铝合金环形零件形/性一体化制造技术  

Technology of Integrated Manufacturing in Forming and Modification of Aluminum Alloy Rings

作　　者：秦芳诚 齐会萍 李永堂 刘崇宇[1] 亓海全 康跃华 QIN Fangcheng;QI Huiping;LI Yongtang;LIU Chongyu;QI Haiquan;KANG Yuehua(College of Materials Science and Engineering,Guilin University of Technology,Guilin 541004,China;Shanxi Key Laboratory of Metallic Materials Forming Theory and Technology,Taiyuan University of Science and Technology,Taiyuan 030024,China;Institute of Materials and Processing,Guangdong Academy of Sciences,Guangzhou 510650,China)

机构地区：[1]桂林理工大学材料科学与工程学院,桂林541004 [2]太原科技大学金属材料成形理论与技术山西省重点实验室,太原030024 [3]广东省科学院材料与加工研究所,广州510650

出　　处：《材料导报》2021年第9期9049-9058,共10页Materials Reports

基　　金：国家自然科学基金(51875383);广西自然科学基金项目(2019GXNSFAA245051,2018GXNSFBA281056);广西科技重大专项(GKAA18242007);广东省科学院创新驱动发展项目(2018GDASCX-0965);桂林理工大学科研启动基金(GUTQDJJ2017140)。

摘　　要：铝合金环形零件作为关键连接、传动、回转和支承部件在重型运载火箭贮箱、风电设备的轴承套圈及齿轮环、压力容器和核反应堆的加强圈等重大装备制造领域应用非常广泛。铝合金环形零件的生产是一个高能耗的热加工过程,现有生产工艺主要有两种:(1)厚板轧制-弯卷-对半焊接成形,环件焊接部位缝组织为弱性能区,无法满足在重载、冲击、高低温和强腐蚀等极端恶劣条件下长期稳定服役时的要求;(2)圆铸锭坯-多向锻造制坯-马架扩孔或环件辗扩,工艺流程冗长,辗扩前开坯、锻造和冲孔工序设备资金投入巨大,多次加热导致能源消耗和材料浪费严重,不利于环境友好型生产。深空探测领域铝合金环件存在几何尺度大、形状精度高、结构刚度低和服役环境苛刻等技术挑战,目前已实现Φ3 m~Φ10 m级大型铝合金环件辗扩生产。环件辗扩过程中的传热-变形-组织演变耦合行为使得环坯经历了多场、多因素作用下多道次、连续局部加载与卸载、不均匀变形和微观组织复杂演变历程。为了实现铝合金环件的辗扩成形,一是要使环件自身整体刚性和辗扩过程稳定,即"控稳";二是要使环件直径扩大与截面充填协同进行,同步获得径-轴向尺寸、截面轮廓及几何精度,即"控形";三是要使成形环件达到所要求的内部组织状态和各向性能,即"控性"。铝合金环形零件用环坯的制备是铝合金环件辗扩成形及其形/性一体化调控的基础,采用多向锻造变形技术可以有效细化大规格圆铸锭的粗大组织、破碎网状共晶化合物,实现组织改性,为后续辗扩过程提供优质环坯。通过开发铝合金环件双向辗扩智能建模仿真方法和基于力控的铝合金环件双向辗扩工艺路径智能仿真优化方法,解决了矩形/异形截面环件径-轴向变形区不协调、环件刚度弱及辗扩过程失稳等问题,实现了各轧辊运动的The applications of aluminum alloy rings as the critical connection,transmission,rotation and supporting components in the bearing and gear rings for wind power equipment and the heavy launch vehicle storage tank,and in the reinforcing rings for pressure vessels and nuclear reactors are increased dramatically.The production of aluminum alloy rings is a hot working process with an energy-extensive consumption.The current techniques are as follows:(i)thick-plate rolling,bend rolling,welding forming by a half.The microstructures are characterized by a weak performance in the welding positions.The rings cannot meet the requirements in long-term service under harsh conditions such as heavy loading,impact,high temperature and strong corrosion.(ii)Cast ingot blank,multi-directional forging,trestle reaming or ring rolling.Due to the cogging,forging and punching,the long process and huge investment in equipments are caused.The repeated heating results in extensive-energy consumption and material wasting,which is not conducive to the environmentally friendly production.Aluminum alloy rings is a major strategic demand for the deep space exploration.The challenges include large geometrical dimension,high shape precision,low structural stiffness and extreme service conditions are presented.Up to now,the large aluminum alloy rings with a diameter of 3—10 m are hot rolled.The couple of deformation-heat transfer-microstructure evolution leads to the complicated development in multi-pass,continuous loading and unloading partly,non-uniform deformation and inhomogeneous microstructure with multi-fields and multi-factors.To realize the hot ring rolling of aluminum alloy,the overall stiffness and the stability of rings should be controlled firstly.Secondly,the integrated control of radial-axial dimensions,section profile and geometric accuracy need to be realized.Thirdly,the required microstructure and properties in each direction of the hot-rolled rings should be achieved.The preparation of aluminum alloy ring blank is the basis o

关 键 词：铝合金环件 辗扩 一体化制造 铸辗复合成形 双金属环件 

分 类 号：TG331[金属学及工艺—金属压力加工] TG142[一般工业技术—材料科学与工程]