K465镍基合金叶片电子束钎焊修复及裂纹控制研究
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摘要
航空工业中所使用的镍基高温合金叶片的焊接修复一直是连接领域研究的热点和难点之一,本文对K465镍基高温合金叶片的电子束钎焊修复进行了研究。K465镍基高温合金的焊接性较差,而电子束钎焊是一种局部加热的钎焊方法,在焊接过程会产生较大的热应力,焊后接头极易产生裂纹。因此,在综合分析接头界面反应产物含量及分布规律的基础上,结合焊接热应力的分布特征,针对K465镍基高温合金叶片的修复,提出了一种控制热输入的电子束钎焊修复方法,实现了K465镍基高温合金叶片电子束钎焊的无裂纹修复。
钎料的研制与选用是K465镍基高温合金电子束钎焊连接的关键问题,考虑电子束钎焊K465合金对钎料的性能要求,采用机械合金化方法制备了一种适合电子束钎焊K465镍基高温合金的高温和高性能镍基钎料。通过电子束钎焊工艺参数对BNi-2、Bпp27和自制1号三种钎料铺展面积影响和不同钎料接头力学性能的研究,选择了自制1号钎料进行真空电子束钎焊研究。
通过对采用自制1号钎料的K465镍基高温合金电子束钎焊接头界面反应产物的分析,发现电子束钎焊的工艺参数对界面反应产物的形成和分布有直接影响。焊接修复的界面共生成五种反应产物,它们分别是:镍基γ固溶体、Ni2Si、Ni3B、Ni3Si和Ni3Al相。
试验结果表明,当电子束钎焊工艺参数改变时,接头界面产物的种类并未发生改变,但对界面产物的形态与数量影响较大。当电子束钎焊束流较小或加热时间较短时,镍基γ固溶体在钎焊接头界面中所占的比例较大;当电子束钎焊束流较大或加热时间较长时,Ni2Si、Ni3B、Ni3Si和Ni3Al钎焊接头界面中所占的比例增加,界面中的基体相镍基γ固溶体所占的比例减少,块状的Ni2Si尺寸变大,分布较集中,主要分布在接头界面和母材的交界处。
研究了工艺参数对接头抗拉强度和断裂部位的影响。结果表明,接头的抗拉强度随着束流和加热时间的增加而升高,当强度达到最大值后,随着束流和加热时间的增加反而降低。在本试验条件下,当束流为2.7mA、加热时间为200s和聚焦电流为1800mA时,接头的最大抗拉强度为760MPa,可达母材强度的82%。
K465镍基高温合金开非贯通槽叶片模拟件电子束钎焊修复接头极易产生裂纹,裂纹大多起裂于焊缝或接头界面附近的母材上,整体沿着纵向穿过钎缝,其主要原因是热应力较大。拉伸断裂往往发生在钎缝和近缝母材处,为脆性穿晶断裂。而开贯通槽叶片模拟件很少产生裂纹。
通过对开非贯通槽叶片模拟件的分析,得到了产生宏观裂纹所对应的冷却时间,并计算了此时的温度和应力分布,发现距试件中心1.3~2.4mm是应力集中区域,且沿Y轴σY方向比X轴σX方向应力值较大,最高可达935MPa,裂纹绝大多数均沿X轴方向分布。对比非贯通槽和贯通槽叶片模拟件的X轴σX方向和Y轴σY方向的应力分布,发现相同位置具有贯通槽试件的应力小于非贯通槽试件。室温时由于接头中仍有826MPa的残余拉应力,从而使开贯通槽试件接头在低应力下拉伸断裂。
根据上述研究结果,本文提出一种束流逐级跃迁热输入控制电子束钎焊K465镍基高温合金叶片无裂纹修复方法:即采用焊前逐级增加束流的预热和焊后逐级减少束流的方式调控焊接热循环曲线,缓解和释放热应力。采用该方法最终获得了K465镍基高温合金叶片模拟件电子束钎焊修复无宏观裂纹接头。并采用X射线衍射技术测定了束流逐级跃迁热输入控制电子束钎焊接头的残余应力场分布。
采用局部束流逐级跃迁热输入控制电子束钎焊修复方法实现了K465镍基高温合金非贯通槽和贯通槽叶片的无裂纹修复。对修复后的叶片进行X射线探伤,结果未发现裂纹和其它焊接缺陷。
Ni-base superalloy blades welding repair always serves as one of the hot and difficult issues in the joining fields. The K465 Ni-base superalloy blades repairing by vacuum electron beam brazing (VEBB) has been studied in this paper. The weldability of K465 alloy is poor, and VEBB is a method only for local heating, these two factors induce the generation of heat stress in the joints during brazing and hot cracks easily formation in the joints after brazing. Therefore, basing on the analysis of composition and distribution of the interfacial reaction products of the joints and heat stress distribution during brazing, a beam current gradual transition heat input control VEBB repair method of K465 Ni-base superalloy blades has been developed, and the crack-free joints of K465 Ni-base superalloy blades have been obtained by VEBB repair.
Development and choice of the filler metal is the key factor of VEBB K465 Ni-base superalloy. Considering the requirement of VEBB on the filler metal, a new Ni-base filler metal with good high temperature property is developed by mechanical alloying. The effect of VEBB parameters on the spreading area and the mechanical property of the joints with BNi-2, Bпp27 and No.1 self-made filler metal were carried out, No.1 self-made filler metal was chosen as the filler metal for VEBB study.
According to the experimental results of interface reactions on the K465 Ni-base superalloy interface, it was found that the VEBB parameters had a direct effect on the formation and distribution of the interface reaction products. There are five reaction products in the repaired joints interface, they are Ni-baseγsolid solution, Ni2Si, Ni3B, Ni3Si and Ni3Al.
The experimental results show that interface reaction products do not change with the electron beam brazing parameters varying, but shape and quantity of reaction products are effectively affected. When the electron beam current is small or heating time is short, the quantity of Ni-baseγsolid solution is large in the brazed joint interface. While the electron beam current is large or heating time is long, the content of Ni2Si, Ni3B, Ni3Si and Ni3Al increases, but the content of Ni-baseγsolid solution decreases in the brazed joint interface. At the same time, the size of Ni2Si become larger, and the distribution of Ni2Si is concentrated on interface between filler metal and base material.
Effects of brazing parameters on joint tensile strength and fracture position are investigated. The joint strength improves as the electron beam current and heating time increase. When the strength comes to the maximum, it declines with the electron beam current and heating time increase. In this work, the largest tensile strength could reach 760MPa, 82 percent of that of base material, when the current is 2.7mA, heating time is 200s and focus current is 1800mA.
Hot cracks easily occurred during VEBB repairing K465 Ni-base superalloy simulating blades with non-through slot. Mostly, cracks occur from the seam and base metal next to the joining interface, then the cracks go along the whole seam. This is mainly because the hot stress is large. Tensile fractures usually appear at the seam and base metal near the seam, which belong to brittle transcrystalline fracture. While simulating blades with through slot rarely produce cracks.
The cooling time of crack initiation was got by analyzing simulating blades with non-through slot. The distribution of temperature and stress was calculated. The results showed that stress concentration area was 1.3~2.4mm away from the center of the specimens. And the stressσY in Y axis direction was higher thanσX in X axis direction, the maximum tensile stress reached to was 935MPa. Most of the cracks were in X axis direction. Comparing the tensile stress distribution ofσX in X axis direction andσY in Y axis direction of simulating blades with non-through and through slot, the tensile stress of simulating blades with non-through slot was less than that of simulating blades with non-through slot at the same position. The residual tensile stress in the joints was 826MPa, resulting in low stress fracture of the through slot specimens joints.
According to the above results, a beam current gradual transition heat input control method was developed, which could obtain crack-free joints of of K465 Ni-base superalloy blades by VEBB. The procedure as follows: application of brazing preheating step-by-step increasing beam current and step-by-step decreasing beam current slow-cooling after brazing, which were used to control brazing thermal cycle and release the heat stress. Finally, macro crack-free joints of K465 Ni-base superalloy simulating blades with non-through slot have been obtained by this method. X-ray diffraction was applied to measure the residual stress distribution by beam current gradual transition heat input control method.
The crack-free joints of K465 Ni-base superalloy blades with non-through slot and through slot were repaired by beam current gradual transition heat input control VEBB method. The results showed there was no crack or any other welding defects by X-ray detection.
钎料的研制与选用是K465镍基高温合金电子束钎焊连接的关键问题,考虑电子束钎焊K465合金对钎料的性能要求,采用机械合金化方法制备了一种适合电子束钎焊K465镍基高温合金的高温和高性能镍基钎料。通过电子束钎焊工艺参数对BNi-2、Bпp27和自制1号三种钎料铺展面积影响和不同钎料接头力学性能的研究,选择了自制1号钎料进行真空电子束钎焊研究。
通过对采用自制1号钎料的K465镍基高温合金电子束钎焊接头界面反应产物的分析,发现电子束钎焊的工艺参数对界面反应产物的形成和分布有直接影响。焊接修复的界面共生成五种反应产物,它们分别是:镍基γ固溶体、Ni2Si、Ni3B、Ni3Si和Ni3Al相。
试验结果表明,当电子束钎焊工艺参数改变时,接头界面产物的种类并未发生改变,但对界面产物的形态与数量影响较大。当电子束钎焊束流较小或加热时间较短时,镍基γ固溶体在钎焊接头界面中所占的比例较大;当电子束钎焊束流较大或加热时间较长时,Ni2Si、Ni3B、Ni3Si和Ni3Al钎焊接头界面中所占的比例增加,界面中的基体相镍基γ固溶体所占的比例减少,块状的Ni2Si尺寸变大,分布较集中,主要分布在接头界面和母材的交界处。
研究了工艺参数对接头抗拉强度和断裂部位的影响。结果表明,接头的抗拉强度随着束流和加热时间的增加而升高,当强度达到最大值后,随着束流和加热时间的增加反而降低。在本试验条件下,当束流为2.7mA、加热时间为200s和聚焦电流为1800mA时,接头的最大抗拉强度为760MPa,可达母材强度的82%。
K465镍基高温合金开非贯通槽叶片模拟件电子束钎焊修复接头极易产生裂纹,裂纹大多起裂于焊缝或接头界面附近的母材上,整体沿着纵向穿过钎缝,其主要原因是热应力较大。拉伸断裂往往发生在钎缝和近缝母材处,为脆性穿晶断裂。而开贯通槽叶片模拟件很少产生裂纹。
通过对开非贯通槽叶片模拟件的分析,得到了产生宏观裂纹所对应的冷却时间,并计算了此时的温度和应力分布,发现距试件中心1.3~2.4mm是应力集中区域,且沿Y轴σY方向比X轴σX方向应力值较大,最高可达935MPa,裂纹绝大多数均沿X轴方向分布。对比非贯通槽和贯通槽叶片模拟件的X轴σX方向和Y轴σY方向的应力分布,发现相同位置具有贯通槽试件的应力小于非贯通槽试件。室温时由于接头中仍有826MPa的残余拉应力,从而使开贯通槽试件接头在低应力下拉伸断裂。
根据上述研究结果,本文提出一种束流逐级跃迁热输入控制电子束钎焊K465镍基高温合金叶片无裂纹修复方法:即采用焊前逐级增加束流的预热和焊后逐级减少束流的方式调控焊接热循环曲线,缓解和释放热应力。采用该方法最终获得了K465镍基高温合金叶片模拟件电子束钎焊修复无宏观裂纹接头。并采用X射线衍射技术测定了束流逐级跃迁热输入控制电子束钎焊接头的残余应力场分布。
采用局部束流逐级跃迁热输入控制电子束钎焊修复方法实现了K465镍基高温合金非贯通槽和贯通槽叶片的无裂纹修复。对修复后的叶片进行X射线探伤,结果未发现裂纹和其它焊接缺陷。
Ni-base superalloy blades welding repair always serves as one of the hot and difficult issues in the joining fields. The K465 Ni-base superalloy blades repairing by vacuum electron beam brazing (VEBB) has been studied in this paper. The weldability of K465 alloy is poor, and VEBB is a method only for local heating, these two factors induce the generation of heat stress in the joints during brazing and hot cracks easily formation in the joints after brazing. Therefore, basing on the analysis of composition and distribution of the interfacial reaction products of the joints and heat stress distribution during brazing, a beam current gradual transition heat input control VEBB repair method of K465 Ni-base superalloy blades has been developed, and the crack-free joints of K465 Ni-base superalloy blades have been obtained by VEBB repair.
Development and choice of the filler metal is the key factor of VEBB K465 Ni-base superalloy. Considering the requirement of VEBB on the filler metal, a new Ni-base filler metal with good high temperature property is developed by mechanical alloying. The effect of VEBB parameters on the spreading area and the mechanical property of the joints with BNi-2, Bпp27 and No.1 self-made filler metal were carried out, No.1 self-made filler metal was chosen as the filler metal for VEBB study.
According to the experimental results of interface reactions on the K465 Ni-base superalloy interface, it was found that the VEBB parameters had a direct effect on the formation and distribution of the interface reaction products. There are five reaction products in the repaired joints interface, they are Ni-baseγsolid solution, Ni2Si, Ni3B, Ni3Si and Ni3Al.
The experimental results show that interface reaction products do not change with the electron beam brazing parameters varying, but shape and quantity of reaction products are effectively affected. When the electron beam current is small or heating time is short, the quantity of Ni-baseγsolid solution is large in the brazed joint interface. While the electron beam current is large or heating time is long, the content of Ni2Si, Ni3B, Ni3Si and Ni3Al increases, but the content of Ni-baseγsolid solution decreases in the brazed joint interface. At the same time, the size of Ni2Si become larger, and the distribution of Ni2Si is concentrated on interface between filler metal and base material.
Effects of brazing parameters on joint tensile strength and fracture position are investigated. The joint strength improves as the electron beam current and heating time increase. When the strength comes to the maximum, it declines with the electron beam current and heating time increase. In this work, the largest tensile strength could reach 760MPa, 82 percent of that of base material, when the current is 2.7mA, heating time is 200s and focus current is 1800mA.
Hot cracks easily occurred during VEBB repairing K465 Ni-base superalloy simulating blades with non-through slot. Mostly, cracks occur from the seam and base metal next to the joining interface, then the cracks go along the whole seam. This is mainly because the hot stress is large. Tensile fractures usually appear at the seam and base metal near the seam, which belong to brittle transcrystalline fracture. While simulating blades with through slot rarely produce cracks.
The cooling time of crack initiation was got by analyzing simulating blades with non-through slot. The distribution of temperature and stress was calculated. The results showed that stress concentration area was 1.3~2.4mm away from the center of the specimens. And the stressσY in Y axis direction was higher thanσX in X axis direction, the maximum tensile stress reached to was 935MPa. Most of the cracks were in X axis direction. Comparing the tensile stress distribution ofσX in X axis direction andσY in Y axis direction of simulating blades with non-through and through slot, the tensile stress of simulating blades with non-through slot was less than that of simulating blades with non-through slot at the same position. The residual tensile stress in the joints was 826MPa, resulting in low stress fracture of the through slot specimens joints.
According to the above results, a beam current gradual transition heat input control method was developed, which could obtain crack-free joints of of K465 Ni-base superalloy blades by VEBB. The procedure as follows: application of brazing preheating step-by-step increasing beam current and step-by-step decreasing beam current slow-cooling after brazing, which were used to control brazing thermal cycle and release the heat stress. Finally, macro crack-free joints of K465 Ni-base superalloy simulating blades with non-through slot have been obtained by this method. X-ray diffraction was applied to measure the residual stress distribution by beam current gradual transition heat input control method.
The crack-free joints of K465 Ni-base superalloy blades with non-through slot and through slot were repaired by beam current gradual transition heat input control VEBB method. The results showed there was no crack or any other welding defects by X-ray detection.
引文
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