所述左冲头和所述右冲头，回收管材内部的超低温介质，取出成形好的异形管件。
  2. 根据权利要求1所述的铝合金异形管件超低温介质压力成形方法，其特征在于：实施步骤一之前将模具冷却至低于123K的设定温度，所述模具包括上模具和下模具，所述上模具和所述下模具上设置有用于循环超低温介质的循环通路，所述模具通过所述循环通路冷却降温。
  3. 根据权利要求2所述的铝合金异形管件超低温介质压力成形方法，其特征在于：先将所述管材冷却至低于123K的设定温度，再将所述管材放入所述模具。
  4. 根据权利要求1或3所述的铝合金异形管件超低温介质压力成形方法，其特征在于：所述管材和所述模具的设定温度范围为3K-123K。
  5. 根据权利要求1所述的铝合金异形管件超低温介质压力成形方法，其特征在于：所述右冲头上设置有连通管材内部的通道，所述通道连通低温加压器，所述低温加压器通过通道向管材内部注入超低温介质。
  6. 根据权利要求5所述的铝合金异形管件超低温介质压力成形方法，其特征在于：所述步骤二中，在所述管材内部和所述模具的型腔内同时注入超低温介质，使管材更均匀、快速冷却至设定温度。
  7. 根据权利要求1所述的铝合金异形管件超低温介质压力成形方法，其特征在于：所述管材为挤压管或拼焊管，所述管材直径不大于2000mm且壁厚为0.2～50mm。
  8. 根据权利要求1所述的铝合金异形管件超低温介质压力成形方法，其特征在于：所述步骤三中，所述管材按照给定的工艺曲线在超低温介质的压力和轴向进给共同作用下贴靠模具成形，所述压力设置为不大于200MPa。
  9. 根据权利要求1所述的铝合金异形管件超低温介质压力成形方法，其特征在于：所述的超低温介质为液氩、液氮或液氦。
  10. 根据权利要求1所述的铝合金异形管件超低温介质压力成形方法，其特征在于：所述管材的材质为Al-Cu合金、Al-Mg-Si合金、Al-Zn-Mg-Cu合金或Al-Li合金。
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