Electroforming nickel dissimilar metal vacuum electron beam welding process method
Through the electroformed nickel differentiated metal vacuum electron beam welding process, the welding bias problem in differentiated metal welding is solved. Through segmented programming and demagnetization processing, welding parameters are optimized, and the high strength and dynamic load requirements of the thrust chamber weld are achieved, achieving the GJB1718A-2005 weld grade I standard.
Patent Information
- Application Number
- CN202411515841.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-29
- Publication Date
- 2025-01-07
AI Technical Summary
During the manufacturing process of the thrust chamber, the different metal welding between electroformed nickel and stainless steel is unevenly distributed due to physical properties, resulting in welding deviation and insufficient effective melting depth of welds, which is difficult to meet the requirements of high strength and dynamic load. GJB1718A-2005 Welding Grade I Standard.
The vacuum electron beam welding process of electroformed nickel different metals is optimized by adjusting the beam spot position in two times during the welding process, combining machine-engraved lines and demagnetization treatment, welding parameters such as working distance, acceleration voltage, beam current and frequency are optimized. Ensure effective melting depth and accuracy of the weld.
It effectively avoids welding deviation, improves welding accuracy and operability, ensures that the welds meet the requirements of high strength and dynamic load, and meets the qualified standards of GJB1718A-2005 weld grade I.
Smart Images
Figure CN119260133A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of thrust chamber dissimilar metal welding, and in particular to a vacuum electron beam welding process method for electroformed nickel dissimilar metals. Background Art
[0002] In the manufacturing process of thrust chamber products, dissimilar steel welding is a key process, especially the dissimilar metal welding between electroformed nickel and stainless steel. This type of weld is often presented as a radial butt weld, which has the characteristics of narrow space deep penetration welding, and there are flow channels distributed around the weld. Due to the complex weld structure and high welding quality requirements, traditional welding methods are difficult to meet the requirements, so high-energy beam welding methods must be used, among which vacuum electron beam welding has become an ideal choice.
[0003] Figure 1 It is a radial butt weld of dissimilar steels in the thrust chamber. The parent materials on both sides of the product are stainless steel (forging) and electroformed nickel layer on the metal substrate respectively. The product structure is annular thin-walled parts. The electroformed nickel segment 3 and the stainless steel segment 4 are matched with the stop gap. The electroformed nickel segment 3 is inserted from the top of the stainless steel segment 4. After assembly, argon arc welding and spot welding are required to connect and fix. This is a non-full penetration weld structure and requires vacuum electron beam welding.
[0004] Figure 2 for Figure 1 A local enlarged schematic diagram, dimension E is the axial avoidance distance between the weld and the parent material flow channel 2 of the electroformed nickel section 3, and dimension F is the axial avoidance distance between the weld and the parent material flow channel 1 of the stainless steel section 4.
[0005] The structure of the thrust chamber radial weld is a rotating body, forming a full-circle weld, and it is a non-full penetration structure. The weld penetration depth is required to exceed 9mm, and the parent materials on both sides are electroformed nickel and stainless steel respectively. The diameter of the weld is φ100-φ590mm, and the flow channel distance between the weld and the parent materials on both sides is 3-9mm and 3-9mm respectively. Such a spatial layout further increases the difficulty of welding.
[0006] This key component in the thrust chamber not only requires the weld to withstand high-strength tensile and shear forces, but also needs to meet the requirements of dynamic load welds, so it must meet the qualified standard of GJB1718A-2005 weld grade I. However, welding of dissimilar steels faces many challenges. Due to the significant differences in physical properties such as melting point, thermal conductivity, and expansion coefficient between electroformed nickel and stainless steel, the heat distribution during welding is uneven, resulting in different volumes of molten metal on both sides of the parent material under the same heat input, which may cause the root of the weld to be offset, and the effective penetration of the weld is insufficient, which cannot meet the product requirements.
[0007] Figure 3 Schematic diagram of radial weld deviation between stainless steel and electroformed nickel dissimilar steel metals (left) and schematic diagram of actual weld requirements (right).
[0008] As a high-energy beam welding method, the basic principle of electron beam welding is to use accelerated and focused electrons to bombard the welding surface in a vacuum, so that the workpieces are melted to achieve welding. However, electron beam welding is sensitive to magnetic fields. The electrons in magnetic workpieces will be affected by the magnetic field and their trajectories will deviate, resulting in welding deviation. Electroformed nickel materials will generate irregular magnetic fields during processing and welding. The magnetic flux of the processed workpiece can locally reach 5GS, which directly hinders the application of electron beam welding.
[0009] Figure 4 It is shown that during the electron beam welding process, the electrons are disturbed by the magnetic fields of the base materials on both sides, and the electrons do not bombard the center of the weld of the workpiece according to the theoretical trajectory.
[0010] Therefore, in order to solve the problem of welding dissimilar metals between electroformed nickel and stainless steel in thrust chamber, an effective solution needs to be proposed, which can not only achieve high penetration welding, but also avoid the risk of weld deviation and ensure the effective penetration of the weld. Summary of the invention
[0011] In order to solve the above problems, the present invention provides a vacuum electron beam welding process method for electroformed nickel dissimilar metals, which solves the welding deviation problem in dissimilar metal welding, improves welding accuracy and operability, optimizes welding parameters, solves the magnetic field interference problem of electroformed nickel materials, and adapts to complex weld structures and high strength requirements.
[0012] The technical solution of the present invention is as follows: The invention discloses a vacuum electron beam welding process method for electroforming nickel dissimilar metals, which is used for welding radial welds of a thrust chamber. The thrust chamber is an annular thin-walled part, the weld is a full-circle annular weld, a non-full penetration structure is adopted, the fusion depth is greater than 9 mm, the upper side and the lower side of the weld are an electroforming nickel section and a stainless steel section respectively, the electroforming nickel section and the stainless steel section are matched with a stopper gap, the electroforming nickel section is inserted from above the stainless steel section, the weld is 3-9 mm away from the second side flow channel of the electroforming nickel section, and 3-9 mm away from the first side flow channel of the stainless steel section. The weld is welded by vacuum electron beam welding, wherein programming is required twice in the vacuum electron beam welding process, the first time the beam spot is deflected to one side of the electroforming nickel section by 0.2-1.5 mm for programming, and the second time the beam spot is deflected to one side of the electroforming nickel section by 1-2 mm for programming.
[0013] Before programming, machine-marked lines are added on one side of the electroformed nickel segment at 0.2-1.5 mm and 1-2 mm from the weld.
[0014] The electron beam welding parameters are as follows: working distance 500-700mm, acceleration voltage 100-150KV, beam current 20-30mA, welding speed 200-1000mm / min, focusing current 1900-2000 mA, function type 8 waveform, amplitude X 0.1-0.5, amplitude Y 0.8-1.5, function frequency 100-2000Hz.
[0015] At the starting point of arcing, the beam spot is aligned with the weld position, and at the ending point of arcing, the beam spot is aligned with the scribed line position. The arcing process is a slow transition from the weld to the scribed line position; at the starting point of arcing, the beam spot slowly transitions from the scribed line position to the weld position and reaches the ending point of arcing.
[0016] The electroformed nickel section is demagnetized before welding; after demagnetization, the average magnetic flux of the entire circle of the electroformed nickel section is 2-3GS.
[0017] The beneficial effects of the present invention are: 1. The present invention discloses a vacuum electron beam welding process method for electroformed nickel dissimilar metals, which solves the problem of welding deviation and ensures the effective penetration depth of the weld: in order to solve the welding deviation problem caused by the difference in physical properties when welding electroformed nickel and stainless steel dissimilar metals, the electron beam spot is aligned with the center of the weld and deviated to the nickel side by 0.2-1.5mm and 1-2mm for segmented welding, which effectively avoids the welding deviation phenomenon, ensures that the effective penetration depth of the weld meets the product requirements, and the root fusion is good.
[0018] 2. The present invention discloses a vacuum electron beam welding process method for electroformed nickel dissimilar metals, which improves welding accuracy and operability: before programming, by machine-adding engraved lines at the positions of 0.2-1.5mm and 1-2mm away from the weld on one side of the electroformed nickel segment, a clear positioning reference is provided for vacuum electron beam welding, which greatly improves the welding accuracy and operability, and makes the welding process more stable and controllable.
[0019] 3. The present invention discloses a vacuum electron beam welding process for electroforming nickel dissimilar metals, which determines suitable welding parameters, including working distance, acceleration voltage, beam current, welding speed, focusing current, function type, amplitude and function frequency, etc. The optimized combination of these parameters makes the welding process more efficient and stable, and can obtain high-quality welds.
[0020] 4. The present invention discloses a vacuum electron beam welding process method for electroformed nickel dissimilar metals. The vacuum electron beam welding process method for electroformed nickel dissimilar metals adopts a large demagnetization machine for demagnetization treatment. Through the demagnetization treatment, the average full-circle magnetic flux of the electroformed nickel segment is reduced to 2-3GS, thereby realizing the feasibility of vacuum electron beam welding.
[0021] 5. The present invention discloses an electroformed nickel dissimilar metal vacuum electron beam welding process method, which is particularly suitable for the radial full-circle annular weld of the thrust chamber and is a non-full penetration structure; the diameter of the weld is φ100-φ590mm, and the flow channel distances with the parent materials on both sides are 3-9mm and 3-9mm respectively, and the spatial layout is complex; through this process method, the weld can withstand high-strength tensile force and shear force, meet the requirements of dynamic load welds, and reach the qualified standard of GJB1718A-2005 weld grade I. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] By reading the detailed description of the preferred embodiment below, the scheme and advantages of the present application will become clear to those skilled in the art. The accompanying drawings are only for the purpose of illustrating the preferred embodiment and are not to be considered as limiting the present invention.
[0023] In the attached picture: Figure 1 This is a schematic diagram of the radial butt weld structure of dissimilar steel in the thrust chamber; Figure 2 for Figure 1 A partial enlarged schematic diagram of the middle weld area; Figure 3 It is a schematic diagram of radial weld deviation of dissimilar steel metals of stainless steel section and electroformed nickel section and a schematic diagram of actual weld requirements; Figure 4 This is a schematic diagram of the process of the influence of the magnetic field on electrons in electron beam welding; Figure 5 A schematic diagram of a line drawing in a vacuum electron beam welding process method for electroforming nickel dissimilar metals according to an embodiment of the present invention; Figure 6 A schematic diagram of programming of a vacuum electron beam welding process method for electroforming nickel dissimilar metals according to an embodiment of the present invention; The components represented by the reference numerals in the figure are: The present invention comprises: 1. flow channel one, 2. flow channel two, 3. electroformed nickel section, 4. stainless steel section, 5. welding seam, and 6. engraved line. DETAILED DESCRIPTION
[0024] The electroformed nickel dissimilar metal vacuum electron beam welding process is particularly suitable for the welding of the radial weld of the thrust chamber.
[0025] like Figure 1 and Figure 2As shown, the thrust chamber is an annular thin-walled part, which is composed of a stainless steel section 4 and an electroformed nickel section 3. The two are matched through the gap of the stopper, and the electroformed nickel section 3 is inserted from the top of the stainless steel section 4. The weld 5 is a full-circle ring weld, located between the electroformed nickel section 3 and the stainless steel section 4, and adopts a non-full penetration structure. The penetration depth is required to be greater than 9mm. The diameter (outer diameter) of the weld 5 is φ100-φ590mm, and the distance between the weld 5 and the side flow channel 2 of the electroformed nickel section 3 is 3-9mm, and the distance between the weld 5 and the side flow channel 1 of the stainless steel section 4 is 3-9mm.
[0026] In order to solve the problem of welding deviation caused by the difference in physical properties when welding dissimilar steels, the specific steps of the through weld alignment scheme of the present invention are as follows: Machine marking lines: Machine marking lines 6 are added on one side of the electroformed nickel segment 3 at positions 0.2-1.5 mm and 1-2 mm away from the axial direction of the weld 5 as a positioning reference during welding, such as Figure 5 shown.
[0027] Programming and welding: During the vacuum electron beam welding process, programming is required twice. The first time, the beam spot is deflected to one side of the electroformed nickel segment 3 by 0.2-1.5mm for programming, and the second time, the beam spot is deflected to one side of the electroformed nickel segment 3 by 1-2mm for programming. In this way, during the welding process, the melt volume of the parent material on the electroformed nickel side is increased, and the fusion ratio of the parent materials on both sides of the dissimilar steel is adjusted, thereby avoiding the offset of the root weld.
[0028] The specific welding parameters are as follows: Working distance: 500-700mm Accelerating voltage: 100-150KV Beam current: 20-30mA Welding speed: 200-1000mm / min Focusing current: 1900-2000mA Function type: Waveform No. 8 Amplitude X: 0.1-0.5 Amplitude Y: 0.8-1.5 Function frequency: 100-2000Hz like Figure 6 As shown, arc starting and arc extinction programming needs to be divided into four points: arc starting point (beam current 0), arc starting end point (beam current peak value), arc ending point (beam current peak value) and arc ending end point (beam current 0).
[0029] In the process of arc starting and arc ending, in order to ensure the stability and quality of welding, it is necessary to carry out precise arc starting and arc ending programming. The specific steps are as follows: Arc starting process: At the arc starting point, align the beam spot with the weld position 5. As the beam current gradually increases, the beam spot slowly transitions to the position of the scribed line 6, which is the arc starting end point.
[0030] Arc closure process: At the start of arc closure, the beam spot slowly transitions from the position of the scribed line 6 to the position of the weld 5. As the beam current gradually decreases, it reaches the end of arc closure.
[0031] Since the electroformed nickel material will generate irregular magnetic fields during processing and welding, which will affect the trajectory of the electron beam, it is necessary to demagnetize the electroformed nickel segment 3. A large demagnetization machine is used for demagnetization. After demagnetization, the average magnetic flux of the entire circle is reduced to 2-3GS, thus realizing the feasibility of vacuum electron beam welding.
[0032] Through the implementation of the above process method, the welding quality of the thrust chamber radial weld 5 has been significantly improved. The effective penetration depth of the weld has reached the product requirements, and the root fusion is good, and no welding deviation occurs. At the same time, the process method also has the advantages of simple operation, high stability, and wide application range, providing strong technical support for the manufacture of key components such as thrust chambers.
[0033] In summary, the electroformed nickel dissimilar metal vacuum electron beam welding process method provided by the present invention solves the problem of welding deviation in dissimilar metal welding, ensures the effective penetration depth and welding quality of the weld, and has significant technical effects and practical value.
Claims
1. A vacuum electron beam welding process for electroformed nickel dissimilar metals, used for welding a radial weld (5) of a thrust chamber, wherein the thrust chamber is an annular thin-walled part, the weld (5) is a full-circle annular weld, adopts a non-full penetration structure, and has a penetration depth of >9 mm. The upper and lower sides of the weld (5) are respectively an electroformed nickel section (3) and a stainless steel section (4), the electroformed nickel section (3) and the stainless steel section (4) are fitted with a stop gap, the electroformed nickel section (3) is inserted from above the stainless steel section (4), the weld (5) is 3-9 mm away from the second side flow channel (2) of the electroformed nickel section (3), and is 3-9 mm away from the first side flow channel (1) of the stainless steel section (4), and is characterized in that: The weld (5) is formed by vacuum electron beam welding, wherein programming is performed twice during the vacuum electron beam welding process. The first time, the beam spot is deflected to one side of the electroformed nickel segment (3) by 0.2-1.5 mm for programming, and the second time, the beam spot is deflected to one side of the electroformed nickel segment (3) by 1-2 mm for programming.
2. The vacuum electron beam welding process for electroformed nickel dissimilar metals according to claim 1, characterized in that: Before programming, engraved lines (6) are machined on one side of the electroformed nickel segment (3) at positions 0.2-1.5 mm and 1-2 mm away from the weld (5).
3. A vacuum electron beam welding process for electroformed nickel dissimilar metals according to claim 1 or 2, characterized in that: The electron beam welding parameters are as follows: working distance 500-700mm, acceleration voltage 100-150KV, beam current 20-30mA, welding speed 200-1000mm / min, focusing current 1900-2000 mA, function type 8 waveform, amplitude X 0.1-0.5, amplitude Y 0.8-1.5, function frequency 100-2000Hz.
4. A vacuum electron beam welding process for electroformed nickel dissimilar metals according to claim 1 or 2, characterized in that: At the arc starting point, the beam spot is aligned with the weld (5) position, and at the arc ending point, the beam spot is aligned with the scribed line (6) position. The arc starting process is a slow transition from the weld (5) position to the scribed line (6) position; at the arc ending point, the beam spot slowly transitions from the scribed line (6) position to the weld (5) position and reaches the arc ending point.
5. The vacuum electron beam welding process for electroformed nickel dissimilar metals according to claim 1, characterized in that: The electroformed nickel segment (3) is demagnetized before welding.
6. The vacuum electron beam welding process for electroformed nickel dissimilar metals according to claim 5, characterized in that: After demagnetization, the electroformed nickel segment (3) has an average magnetic flux of 2-3 GS in the entire circle.