7085铝合金残余应力及加工变形的数值仿真与试验

毛坯残余应力的测量以及零件的加工变形分析是航空整体结构件数控加工工艺研究的难题。应用MSC.Marc软件对某型飞机主起支撑接头的7085铝合金锻件毛坯的淬火-压缩工艺进行了数值仿真,获得了毛坯残余应力分布趋势;应用X射线衍射法与钻孔法测量了毛坯表层残余应力分布,提出了基于系数修正法的毛坯残余应力分析方法,通过最小二乘法（LSM）拟合仿真值与试验值以获得应力修正系数,并对毛坯残余应力分布的仿真结果进行修正,获得了实际毛坯的残余应力分布;由此进行了主起支撑接头缩比零件加工变形仿真与验证试验。研究结果表明：7085铝合金块状毛坯残余应力数值仿真结果与测试结果的趋势吻合,为应力修正提供了物理基础;相对于未修正的应力分布,基于修正后的应力分布仿真获得的变形结果精度提高了50%;7085-T7452铝合金的毛坯残余应力是导致主起支撑接头加工变形的主要因素。     

大型机翼整体壁板时效成形技术

 分析了单级时效、双/多级时效、振动时效以及应力位向效应等工艺措施和因素对铝合金机翼整体壁板材料时效成形特性的影响,得到以下结论：应采用双/多级时效处理,以提高成形后壁板材料的综合性能;应采用振动时效应力松弛,以加速应力松弛,降低回弹,并提高成形后壁板材料的抗疲劳性能;对时效过程中存在应力位向效应的铝合金,应设计合适的时间温度曲线与加载曲线,以避免壁板材料因应力位向效应产生各向异性,导致材料屈服强度降低。提出了大型机翼整体壁板时效成形的工艺流程,给出了成形过程中热压罐内的温度时间曲线和气压时间曲线;提出了成形工装的模块化、标准化与柔性化设计以及解决壁板时效成形回弹问题的有限元方法,并对中国研究发展大型机翼整体壁板时效成形技术提出了建议。     

机载雷达制造技术的特点

本文从装配、表面防护和密封、铝合金焊接、铝合金精密铸造、精密机械加工和检测与试验等方面分析了机载雷达制造技术的特点。     

γ-TiAl合金铣削加工表面残余应力研究

为了探索高温理想结构材料γ-Ti Al合金铣削表面残余应力特性,结合正交试验数据处理方法中的极差分析法,建立各工艺因素情况下不同水平对表面残余应力的关系曲线,并对其工艺过程中的热力影响机理进行分析;同时建立面向残余应力的各因素灵敏度数学模型,进而确定以获取较大残余压应力为目标的工艺参数优选区间。研究表明:在试验参数限定范围内,步进方向以及进给方向均呈现为残余压应力,主要原因是冷塑性变形占主导作用。通过对灵敏度数学模型进行分析,发现残余应力对设计变量中的铣削速度变化最敏感,对每齿进给量、铣削深度和铣削宽度的敏感程度近似相同,为Ti Al金属间化合物铣削表面残余应力控制研究提供了理论依据。     

工艺参数对搅拌摩擦焊7022铝合金残余应力及耐磨耐蚀性能的影响

采用不同的焊接参数对10mm厚7022铝合金进行搅拌摩擦焊研究.利用X射线应力分析仪检测焊接试样的残余应力分布;利用摩擦磨损试验机对焊缝试样进行磨损性能研究,并通过三维形貌仪观察其磨损形貌;利用pH=5的Na2SO4溶液对焊接试样进行腐蚀试验,并通过SEM观察其表面腐蚀形貌.结果表明:各参数下焊接试样的残余应力均较小,...     

Residual Strength of Stiffened LY12CZ Aluminum Alloy Panels with Widespread Fatigue Damage

Experimental and analytical investigations on the residual strength of the stiffened LY12CZ aluminum alloy panels with widespread fatigue damage （WFD） are conducted. Nine stiffened LY12CZ aluminum alloy panels with three different types of damage are tested for residual strength. Each specimen is pre-cracked at rivet holes by saw cuts and subjected to a monotonically increasing tensile load until failure is occurred and the failure load is recorded. The stress intensity factors at the tips of the lead crack and the adjacent WFD cracks of the stiffened aluminum alloy panels are calculated by compounding approach and finite element method （FEM） respectively. The residual strength of the stiffened panels with WFD is evaluated by the engineering method with plastic zone linkup criterion and the FEM with apparent fracture toughness criterion respectively. The predicted residual strength agrees well with the experiment results. It indicates that in engineering practice these methods can be used for residual strength evaluation with the acceptable accuracy. It can be seen from this research that WFD can significantly reduce the residual strength and the critical crack length of the stiffened panels with WFD. The effect of WFD crack length on residual strength is also studied.     

铝锂合金激光焊T型接头残余应力分布特征

分别采用激光焊、激光填丝焊、MIG焊等焊接方法对5A90铝锂合金T型接头进行焊接,然后采用X射线衍射法对其进行残余应力测量,获得了T型接头垂直于焊缝方向不同位置处的残余应力分布,并分析了不同焊接方法对其残余应力分布规律的影响。     

GH3536电子束焊接残余应力分布分析

采用应力释放法测量了10mm厚GH3536高温合金电子束焊接纵向残余应力分布.结果表明:高温合金电子束焊接残余应力分布范围较小,约为焊缝宽度的4-7倍.残余应力的最大值可达到材料的屈服极限.研究成果为优化电子束焊接工艺和应力与变形分析提供了理论依据和指导.     

基于形状改变比能和材料属性离散的焊接残余应力估算

为了提高焊接残余应力测量精度,在2219-T87铝合金TIG焊接接头残余应力测定试验基础上,通过离散接头材料属性并利用形状改变比能对焊接残余应力进行塑性修正,分别研究孔边塑性变形和接头强度不匹配对焊接残余应力估算的影响。结果表明：同时考虑孔边塑性变形和接头强度不匹配因素的焊接残余应力估算方法,比线弹性残余应力计算方法能最大减小39.8%的误差;当测量点距焊缝距离小于8mm时,在考虑孔边塑性变形的情况下,同时考虑接头不匹配的影响相比不考虑其影响可最大减小40.6%的误差;当测量点距焊缝距离大于8mm时,可忽略接头强度不匹配对焊接残余应力估算的影响。     

TC2薄壁钣金异型环快速制造工艺

对某种柔性的薄壁TC2钛合金异型环,传统的制造工艺由下料、拼焊、成形、机械加工、表面处理等工序组成。针对该工艺流程繁复、制造成本高的问题,提出一种不用成形的快速制造方法。该方法利用异形环平直母线可精确展开的特征,对其不同半径的锥面逐步展开后合理叠加成精确的展开图形,依图形下料并对焊成环。此方法仅需下料和焊接,无需成形和机械加工,流程简单,为该类零件的低成本、快速制造提供了新途径。     

航空高强度铝合金残余应力的抑制与消除

从残余应力的产生和释放两个方面 ,讨论了抑制与消除铝合金中残余应力的若干技术与方法。首先 ,从尽量减少残余应力的产生又兼顾获得所需机械性能的角度 ,分析了采用热水淬火、喷雾淬火及有机介质淬火等淬火工艺。其次讨论了消除铝合金中残余应力的若干技术方法的特点、效果与适用场合 ,并指出在铝合金结构件淬火后的不稳定状态进行残余应力消除处理效果最佳     

GH4096合金固溶冷却方式对性能和残余应力的影响

为了在保证GH4096合金主要力学性能的前提下,降低薄壁类零件用锻件的内部残余应力,提高零件加工过程的尺寸控制精度,研究空冷,风冷,油冷,盐浴等固溶冷却方式对GH4096合金环锻件析出相的尺寸和形貌、主要力学性能和内部残余应力的影响。结果表明:与采用传统油冷的试件相比,空冷试件的二次、三次γ′相较为粗大,蠕变性能和高温拉伸性能有较大幅度的降低,风冷试件的二次γ′相尺寸略有增大,三次γ′相尺寸相当,蠕变性能和拉伸性能有小幅降低,盐浴冷却试件的二次、三次γ′相尺寸相当,蠕变性能和拉伸性能相差较小。采用风冷的试件内部残余应力可控制在±100 MPa以内,比油冷和盐浴冷却的试件降低50%以上。GH4096合金环件固溶处理冷却方式采用风冷与传统的油冷和盐浴冷却方法相比,可以明显降低锻件内部残余应力,蠕变和高温拉伸等性能只有小幅降低,有助于改善GH4096合金薄壁零件冷加工过程的变形问题,提高尺寸控制精度。     

Experimental study of effect of post processing on fracture toughness and fatigue crack growth performance of selective laser melting Ti-6Al-4V

For Ti-6Al-4V, a titanium alloy increasingly used in aerospace structure, selective laser melting (SLM) is an attractive additive manufacturing technology, which is attributed to its complex construction capability with high accuracy and good surface quality. In order to obtain qualified mechanical properties, SLM parameters and post processing should be tailored for diverse service conditions. Fracture toughness and fatigue crack growth (FCG) behavior are critical characteristics for damage tolerance evaluation of such metallic structures, and they are affected by post processing technologies significantly. The objective of this study is to obtain the fracture toughness and fatigue crack growth behavior of Ti-6Al-4V manufactured by SLM, and to evaluate the influence of post-SLM thermomechanical treatment and surface machining. Fracture toughness and FCG tests were performed for SLM Ti-6Al-4V in three types of post processing status: as-built, heat treated and hot isostatically pressed (HIPed), respectively. Specimens with as-built and machined surface were tested. The microstructure and fractography were analyzed as well in order to investigate the relevance among manufacture process, microstructure and mechanical properties. The results demonstrate that as-built SLM Ti-6Al-4V presents poor ductility and FCG behavior due to martensitic microstructure and residual stresses. Both heat treatment and hot isostatic pressing improve the plane-stress fracture toughness and FCG performance considerably, while surface machining shows slight effect.     

Manufacturing With Lasers Developments and Opportunities

Developments and opportunities for manufacturing with lasers are considered in three broad themes. Process enhancements, in particular hybrid-laser arc welding and twin spot laser welding are described. Two examples of novel manufacturing processes (laser joining of aluminium to steel and laser direct metal deposition) are considered. Finally, a new laser source (Yb: YAG fibre laser) is introduced as an additional competing processing capability.     

Advances and challenges on springback control for creep age forming of aluminum alloy

Creep age forming(CAF) is an advanced forming technology that combines creep deformation and age hardening processes. When compared with the conventional forming technologies including roll bending and shot-peen forming, CAF has many advantages of low residual stress,excellent dimensional stability, good service performance and short production cycle. It is an optimal technique for precise manufacturing for shape and properties of large-scale complicated thinwalled components of light-weight and...     

An allowance allocation method based on dynamic approximation via online inspection data for deformation control of structural parts

Deformation resulting from residual stress has been a significant issue in machining. As allowance allocation can directly impact the residual stress on part deformation, it is essential for deformation control. However, it is difficult to adjust allowance allocation by traditional simulation methods based on residual stress, as the residual stress cannot be accurately measured or predicted, and many unexpected factors during machining process cannot be simulated accurately. Different from traditional methods, this paper proposes an allowance allocation method based on dynamic approximation via online inspection data for deformation control of structural parts. An Autoregressive Integrated Moving Average (ARIMA) model for dynamic allowance allocation is established so as to approach the minimum deformation, which is based on the in-process deformation inspection data during the alternative machining process of upside and downside. The effectiveness of the method is verified both by simulation cases and real machining experiments of aircraft structural parts, and the results show that part deformation can be significantly reduced.     

ARALL层压板结构工艺及性能分析

论述了目前在航空领域发展非常迅速的ARALL层压板结构和芳纶预浸料的制造工艺,预浸料在具有高的抗疲劳特性和拉伸特性的ARALL层压板结构中起到一个非常重要的承力和抗疲劳作用。本结构所采用的制造方法是纤维拉伸法,是一种能使ARALL结构的铝板层具有残余压应力,使纤维层也具有残余拉应力的方法,从而改善了材料本体的抗疲劳性能。     

浅析搅拌摩擦焊残余应力

讨论了搅拌摩擦焊残余应力的产生原因,在已有的试验结果的基础上对残余应力的分布和规律进行了概述。并且以钨极氩弧焊(TIG)为例,将搅拌摩擦焊与传统熔焊的残余应力分布进行了对比,进一步肯定了搅拌摩擦焊在铝合金焊接时的优越性。同时还介绍了对搅拌摩擦焊残余应力的控制方法及其效果,最后对有关搅拌摩擦焊的残余应力的研究工作做出了展望。     

碳纤维增强铝合金层合板的残余热应力分析

碳纤维增强铝合金层合板（CARALL）是由碳纤维复合材料和铝合金薄板制成的,由于碳纤维复合材料和铝合金的热膨胀系数相差很大,加热固化后会产生较大的残余热应力。本文对碳纤维增强铝合金层合板中残余热应力进行了分析,并在碳纤维增强铝合金层合板的加热固化阶段,使用二次加热法来降低碳纤维复合材料和铝合金薄板的粘结温度,从而降低残余热应力。     

铝锂合金研究进展及发展趋势

铝锂合金历经三代发展,形成了完善的材料谱系,具有高比强度、高比韧度、高耐损伤的特点,是一种具有替代传统铝合金潜力,高减重效益的轻质合金,被认为是21世纪飞行器和舰船理想的结构材料。本文回顾了铝锂合金的发展历程,介绍了铝锂合金的成分设计思路、主要制备方法、先进应用技术等方面的研究进展,梳理了铝锂合金的发展趋势,指出成本较高是制约铝锂合金进一步大规模应用的主要问题,提出完善铝锂合金产品类型,开展抗疲劳、耐损伤、低密度铝锂合金研制,研究铝锂合金大型零件的整体制造技术,开发开展铝锂合金时效成形技术,激光焊、搅拌摩擦焊等先进连接技术等应用研究方向。