Titanium alloy high-stiffener structure one-shot electron beam welding forming method

Abstract

The present application relates to the technical field of welding, in particular to a titanium alloy high stud structure one-time electron beam welding forming method, comprising the following steps: analyzing the height of the high stud and the length dimension of the web section on both sides of the high stud, constructing a double-layer profile area composed of the first web section and the high stud, and a single-layer profile area of the second web section; adjusting the assembly angle to reduce the height of the double-layer profile area and designing the welding direction; according to the horizontal projection length relationship between the first web section and the high stud of the double-layer profile area, designing the length of the beam current block of the upper and lower layers, realizing the first web section beam current welding first, then the high stud beam current welding, and gradually completing the welding of the double-layer profile area; adjusting the focusing position of the electron beam so that the focusing position deviates from the midsection of the double-layer profile area; performing welding heat input parameter adjustment to realize one-time electron beam welding forming, observing the weld forming, and detecting the internal quality of the weld. The present application solves the technical problem of precise welding manufacturing difficulty of the high stud structure.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and in particular to a method for one-time electron beam welding of titanium alloy high-rib structures. Background Technology

[0002] In the aerospace industry, titanium alloy ribbed structures are widely used to achieve lightweight, high rigidity, and high load-bearing capacity. For highly ribbed titanium alloy structures, due to their three-dimensional structural characteristics, the manufacturing capabilities of forging and casting are beyond the scope of traditional integral manufacturing methods. Furthermore, if large-thickness integral forging blanks are used, the thin wall thickness and high right-angle ribs of the structure make CNC precision machining of long, straight, or large components prone to exceeding tolerances and extremely difficult.

[0003] Currently, the conventional manufacturing method involves disassembling the high-stiffening structure into smaller components and using auxiliary corner boxes and lugs. While these components can be mechanically connected and assembled using rivets, this introduces problems such as increased weight and lower load-bearing capacity. Analysis suggests that welding is an ideal solution, but for thin-walled sections with high stiffenings, conventional manual welding methods result in significant deformation and difficulty in defect control, failing to meet requirements for high weld quality and dimensional accuracy. Electron beam welding, on the other hand, offers advantages such as high energy density, low heat input, narrow heat-affected zone, high weld quality, and high automation. It is suitable for welding sections of equal thickness and is widely used in the welding and manufacturing of precision parts in the aerospace, weaponry, electronics, and shipbuilding industries. However, for high-stiffening structures with large-thickness equal-section sections, CNC precision machining after electron beam welding is also unsuitable. This is because when using electron beam welding to assemble the high-stiffening section components after CNC precision machining, the relative positions of the web plane and the high stiffenings present challenges, and the transition area between them also presents difficulties in weld quality control. Summary of the Invention

[0004] (a) Technical problems to be solved

[0005] This invention provides a one-time electron beam welding forming method for titanium alloy high-rib structures, solving the technical problem of difficult precision welding manufacturing of high-rib structures.

[0006] (II) Technical Solution

[0007] Embodiments of the present invention propose a one-step electron beam welding forming method for titanium alloy high-rib structures, comprising the following steps:

[0008] S1, analyze the height of the high reinforcement and the length of the web segments on both sides of the high reinforcement, construct the double-layer profile area composed of the first web segment and the high reinforcement, and the single-layer profile area of ​​the second web segment.

[0009] S2, Adjust the assembly angle to reduce the height of the double-layer profile area, and design the welding direction;

[0010] S3. Based on the horizontal projection length relationship between the first web section and the high vertical rib of the double-layer profile area, the length of the beam guide block of the upper and lower profiles is designed to realize the beam welding of the first web section first, and the beam welding of the high vertical rib first, and the welding of the double-layer profile area is gradually completed.

[0011] S4, adjust the focusing position of the electron beam so that the focusing position deviates downward from the mid-section of the double-layer profile region;

[0012] S5 allows for the adjustment of welding heat input parameters to achieve one-time electron beam welding formation, observation of weld formation, and detection of the internal quality of the weld.

[0013] Furthermore, the length of the first web segment is greater than or equal to the length of the second web segment.

[0014] Furthermore, in S2, the assembly angle is selected as 45°.

[0015] Furthermore, in S2, the direction of transition from the double-layer profile to the single-layer profile is selected as the welding direction.

[0016] Furthermore, in S3, a first flow-guiding block is provided at the starting end of the first web segment, a second flow-guiding block is provided at the starting end of the high upright rib, and a flow-receiving block is provided at the ending end of the second web segment.

[0017] Furthermore, the horizontal projection length of the first web segment is greater than or equal to the horizontal projection length of the high vertical rib, the length of the first beam guide block is 50mm to 60mm, and the length of the second beam guide block is 20mm to 30mm.

[0018] Furthermore, the horizontal projection length of the first web segment is less than the horizontal projection length of the high rib, the length of the first beam guide block is 50mm to 60mm plus the difference between the length of the high rib and the length of the first web segment, and the length of the second beam guide block is 20mm to 30mm.

[0019] Furthermore, the thickness of the convergent flow block is 2mm to 5mm, and the length is 30mm to 50mm.

[0020] Furthermore, in S4, based on the focusing current at the cross-sectional position in the double-layer profile region, the focusing current of the electron beam is reduced by 10mA to 50mA, and the focusing current in the single-layer profile region is adjusted according to the height position.

[0021] (III) Beneficial Effects

[0022] In summary, the present invention has the following advantages:

[0023] 1. Based on the analysis of the height of the high rib and the length of the web sections on both sides, the longer web section is selected to form a double-layer profile area with the high rib. Under the condition of 45° assembly angle, the welding direction from the double-layer profile area to the single-layer profile area is designed, which provides the basic conditions for the one-time welding of the high rib structure and can improve the stability of the welding process and the quality of the weld formation.

[0024] 2. Based on the horizontal projection length relationship between the web section and the high rib in the double-face area, the length of the beam-guiding block of the upper web section is designed to be greater than that of the beam-guiding block of the lower high rib, and to compensate for the length difference with the high rib. This allows the upper web section to be welded first, followed by the high rib section, to be welded when welding the same beam, thus gradually completing the welding of the double-face. This ensures a smooth transition between the beam initiation and welding, reduces defects in the beam initiation / reception section, improves the welding quality of the high rib structure, and is beneficial to the stability control of the welding process.

[0025] 3. Based on the downward eccentric adjustment of the focusing position, the active area of ​​the electron beam is brought closer to the lower surface, which improves the welding and forming quality of the lower metal and helps to solve the forming problem caused by the large distance between the two surfaces. Attached Figure Description

[0026] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the embodiments of the present invention will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a front view schematic diagram of the titanium alloy high-rib welded structure according to an embodiment of the present invention;

[0028] Figure 2 yes Figure 1 A side view diagram;

[0029] Figure 3 This is a schematic diagram of the welding cross-section of an embodiment of the present invention;

[0030] Figure 4 This is a schematic diagram of welding assembly according to an embodiment of the present invention;

[0031] Figure 5 This is a schematic diagram of the beam inlet / outlet configuration according to an embodiment of the present invention;

[0032] Figure 6 This is a schematic diagram of the focusing current process control according to an embodiment of the present invention;

[0033] In the figure: 1. First web segment; 2. Second web segment; 3. High vertical rib; 4. Flanged strip; 5. Electron beam; 6. Welded section; 7. First beam initiator; 8. Second beam initiator; 9. Beam take-off block. Detailed Implementation

[0034] The embodiments of the present invention will be further described in detail below with reference to the accompanying drawings and examples. The following detailed description of the embodiments and the accompanying drawings are used to illustrate the principles of the present invention by way of example, but should not be used to limit the scope of the present invention. That is, the present invention is not limited to the described embodiments, and any modifications, substitutions and improvements to the parts, components and connection methods are covered without departing from the spirit of the present invention.

[0035] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0036] Please refer to Figures 1-3 The titanium alloy high-strength welded structure consists of a web, high vertical ribs 3, and flanges 4. The weld section 6 is located between the webs and high vertical ribs 3 where the two workpieces are joined. In the weld section 6, the web is perpendicular to the high vertical ribs 3. The height HJ of the high vertical ribs 3 is 100mm to 150mm, and the thickness δ of the web and high vertical ribs 3 is 2mm to 8mm. The length of the web is L1+L2+δ. The longer segment of the web is defined as the first web segment 1, and its length is defined as L1. The shorter segment is defined as the second web segment 2, and its length is defined as L2, i.e., L1>L2>δ.

[0037] The use of a single electron beam welding process avoids defects such as lap joints, porosity, and incomplete penetration caused by multiple or segmented beam initiation and termination. This improves the welding quality of the transition area between the web and the high rib 3, while also reducing welding deformation. Single-stage welding refers to welding from one end of the web to the other. Due to the presence of the high rib 3, welding perpendicular to the web is not possible; the assembly angle needs to be adjusted. Welding begins at the end of the first web segment 1, penetrates through the double-layer profile area of ​​the first web segment 1 and the high rib 3 in a single pass, and then completes the welding through the single-layer profile area of ​​the second web segment 2.

[0038] However, the above solution faces a major problem:

[0039] (1) After adjusting the assembly angle, the horizontal projection length of the lower layer high vertical rib 3 may exceed the horizontal projection length of the first web section 1 or the second web section 2 of the web, which is not conducive to the stability control of the welding process.

[0040] (2) The difference in welding working distance between the upper end of the first web section 1 of the web at the welding start section and the lower end of the high vertical rib 3 is large, which is not conducive to the welding forming control of the double-layer surface.

[0041] Please refer to Figures 4-6 To address the above problems, embodiments of the present invention propose a one-step electron beam welding forming method for titanium alloy high-rib structures, comprising the following steps:

[0042] S1, analyze the height of the high vertical reinforcement 3 and the length of the web segments on both sides of the high vertical reinforcement 3, and construct the double-layer profile area composed of the first web segment 1 and the high vertical reinforcement 3, and the single-layer profile area of ​​the second web segment 2.

[0043] S2, Adjust the assembly angle to reduce the height of the double-layer profile area, and design the welding direction;

[0044] S3. Based on the horizontal projection length relationship between the first web section 1 and the high vertical rib 3 of the double-layer profile area, the length of the beam guide block of the upper and lower profiles is designed to realize beam welding starting from the first web section 1 and then beam welding starting from the high vertical rib 3, and gradually complete the welding of the double-layer profile area.

[0045] S4, adjust the focusing position of electron beam 5 so that the focusing position deviates downward from the mid-section of the double-layer profile region;

[0046] S5 allows for the adjustment of welding heat input parameters to achieve one-time electron beam welding, followed by observation of weld formation and detection of internal weld quality.

[0047] In some embodiments, the length of the first web segment 1 is greater than or equal to the length of the second web segment 2.

[0048] In some embodiments, in S2, the assembly angle is selected as 45° to ensure that the working distance between the first web section 1 and the high vertical rib 3 in the double-layer profile area is close to the minimum. The above solution is the best solution, but it does not limit the scope of protection of the present invention.

[0049] In some embodiments, in S2, the direction of transition from the double-layer profile to the single-layer profile is selected as the welding direction. Since the welding thickness of the double-layer profile area is greater than that of the single-layer profile area, selecting the welding direction of transition from the double-layer profile area to the single-layer profile area can obtain stable weld formation and thus obtain higher welding quality.

[0050] In some embodiments, in S3, a first flow-guiding block 7 is provided at the starting end of the first web segment 1, a second flow-guiding block 8 is provided at the starting end of the high rib 3, and a flow-receiving block 9 is provided at the ending end of the second web segment 2, so as to reduce defects in the flow-guiding / receiving sections and improve the welding quality of the rib profile structure. The thicknesses of the first flow-guiding block 7 and the second flow-guiding block 8 are respectively matched with the thicknesses of the web and the high rib 3, wherein the horizontal projection length of the first web segment 1 is L3, and the horizontal projection length of the high rib 3 is L4.

[0051] (1) When L3 = L4, the length L5 of the first beam-guiding block 7 is 50mm to 60mm, and the length L6 of the second beam-guiding block 8 is 20mm to 30mm. The beam-guiding fluctuation zone is designed on the upper surface beam-guiding block of the web, and at the same time, a forming transition stability zone is designed on the lower surface beam-guiding block of the high vertical rib 3 to ensure the smooth transition of beam-guiding and forming.

[0052] (2) When L3 > L4, the length L5 of the first beam-guiding block 7 is 50mm to 60mm and the length L6 of the second beam-guiding block 8 is 20mm to 30mm to ensure a smooth transition of beam-guiding and shaping.

[0053] (3) When L3 < L4, the length of the first beam-guiding block 7 is the difference between the length of the high vertical rib 3 and the length of the first web section 1, which is 50mm to 60mm. That is, L5 = HJ - L1 + (50 to 60)mm. The length L6 of the second beam-guiding block 8 is 20mm to 30mm. That is, the first beam-guiding block 7 compensates for the short length of the upper web surface, while ensuring the length of the beam-guiding flow, ensuring the design of the forming transition stability zone on the lower surface beam-guiding block, and ensuring the smooth beam-guiding flow and forming transition of the entire surface.

[0054] In some embodiments, the thickness of the convergence block 9 is 2mm to 5mm, and its length L7 is 30mm to 50mm.

[0055] In some embodiments, in S4, in order to solve the problem that the large difference in welding distance between the two layers is not conducive to forming, considering that the parameter margin of the electron beam 5 focusing on the first web segment 1 of the upper layer of the double-layer surface is large, the focusing current of the electron beam 5 is adjusted so that the focusing position deviates downward from the middle section of the double-layer surface and is closer to the lower layer surface, thereby improving the forming quality of the lower layer metal.

[0056] Please refer to Figure 6 Based on the focusing current If0 at the cross-sectional position in the double-layer profile area, the electron beam 5 reduces the focusing current by 10mA~50mA to If1, while the focusing current in other single-layer profile areas is adjusted according to the height position. The focusing current curve for conventional electron welding of ribbed profiles is a, and the focusing current curve for the adjusted high-rib 3 profile structure is b.

[0057] Example:

[0058] Taking a vertically reinforced titanium alloy structure with a wall thickness of 3mm, a rib height of 150mm, and web lengths L1 and L2 on both sides of the rib of 150mm as an example, the specific implementation is as follows:

[0059] (1) L1=L2=HJ=150mm, select either L1 or L2 segment of the web and the vertical reinforcement to form a welded double-layer profile area, select an assembly angle of 45°, and design the welding direction from the double-layer profile to the single-layer profile.

[0060] (2) Design the auxiliary process blocks for guiding / receiving the beam. The thickness of the guiding block is 3mm, and the lengths L5 and L6 are designed to be 60mm and 30mm respectively. The thickness of the receiving block 9 is 6mm, and the length L7 is designed to be 50mm.

[0061] (3) Welding process control: Under the condition that the shortest working distance at the end of the web plate is 300mm, the focusing current If0 = 2350mA at the mid-section position of the double-layer profile, and the focusing current If0 = 2300mA → 2310mA at the start and end positions of the double-layer profile, the focusing curve is obtained.

[0062] (4) Electron beam welding and inspection: According to the focusing curve, electron beam 5 welding is carried out to achieve one-time forming of electron beam 5 welding of the high vertical rib 3 surface. The weld formation is observed and the internal quality of the weld is inspected to ensure it meets the requirements.

[0063] It should be noted that the various embodiments in this specification are described in a progressive manner, and the same or similar parts between the various embodiments can be referred to mutually. Each embodiment focuses on describing the differences from other embodiments. For the embodiments of the method, relevant parts can be referred to the description of the device embodiments. The present invention is not limited to the specific steps and structures described above and shown in the figures. Furthermore, for the sake of brevity, detailed descriptions of known methods and techniques are omitted here.

[0064] The above description is merely an embodiment of this application and is not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art without departing from the scope of the invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principle of this application should be included within the scope of the claims of this application.

Claims

1. A method for one-time electron beam welding forming of a titanium alloy high-rib structure, characterized in that, Including the following steps: S1, the titanium alloy high-rib welded structure consists of a web, high ribs and flanges. The welding section is located between the webs and high ribs where the two workpieces are joined. The height of the high ribs and the length of the web segments on both sides of the high ribs are analyzed to construct a double-layer profile area composed of the first web segment and the high ribs, and a single-layer profile area of ​​the second web segment. S2, Adjust the assembly angle to reduce the height of the double-layer profile area, and design the welding direction; S3, based on the horizontal projection length relationship between the first web section and the high rib in the double-layer profile area, the length of the beam guiding block of the upper and lower profiles is designed to achieve beam welding starting from the first web section, then beam welding starting from the high rib, and gradually completing the welding of the double-layer profile area; wherein, the weld is formed by one-time electron beam welding, which means welding from one end of the web to the other end, starting from the end point of the first web section of the web, passing through the double-layer profile area of ​​the first web section and the high rib in one-time penetration welding, and then completing the welding through the single-layer profile area of ​​the second web section; S4, adjust the focusing position of the electron beam so that the focusing position deviates downward from the mid-section of the double-layer profile region; S5 allows for the adjustment of welding heat input parameters to achieve one-time electron beam welding formation, observation of weld formation, and detection of the internal quality of the weld.

2. The method for one-time electron beam welding and forming of a titanium alloy high-rib structure according to claim 1, characterized in that, The length of the first web segment is greater than or equal to the length of the second web segment.

3. The method for one-time electron beam welding and forming of a titanium alloy high-rib structure according to claim 1, characterized in that, In S2, the assembly angle is selected as 45°.

4. The method for one-time electron beam welding and forming of a titanium alloy high-rib structure according to claim 1, characterized in that, In S2, the direction of transition from the double-layer profile to the single-layer profile is selected as the welding direction.

5. The method for one-time electron beam welding and forming of a titanium alloy high-rib structure according to claim 1, characterized in that, In S3, a first beam-guiding block is provided at the starting end of the first web segment, a second beam-guiding block is provided at the starting end of the high upright rib, and a beam-receiving block is provided at the ending end of the second web segment.

6. The method for one-time electron beam welding and forming of a titanium alloy high-rib structure according to claim 5, characterized in that, The horizontal projection length of the first web segment is greater than or equal to the horizontal projection length of the high vertical rib, the length of the first beam guide block is 50mm~60mm, and the length of the second beam guide block is 20mm~30mm.

7. The method for one-time electron beam welding and forming of a titanium alloy high-rib structure according to claim 5, characterized in that, The horizontal projection length of the first web segment is less than the horizontal projection length of the high rib. The length of the first beam guide block is 50mm~60mm plus the difference between the length of the high rib and the length of the first web segment. The length of the second beam guide block is 20mm~30mm.

8. The method for one-time electron beam welding and forming of a titanium alloy high-rib structure according to claim 5, characterized in that, The thickness of the convergent flow block is 2mm~5mm, and the length is 30mm~50mm.

9. The method for one-time electron beam welding and forming of a titanium alloy high-rib structure according to claim 1, characterized in that, In S4, based on the focusing current at the cross-sectional position in the double-layer profile region, the focusing current of the electron beam is reduced by 10mA~50mA, and the focusing current in the single-layer profile region is adjusted according to the height position.

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