CN112453673A - Welding method for thin-wall close-packed hole column complex-structure laminate - Google Patents
Welding method for thin-wall close-packed hole column complex-structure laminate Download PDFInfo
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- CN112453673A CN112453673A CN202011223705.1A CN202011223705A CN112453673A CN 112453673 A CN112453673 A CN 112453673A CN 202011223705 A CN202011223705 A CN 202011223705A CN 112453673 A CN112453673 A CN 112453673A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K15/00—Electron-beam welding or cutting
- B23K15/06—Electron-beam welding or cutting within a vacuum chamber
Abstract
The invention discloses a welding method of a thin-wall densely-arranged hole column complex-structure laminate, which comprises the following steps: assembling a combined bottom plate (1) and a cover plate (2); pressing plates (7) are respectively assembled on the outer surfaces of the bottom plate (1) and the cover plate (2); wrapping the combined bottom plate (1), cover plate (2) and pressure plate (7) with a metal sheet, sealing and welding the opening of the sheath (8), and reserving an opening at the position of the welding line (9); sealing the opening left at the welding seam (9); performing gas pressurization diffusion welding between the base plate (1) and the cover plate (2) on the sheath subjected to sealing, wherein the gas pressure is 1-20 MPa, the heat preservation temperature is 1050-1250 ℃, and the heat preservation time is 1-5 h; and removing the sheath (8) and the pressing plate (7) to obtain the welded thin-wall close-packed hole column complex-structure laminate. The invention solves the problem of diffusion welding of the laminated plate with the thin-wall densely-arranged hole columns and the complex structure, realizes precise dimensional precision control and obtains the porous laminated plate with high strength and high welding rate.
Description
Technical Field
The invention belongs to the technical field of welding of thin-wall complex structural members, and particularly relates to a method for welding a laminate with a thin-wall densely-arranged hole column complex structure.
Background
In the fields of aviation, aerospace, gas turbines and the like, along with the continuous development and progress of science and technology, a combustion chamber of an engine puts higher requirements on the high-temperature resistance of materials and the weight reduction effect of a structure, and a thin-wall close-packed hole column laminate structure has the capability of efficient cooling while reducing the weight of parts and can well meet the performance requirements on two aspects of cooling and weight reduction. The close-packed hole column complex structure laminate cooling is also called quasi-divergent cooling, integrates impingement cooling, convection cooling and air film cooling, and is one of the composite cooling technical schemes with the highest cooling efficiency at present.
There are data showing that the porous laminate is mainly manufactured by photochemical etching and soldering/diffusion welding. Fig. 1 is a schematic view of a thin-walled close-packed pore column complex structure laminate, as shown, a porous laminate is formed by brazing/diffusion welding two or more layers of heat-resistant metal sheets (a base plate 1 and a cover plate 2), each of which has a preformed structure with through-holes 5 or 6, and each of which has a surface boss 4 of a corresponding form on the surface. The thin-wall close-packed hole column laminate has a complex structure and great manufacturing technical difficulty, and because the brazing/TLP diffusion welding seam has the problems of joint brittleness, insufficient temperature resistance, difficult deformation processing after welding, seam cracking during tailor welding and the like, the diffusion welding process with better performance tends to be adopted from the aspects of improving the performance and the reliability, and improving the subsequent deformation and welding processing manufacturability.
For the welding of the laminated plates with thin-wall complex structure with weak rigidity, the problem of difficult dimensional precision control exists, especially for the structure of the porous layer plate of high-temperature alloy, the diffusion welding needs to apply uniform pressure at high temperature so as to ensure the necessary bonding rate and avoid excessive deformation, and the uniform pressure is particularly difficult to apply when welding large-area thin plates. The conventional diffusion welding pressure needs to be ensured through a pressure head or a die, but the die is influenced by factors such as insufficient strength and rigidity, creep deformation, expansion dislocation, uneven pressure transmission, insufficient fitting precision of original part processing and the like at high temperature, and is difficult to ensure close fit and uniform pressure application with a large-area laminated plate.
Disclosure of Invention
In view of the above situation in the prior art, the present invention aims to provide a method for welding a thin-wall close-packed hole column laminate with a complex structure based on gas pressure diffusion welding, so as to realize precise welding formation of the thin-wall laminate with the complex structure, and meanwhile, a welding joint meets the requirements of high strength and high welding rate.
The above object of the present invention is achieved by the following technical solutions:
a method for welding a thin-wall close-packed hole column complex-structure laminate comprises the following specific steps:
positioning points are respectively welded on the side edges of the bottom plate and the cover plate, the bottom plate and the cover plate are assembled and combined together according to the surrounding positioning holes, the plates are prevented from being staggered, and the through holes of the bottom plate and the cover plate are staggered;
respectively assembling pressing plates on the outer surfaces of the combined bottom plate and the combined cover plate, and fixing the side surfaces of the two pressing plates by using metal foils in a spot welding manner to enable the bottom plate, the cover plate and the pressing plates to form a whole;
wrapping the combined bottom plate, cover plate and pressing plate by using a metal sheet, sealing and welding the opening of the sheath, and reserving an opening of 2-10 mm at the position of a welding line;
sealing the opening left at the welding seam by adopting vacuum electron beam welding;
and carrying out gas pressurization diffusion welding between the bottom plate and the cover plate on the sheath after the sealing is finished, wherein the process parameters are as follows: the gas pressure is 1-20 MPa, the heat preservation temperature is 1050-1250 ℃, and the heat preservation time is 1-5 h;
removing the sheath and the pressing plate to obtain a welded thin-wall close-packed hole column complex-structure laminate, and inspecting the welding rate and the inner cavity pressing amount of the laminate.
Preferably, the thin-wall close-packed hole column complex structure laminate can be two layers or more.
Preferably, the thin-wall close-packed hole column complex structural layer plate material is the same or different material of high-temperature alloy and stainless steel.
Preferably, the bosses and the through holes of the thin-wall close-packed hole column complex structure can be circular, rectangular or irregular.
Preferably, the bosses with the complex structures of the thin-wall close-packed hole columns are processed and formed by adopting a photographic electrolytic processing method.
Preferably, the four sides of the bottom plate are provided with 2-10 mm steps to prevent the edges from collapsing and excessively deforming in the welding process.
Preferably, the laminate should be jacket sealed within 3 days of completion of the surface treatment to prevent interfacial contamination.
Preferably, the material of the pressure plate is a high-temperature-resistant alloy with a close linear expansion coefficient of the welded parent metal, the thickness of the pressure plate is 2-10 mm, and the shape and the size of the pressure plate are consistent with those of the welded parent metal.
Preferably, the surface of the press plate should be flat and free of defects, and a ceramic coating of alumina, zirconia, or the like is applied by cold spray or plasma spray.
Preferably, the metal sheet is a stainless steel sheet with a thickness of 0.5-1.5 mm.
Preferably, the vacuum degree of vacuum electron beam sealing welding is less than 5 x 10-3Pa。
The invention solves the problem of diffusion welding of the laminated plate with the thin-wall densely-arranged hole columns and the complex structure, realizes precise dimensional precision control and obtains the porous laminated plate with high strength and high welding rate. The welding rate of the laminated plate with the thin-wall close-packed hole column complex structure prepared by the invention can reach more than 98%, and the reduction of the inner cavity is not higher than 0.07 mm.
Drawings
FIG. 1 is a schematic view of a complex-structured laminate of thin-walled close-packed columns of holes;
FIG. 2 is a process flow diagram of the method of the present invention;
FIG. 3 is a schematic view of the assembly of a laminate gas pressure diffusion bonding structure in the method of the present invention.
Detailed Description
For a clearer understanding of the objects, technical solutions and advantages of the present invention, the present invention will be described in further detail below with reference to the accompanying drawings and embodiments.
FIG. 2 is a process flow diagram of the method of the present invention. As shown in the figure, in practical implementation, the welding method of the present invention includes the following steps:
and step 05, visually inspecting the appearance quality of the bottom plate 1 and the cover plate 2, measuring the sizes of relevant characteristic positions, performing ultrasonic cleaning by using an oil removing agent aqueous solution after determining that no appearance defect exists and no size excess difference exists, and then washing the cleaned product under flowing water and airing or blow-drying the product.
And step 10, processing the surfaces of the base plate 1 and the cover plate 2 which need to be diffusion-welded, wherein the surface processing mode comprises laser cleaning, steel wire brush polishing or sand paper polishing, then wiping the surfaces of the parts by using acetone or absolute ethyl alcohol, and then airing or drying.
Step 15, assembling and combining the base plate 1 and the cover plate 2 after surface treatment according to the positioning holes on the periphery, wherein the positions of the through hole 5 of the base plate 1 and the through hole 6 of the cover plate 2 are staggered, and welding a positioning point on each side edge of the plate by adopting TIG welding to prevent the plates from being staggered; in addition, preferably, the four sides of the bottom plate 1 may be provided with steps 3 (see fig. 1) of 2-10 mm to prevent the side portions from being crushed and excessively deformed during the welding process.
Step 20, respectively assembling a pressing plate 7 on the outer surfaces of the combined bottom plate 1 and the combined cover plate 2, and fixing the side surfaces of the two pressing plates 7 by using Ni foil in a spot welding manner to enable the bottom plate 1, the cover plate 2 and the pressing plates 7 to form a whole; preferably, the surface of the press plate 7 should be flat and free of defects, and a ceramic coating of alumina, zirconia, or the like is applied by cold spray or plasma spray. The material of the pressing plate 7 is a high-temperature resistant alloy with a close linear expansion coefficient of the welded parent metal, the thickness is 2-10 mm, and the shape and the size are consistent with those of the welded parent metal.
Step 25, wrapping the combined bottom plate 1, the cover plate 2 and the pressing plate 7 by using a stainless steel plate with the thickness of 0.5-1.5 mm, sealing and welding the opening of the stainless steel sheath 8 by adopting TIG welding, and reserving an opening with the thickness of 2-10 mm at the position of a welding line 9 (see figure 3);
step 30, sealing the opening left at the welding seam 9 by adopting vacuum electron beam welding, wherein the vacuum degree during the vacuum electron beam welding is lower than 5 multiplied by 10-3Pa；
Step 35, placing the sheath subjected to sealing into a gas pressurization furnace, paving the ceramic sheet below the sheath, and realizing diffusion welding between the base plate 1 and the cover plate 2 under the action of inert gas pressure and temperature, wherein the gas pressurization diffusion welding process parameters are as follows: the gas pressure is 1-20 MPa, the heat preservation temperature is 1050-1250 ℃, and the heat preservation time is 1-5 h;
and step 40, cutting the stainless steel sheath 8 from the edge, taking off the pressing plate 7 to obtain the welded thin-wall densely-arranged hole column complex-structure laminate, and inspecting the welding rate and the inner cavity pressing amount of the laminate.
The first embodiment is as follows:
a welding method of a high-temperature alloy thin-wall close-packed hole column complex-structure laminate adopts the following process steps to weld:
step 05, visually inspecting the appearance quality of the bottom plate 1 and the cover plate 2, measuring the sizes of relevant characteristic positions, performing ultrasonic cleaning by using an oil removing agent aqueous solution after determining that no appearance defect and no size over-difference exist, and then washing and drying the bottom plate and the cover plate under flowing water;
step 10, processing the surfaces of the base plate 1 and the cover plate 2 which need to be diffusion-welded, wherein the surface processing mode adopts laser cleaning, then wiping the surfaces of the parts by acetone, and then drying the parts;
step 15, assembling and combining the bottom plate 1 and the cover plate 2 after surface treatment according to positioning holes on the periphery, wherein the positions of the through holes 5 and the through holes 6 need to be staggered, and adopting TIG welding to weld positioning points on the side edges of the plates respectively to prevent the plates from being staggered;
step 20, respectively assembling a pressing plate 7 on the outer surfaces of the combined bottom plate 1 and the combined cover plate 2, and fixing the side surfaces of the two pressing plates 7 by using Ni foil in a spot welding manner to enable the bottom plate 1, the cover plate 2 and the pressing plates 7 to form a whole;
step 25, wrapping the combined bottom plate 1, the cover plate 2 and the pressing plate 7 by using a stainless steel plate with the thickness of 0.5mm, sealing and welding the opening of the stainless steel sheath 8 by adopting TIG welding, and reserving a 2mm opening at the position of a welding line 9;
step 30, sealing the opening left at the welding seam 9 by adopting vacuum electron beam welding;
step 35, placing the sheath subjected to sealing into a gas pressurization furnace, paving the ceramic sheet below the sheath, and realizing diffusion welding between the base plate 1 and the cover plate 2 under the action of inert gas pressure and temperature, wherein the gas pressurization diffusion welding process parameters are as follows: the gas pressure is 1MPa, the heat preservation temperature is 1200 ℃, and the heat preservation time is 1 h;
and step 40, cutting the stainless steel sheath 8 from the edge, taking off the pressing plate 7, and obtaining the welded thin-wall close-packed hole column complex-structure laminate with the welding rate of 99.3% and the inner cavity pressing amount of about 0.04 mm.
Example two:
a welding method of a stainless steel three-layer close-packed hole column complex structure laminate adopts the following process steps to weld:
step 05, visually inspecting the appearance quality of the bottom plate 1 (two plates) and the cover plate 2, measuring the sizes of relevant characteristic positions, performing ultrasonic cleaning by using an oil removing agent aqueous solution after determining that no appearance defect and no size over-difference exist, and then washing and drying the bottom plate 1 (two plates) and the cover plate under flowing water;
step 10, processing the surfaces of the two base plates 1 and the cover plate 2 which need to be diffusion-welded, wherein the surface processing mode adopts laser cleaning, then wiping the surfaces of the parts by absolute ethyl alcohol, and then drying the parts;
step 15, assembling and combining the two bottom plates 1 and the cover plate 2 after surface treatment according to positioning holes on the periphery, wherein the cover plate 2 is clamped between the two bottom plates 1, and welding positioning points on the side edges of the plates by adopting TIG welding to prevent the plates from being staggered;
step 20, respectively assembling a pressing plate 7 on the outer surfaces of the two combined bottom plates 1 and the cover plate 2, and fixing the side surfaces of the two pressing plates 7 by using Ni foil in a spot welding manner to enable the bottom plates 1, the cover plate 2 and the pressing plates 7 to form a whole;
step 25, wrapping the combined bottom plate 1, cover plate 2 and pressing plate 7 by using a stainless steel plate with the thickness of 1.5mm, sealing and welding the opening of the stainless steel sheath 8 by adopting TIG welding, and reserving a 10mm opening at the position of a welding line 9;
step 30, sealing the opening left at the welding seam 9 by adopting vacuum electron beam welding with the vacuum degree of 2 multiplied by 10-3Pa；
Step 35, placing the sheath subjected to sealing into a gas pressurization furnace, paving the ceramic sheet below the sheath, and realizing diffusion welding between the bottom plate 1 and the cover plate 2 and the bottom plate 1 under the action of inert gas pressure and temperature, wherein the gas pressurization diffusion welding process parameters are as follows: the gas pressure is 20MPa, the heat preservation temperature is 1050 ℃, and the heat preservation time is 5 h;
and step 40, cutting the stainless steel sheath 8 from the edge, taking off the pressing plate 7, and obtaining the welded three-layer thin-wall close-spaced hole column complex-structure laminate with the welding rate of 98.5% and the inner cavity rolling reduction of about 0.05 mm.
The technical scheme has the advantages and beneficial effects that:
1. the invention adopts the technical scheme of gas pressurization diffusion welding, can solve the technical problems of easy deformation, difficult pressurization and the like of a large-area thin-wall densely-arranged hole column complex-structure laminate in the diffusion welding process, realizes the integral uniform pressurization welding of a large-area laminate, can solve the precise forming problem of the complex laminate structure with low cost and high quality due to the simple adopted die (pressure plate), and has simple process and high reliability;
2. the invention adopts reasonable TIG welding, spot welding, vacuum electron beam welding, gas pressurization diffusion welding and other combined welding technologies, fully utilizes the advantages of each welding method, can realize the laminate welding of multi-layer, multi-material combination and special-shaped hole column structure, and has wide process applicability;
3. the invention can realize solid phase connection at the welding seam between each layer plate, thereby avoiding the technical problems of brittleness, split welding cracking, welding hole blocking and the like of joints formed by brazing filler metal or intermediate alloy, simultaneously the tensile strength of the joints can reach more than 90 percent of the parent metal, the welding rate of the thin-wall close-packed hole column complex structure layer plate can reach more than 98 percent, and the reduction of the inner cavity is not higher than 0.07 mm.
Claims (10)
1. A welding method of a thin-wall close-packed hole column complex-structure laminate comprises the following steps:
positioning points are respectively welded on the side edges of the bottom plate (1) and the cover plate (2), the bottom plate (1) and the cover plate (2) are assembled and combined together according to the surrounding positioning holes, and the through holes (5) of the bottom plate (1) and the through holes (6) of the cover plate (2) are staggered;
respectively assembling pressing plates (7) on the outer surfaces of the combined bottom plate (1) and the combined cover plate (2), and fixing the side surfaces of the two pressing plates (7) by spot welding through metal foils;
wrapping the combined bottom plate (1), cover plate (2) and pressure plate (7) with a metal sheet, sealing and welding the opening of the sheath (8), and leaving an opening at the position of the welding line (9);
sealing the opening left at the welding seam (9) by adopting vacuum electron beam welding;
and (3) carrying out gas pressurization diffusion welding between the bottom plate (1) and the cover plate (2) on the sheath after sealing, wherein the process parameters are as follows: the gas pressure is 1-20 MPa, the heat preservation temperature is 1050-1250 ℃, and the heat preservation time is 1-5 h;
and removing the sheath (8) and the pressing plate (7) to obtain the welded thin-wall close-packed hole column complex-structure laminate.
2. The method of claim 1, wherein the thin-walled close-packed pore column complex structured laminate is two or more layers.
3. The method according to claim 1, wherein the thin-wall close-packed hole column complex structural layer plate material is a same or different material of high-temperature alloy and stainless steel.
4. The method of claim 1, wherein the bosses and through-holes of the thin-walled close-packed pore column complex structure are circular, rectangular, or irregular in shape.
5. The method of claim 1, wherein the complex-structured bosses of the thin-walled close-packed columns are formed by photo-electrochemical machining.
6. A method according to claim 1, wherein the four sides of the base plate (1) are provided with steps (3) of 2-10 mm.
7. The method according to claim 1, wherein the material of the pressure plate (7) is a high temperature resistant alloy having a linear expansion coefficient close to that of the welded parent metal, a thickness of 2 to 10mm, and a shape and a size consistent with that of the welded parent metal.
8. A method according to claim 1, wherein the surface of the press plate (7) is flat and free of defects and a ceramic coating of alumina or zirconia is applied by cold spraying or plasma spraying.
9. The method according to claim 1, wherein the metal sheet is a stainless steel sheet having a thickness of 0.5 to 1.5 mm.
10. The method of claim 1 wherein the vacuum electron beam seal is applied at a vacuum level of less than 5 x 10-3Pa。
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