辅助加热温度对铝合金厚板FSW焊缝成形的影响

对铝合金厚板搅拌摩擦焊（FSW）而言,焊缝底部金属温度低、流动能力差是导致焊缝成形困难的主要原因。为此,本研究采用辅助加热的方式对待焊母材底部进行预热,分析辅助加热温度对厚板搅拌摩擦焊焊缝成形的影响。结果表明,随着辅助加热温度从20℃升高至80℃时,焊缝成形质量先变好后变差,宏观表现为焊缝内部焊核区宽度、高度及面积呈现先增大后减小的趋势,而疏松区面积呈现先减小后增大的趋势。其中,当辅助加热温度为40℃时,焊缝成形质量最好,焊核区尺寸最大,疏松区消失;而当辅助加热温度升高至80℃时,焊缝成形质量最差,疏松区面积最大。研究认为,其主要原因是添加合适的辅助加热温度可显著提高焊核区塑性金属的峰值温度及高温停留时间,塑性金属流动能力明显提高,焊缝成形质量得到极大改善。焊核区塑性金属的迁移方式由沿搅拌针表面向焊缝上部高温区迁移向挤压焊核区周边冷金属横向迁移转变。但是,当辅助加热温度太高时,焊核区塑性金属迁移方式开始转变为原始的沿搅拌针表面向焊缝上部高温区迁移,且此迁移程度有明显增大的趋势,导致焊缝内部疏松区缺陷再次出现。     

钛合金TB6刀具磨损铣削实验研究

使用硬质合金刀具对钛合金TB6进行正交铣削实验,对比分析不同切削参数下的刀具磨损情况,并用实验结果进行回归分析得到刀具磨损的回归公式。结果表明:刀具主要磨损在后刀面,其磨损大都呈现一条带状磨损带,在速度增大时大磨损带变长,刀具易发生脆性破损,且在刀具表面会出现钛合金粘连;对刀具耐用度的影响大小依次为切削速度、进给量、切削宽度和切削深度;刀具磨损回归方程具有良好的回归方差,能够很好的对刀具寿命进行预测。     

镁合金铸件缺陷搅拌摩擦修复工艺方法

针对航天器铸件缺陷率高,修复难度大的现状,提出采用搅拌摩擦加工技术实现缺陷修复的新方法。首先制备了含缺陷的AZ91D镁合金试板,并以此作为实验材料进行了搅拌摩擦修复工艺实验,在旋转速度为500r/min,前进速度100mm/min,下压量为1.5mm的工艺参数下,修复区域成形良好。修复前后X射线照片表明,搅拌摩擦加工技术有效修复了镁合金试板中的铸造缺陷。最后对航天器铸件中常见的T形结构和角形结构开展了对应的实验研究,在现有条件下,采用自制简易夹具,可以完成T形结构和角形结构的搅拌摩擦加工。研究结果表明,采用搅拌摩擦方法修复航天器铸件缺陷从技术上是可行的。     

优化镍基高温合金X-750热处理工艺参数的非线性超声无损评估方法

为了获得更好的材料性能,需要对热处理工艺参数进行精确地优化。非线性超声无损检测技术是一种可以有效表征材料微观结构状态变化的评估方法,可以用来评估、优化热处理工艺参数。利用非线性超声波对热处理后的X-750合金材料进行评估,根据超声传播的非线性响应不同,对材料的性能变化做出判断,并与线性超声检测技术的评估结果进行了对比研究。研究发现经过热处理之后,材料性能显著提高,在其中传播的超声非线性响应则明显下降。材料经过热处理后性能提升越大,其声学非线性响应就会变得越小。根据超声波传播的非线性响应定性评估了3种不同的热处理工艺,明确了最优的镍基高温合金X-750退火工艺参数。研究证实了非线性超声方法的敏感度优于传统的线性超声评估方法,可以对材料的热处理效果进行无损评估,从而对热处理工艺参数进行优化与完善。     

新型铝锂合金AA2198高频疲劳红外热耗散演化规律

利用红外成像技术开展新型铝锂合金AA2198高频疲劳（100 Hz）热耗散演化规律研究,发现不同应力条件下疲劳热耗散呈现上下波动特征,试件平均温度随着加载应力的提升有增加的趋势,但升温现象并不明显,不同应力条件下温度变化幅值小于1℃。疲劳试验初期和疲劳断裂时伴随着急剧升温过程,提出的能量转化理论模型合理解释了疲劳热耗散演化过程。研究还发现,喷丸强化在试件表面形成的残余压应力有助于激发疲劳裂纹的闭合效应,对试件的升温过程具有抑制作用。     

热处理对激光增材制造TC4合金耐蚀性及室温压缩蠕变性能的影响

随着钛合金装备在航空、航天、航海等领域的使用逐渐增多,其服役环境日益严苛,对构件材料的抗腐蚀性能及室温应力蠕变性能提出了更高要求。针对钛合金耐蚀性及抗压缩蠕变的性能,分析了激光增材制造TC4合金不同热处理状态试样电化学及室温压缩蠕变性能,并结合蠕变曲线修正了蠕变第Ⅰ阶段本构方程的参数。结果表明,双重退火处理会显著减小增材制造TC4钛合金中α板条长径比与尺寸,而固溶时效可使α板条长径比增大、尺寸减小,导致了材料耐蚀性、屈服极限以及抗压缩蠕变性能的变化。沉积态合金经过固溶时效后自腐蚀电流降低64.92%,稳态蠕变应变率降低46.31%,蠕变应变降低50%。而经过双重退火后合金自腐蚀电流降低26.14%,稳态蠕变应变率提升111.20%,蠕变应变提升48.68%。相比于铸锻工艺制备TC4合金蠕变本构方程,修正后的拟合系数与蠕变曲线吻合度更高。     

Milling surface roughness for 7050 aluminum alloy cavity influenced by nozzle position of nanofluid minimum quantity lubrication

In nanofluid minimum quantity lubrication (NMQL) milling of aviation aluminum alloy, it is the bottleneck problem to adjust the position parameters (target distance, incidence angle, and elevation angle) of the nozzle to improve the surface roughness of milling, which has large and uncontrollable errors. In this paper, the influence law of milling cutter speed, helical angle, and cavity shape on the flow field around the milling cutter was studied, and the optimal nozzle profile parameters were obtained. Using 7050 aluminum alloy as the workpiece material, the milling experiment of the NMQL cavity was conducted by utilizing cottonseed oil-based Al₂O₃ nanofluid. Results show that the high velocity of the surrounding air flow field and the strong gas barrier could be attributed to high rotating velocities of the milling cutter. The incidence angle of the nozzle was consistent with the helical angle of the milling cutter, the target distance was appropriate at 25–30 mm, and the elevation angle was suitable at 60°–65°. The range and variance analyses of the signal-to-noise ratio of milling force and roughness were performed, and the chip morphology was observed and analyzed. The results show that the optimal combination of nozzle position parameters was the target distance of 30 mm, the incidence angle of 35°, and the elevation angle of 60°. Among these parameters, target distance had the largest impact on cutting performance with a contribution rate of more than 55%, followed by incidence angle and elevation contribution rate. Analysis by orthogonal experiment revealed that the nozzle position parameters were appropriate, and R_a (0.087 μm) was reduced by 30.4% from the maximum value (0.125 μm). Moreover, R_sm (0.05 mm) was minimum, which was 36% lower than that of the seventh group (R_sm = 0.078 mm).     

Brazing diamond grits onto AA7075 aluminium alloy substrate with Ag–Cu–Ti filler alloy by laser heating

The brazing of diamond is a promising way to fabricate grinding wheels for efficient machining and precision grinding. This work investigated the feasibility of bonding diamond grits onto Aluminium Alloy 7075 (AA7075) substrate with a Ag–Cu–Ti filler alloy via laser fusion brazing. The interfacial microstructures and the strength of the brazed diamond joints were studied. The cross-section of the brazed diamond joint consists of a molten filler alloy layer, a molten pool, a heat effect zone, a columnar crystal zone and an equiaxed crystal zone. Within the interface of the filler alloy/substrate metal, microstructures observed possibly were Ag(s.s), Al(s.s), TixAl, Al2Cu and Mg intermetallic compounds. A layer of TiC with a thickness of about 30–50 nm was found at the bonding interface of the diamond/filler alloy. The averaged peak shear force of the brazed joints was found to be approximately 39.8 N. The abrasion grinding test indicated that the diamond/AA7075 brazed joint was adequate for grinding. However, the pulled-off of grit was found to be the primary failure of this type of brazed joint. This work broadened the brazing diamond technique and the range of applications of brazed diamond wheels for efficient grinding.     

高强铝合金复合脉冲VPTIG焊缝组织和性能

采用超快速变换复合超音频脉冲方波变极性TIG电弧焊接工艺进行2219-T87高强铝合金焊接,研究分析了焊缝显微组织和接头拉伸性能变化.结果表明,2219-T87铝合金复合超音频脉冲电流变极性焊接接头的组织和性能均发生显著变化,焊缝区显微组织明显细化,由粗大柱状晶向细小等轴晶转变,接头抗拉强度和断后伸长率显著提高.接头断口由脆性断裂主要特征转变为"韧性+脆性"的混合型断裂模式.在一定范围内,脉冲电流频率越高,脉冲占空比越小,作用效果越明显.复合超音频脉冲电流频率为40 kHz,脉冲电流占空比为20%时,接头抗拉强度和断后伸长率分别达到母材金属的70%和58%.