搅拌摩擦焊的缺陷类型及其检测技术

简要介绍了搅拌摩擦焊的工艺特点及其在航空结构中的应用;分析了搅拌摩擦焊的缺陷类型;根据新型制造工艺所提出的新的检测需求,介绍了可用于搅拌摩擦焊的检测方法。     

TC18钛合金焊接接头力学性能试验研究

氩弧焊和电子束焊是钛合金加工中两类常见的工艺方法,对比研究两种工艺对焊接接头力学性能的影响对其在工程中的合理选用具有重要的参考价值。完成了TC18钛合金氩弧焊接头和电子束焊接头的静力拉伸及旋转弯曲疲劳试验,并根据试验结果对两类焊接接头的力学性能进行了对比分析,采用统计学方法给出了二者的中值疲劳寿命SN曲线及疲劳极限。研究结果表明：氩弧焊接头焊缝区内晶粒粗大,使得材料的力学性能明显劣化;电子柬焊接头具有更高的抗拉强度与更好的高周疲劳性能,更有利于工程应用。     

燃气喷射推力矢量喷管气固两相流数值模拟

利用Euler-Lagrangian方法模拟了固体火箭发动机燃气喷射推力矢量喷管气固两相内流场,研究了固体颗粒对喷管推力矢量性能的影响.气相采用Roe格式和MUSCL (monotone upstream-centred schemes for conservation laws)插值进行空间2阶迎风离散,时间推进采用隐式时间格式;固体颗粒相采用随机轨道模型计算颗粒轨迹,并与气相进行双向耦合.结果表明:固体颗粒的存在使弓形激波强度增强,但降低了推力矢量角和推力系数;颗粒质量分数相同时,粒径越大,推力矢量角和推力系数越大;颗粒直径相同时,颗粒质量分数越大,推力矢量角和推力系数越小.      

热水火箭发动机喷管性能的影响因素

为了更好地了解影响热水火箭发动机喷管性能的因素,分别对不同参数条件下喷管内流场进行数值模拟.重点研究不同初始条件如不同初始压力、初始气体体积分数及过冷度和不同喷管结构如不同扩张比、收敛半角及扩张半角对推力的影响规律,计算结果表明:初始压力越大,推力越大;随着初始气体体积分数增大,推力会有一个先增大后减小的过程;热水火箭发动机内部初始温度越接近于饱和温度,推力越大;随着扩张比的增加,推力会有一个先增大后减小的过程;收敛半角对推力影响不大;扩张半角越大,推力越小.      

TY-4火箭发射装置导流器热结构计算分析

根据TY-4火箭离轨段燃气流瞬态特性,对双面楔形导流器面板强度、温度参数和离轨扰动等具体技术问题进行了计算分析。结果表明,采用熔点和导热系数高的导流材料,使热量沿厚度方向传递,可以容纳燃气传热,降低表面温度,减少烧蚀;导流型面和冲击角的设计,对于减小冲击,抑制火箭起始扰动有重要作用。     

铝合金厚板FSW焊缝成形及金属流动行为分析

采用三角平面圆锥形搅拌针焊接20 mm厚的铝板,分析工艺参数对焊缝成形及金属流动特征影响。随着旋转速度增加,单位时间内金属迁移量增大,焊核区面积增加,疏松区面积减小至消失;而过大的旋转速度反而使疏松缺陷再次出现。适当减小焊接速度,增大单位长度内焊缝热输入,改善焊缝成形,但焊接速度过小易导致焊缝上部受热过多,疏松区及内部孔洞变大。在合适的参数下焊接时,瞬时空腔的出现可使更多塑化金属绕搅拌针做圆周迁移,即提高了沿水平方向的“抽吸-挤压”效应,改善了金属流动性,减少甚至消除焊缝内部缺陷。     

Effects of traverse speed on weld formation,microstructure and mechanical properties of ZK60 Mg alloy joint by bobbin tool friction stir welding

ZK60B (Mg-6% Zn-0.6% Zr) alloy joints fabricated by bobbin tool friction stir welding (BTFSW) with various traverse speeds were investigated. The sound joint fabricated by the BTFSW was possible under the appropriate welding parameters. The severe plastic deformation during BTFSW resulted in dispersion and segregation of the Zr-rich particles within the stirred zone (SZ) followed by evolution of a bimodal grain structure with distributed bands of 0.8–1.7 μm ultrafine grains and 4.1–7.1 μm equiaxed grains. Micro-hardness of SZ is substantially reduced in contrast to that of parent metal (PM) in spite of the finer grain size owing to dissolution of Mg-Zn based precipitates having hardening effects on alpha-Mg matrix. With the decrease in traverse speed, randomization degree of the plasticized metal flow increases, which is evidenced by the randomized arc line pattern at the low traverse speed. Among all defect-free joints, the 200 mm/min joint exhibits the weakest isotropy of texture within SZ and the best tensile properties, which has reduced ultimate tensile strength and yield strength by 5.4% and by 22.2%, respectively, as compared to the PM. The randomized texture hinders the joint fracturing within SZ at low elongation. Therefore, a relatively high elongation of 10.8% was achieved, which corresponded to 72% of the PM value.     

Effect of beam current on microstructures and mechanical properties of joints of TZM/30CrMnSiA by electron beam welding

Electron beam welding experiments of TZM alloy and 30CrMnSiA steel butt joints were carried out with different beam currents. Microstructures and chemical compositions of typical zones were analyzed by optical microscopy, scanning electron microscopy and X-ray diffraction. The mechanical properties of the joints were evaluated by tensile strength tests. Besides, nanoindentation tests were carried out to compare the brittleness of the reaction layer and other typical microstructures. The results illustrated that the reaction layer at the interface between fusion zone (FZ) and TZM alloy was the weak position of the joint, which was divided into Fe₂Mo layer and a mixture layer of Fe₂Mo and α-Fe phases. As the beam current increased, the thickness of the Fe₂Mo layer decreased, which resulted in the increasing of the tensile strength of the joints. When the beam current exceeded 24 mA, the formation of the joint was poor with a low tensile strength. When the beam current was 24 mA, the joint presented the highest strength of 191.3 MPa and the joint fractured along the Fe₂Mo layer near the TZM alloy side with a brittle fracture mode.     

电子束焊接熔池流场数值模拟研究

基于电子束焊接"钉型"焊缝特征,建立了高斯面和旋转高斯衰减体复合热源模型,采用ANSYS FLOTRAN CFD有限元软件,对焊接熔池流场进行了数值模拟,研究了熔池内液态金属在温度场作用下涡漩流动过程,电子束、熔池、液态金属蒸汽之间相互作用关系,电子束匙孔效应、匙孔壁能量传递方式,熔深方向液态金属流动机理等;将316L不锈钢热物性参数输入复合热源模型,通过仿真计算,得到了316L不锈钢焊接工艺规范,即加速电压为60 kV,电子束流为30 mA,焊接速度为8 mm/s,采用该规范焊接的316L不锈钢试件焊缝拉伸强度为425 MPa,满足设计要求。通过对比数值模拟与实际焊接结果表明:模拟熔池形貌与实际焊缝形貌一致,数值计算结果与焊接试验结果相吻合,从而证明复合热源模型是正确和适用的。     

整体叶盘叶片焊缝裂纹相控阵超声检测

裂纹是线性摩擦焊整体叶盘结构制造过程中叶片焊缝区域常见的缺陷类型之一。由于叶片焊缝区域结构复杂且裂纹缺陷尺寸小,因此焊缝区域裂纹缺陷的检测难度大。为了满足新工艺的应用要求,研究了焊缝区域的相控阵超声全覆盖检测方法,建立了焊缝区域相控阵超声检测的有限元仿真模型,研究了裂纹特征参数和声束聚焦点位置对检测方案的影响,验证了检测方案的可行性与正确性。构建了机器人化的相控阵超声检测系统,模拟了声束在线性摩擦焊叶片试样中的传播过程,实现了对叶片中预制裂纹缺陷的识别。研究结果表明,设计的检测方案能够满足叶片快速检测的要求。