Multi-material variable gradient part and manufacturing method thereof

Abstract

The invention discloses a multi-material variable gradient part and a manufacturing method thereof, and the manufacturing method comprises the following steps: analyzing the working temperature and load of the part, and evaluating the feasibility of a double-material or multi-material scheme; selecting raw materials, and determining the diameter of a wire and a wire pretreatment process; designing a mold, and arranging and winding the raw materials in the mold; performing heat treatment on the blank after weaving and winding; and demolding and defect monitoring. Multi-material variable gradient part manufacturing is achieved through the procedures of multi-material wire splicing, winding forming and hot isostatic pressing, the problem that the gradient change of a connection interface is large due to sleeving or welding of two materials is solved, and the design requirement for mechanical property differences of different parts of a single part in the severe working environment is met.

Description

Technical Field

[0001] The invention belongs to the technical field of special processing, and in particular relates to a multi-material variable gradient part and a manufacturing method thereof. Background Art

[0002] The working environment of aircraft engines is complex, and there are harsh working conditions where the working temperature difference on a part is greater than 300°C, so different parts of the parts have different requirements for the mechanical properties of the material. For example, the working temperature of the high-pressure turbine disc rim is about 600°C, and the working temperature of the wheel center is about 300°C. The design requires that the rim material has good creep performance, and the wheel center material has good low-cycle fatigue performance. At present, different grain sizes can be obtained by implementing different heat treatment processes on the rim and the wheel center to meet the above requirements, but the actual benefits are not obvious. Another method is to use different materials to splice the rim and the wheel center into a wheel disc part. The current research scheme is to hot isostatic pressing after the rim and the wheel center are sleeved. The performance gradient of the sleeve interface material is large, and it is difficult to evaluate the mechanics and life of the sleeve area.

[0003] At present, the commonly used solution for multi-material connection is welding, such as friction welding and hot isostatic diffusion welding. In the field of aero-engines, friction welding is often used in the manufacture of integral blade disks, that is, welding blades on the rim. Hot isostatic diffusion welding is often used in the manufacture of dual-performance wheel disks. However, the above two methods are both "hard" transitions of multiple materials, and the transition area is on the order of 1mm-5mm. The organizational transition of the two materials is completed in such a narrow transition area, which is prone to form defects, internal stresses and weak strength areas in the transition area. Due to the undesignability of the microstructure of the transition zone and the randomness of the process, there is currently no mature strength simulation method for safety assessment. Therefore, a part preparation method that meets the differentiated requirements of different parts of the part for material properties and has a designable material transition zone is needed.

[0004] The patent document announced as CN113290846A discloses a composite multi-material additive manufacturing device and method based on DLP and FDM, which combines DLP photocuring and FDM fused deposition modeling technology to achieve composite additive processing of multiple materials. After the photosensitive resin is exposed and processed by the DLP light machine, the remaining processing can be carried out with the FDM nozzle according to the design or structural requirements. At the same time, the nozzle converter can be used to replace different materials to achieve material conversion. Before switching the processing method, the processing plane needs to be accurately positioned to avoid errors. By working back and forth like this, gradient additive manufacturing of multiple materials can be achieved. However, the materials used in this patented method are homogeneous, and it is impossible to obtain a single part with the properties of two or more materials. Summary of the invention

[0005] In order to solve the above technical problems, the present invention provides a multi-material variable gradient part and a manufacturing method thereof.

[0006] The present invention is achieved through the following technical solutions.

[0007] The present invention provides a method for manufacturing a multi-material variable gradient part, comprising the following steps:

[0008] S1: Analyze the working temperature and load of parts to evaluate the feasibility of dual-material or multi-material solutions;

[0009] S2: Raw material selection, wire diameter determination and wire pretreatment process;

[0010] S3: Design the mold, arrange and wrap the raw materials in the mold;

[0011] S4: prepare the heat treatment process of the blank after winding;

[0012] S5: Demolding and defect monitoring.

[0013] Preferably, the number of types of the raw materials is greater than or equal to two, and the raw materials are added into the mold in the form of wires and arranged.

[0014] Preferably, during the arrangement process, a transition zone is provided between adjacent different raw materials, and the transition zone includes two or more of the adjacent different raw materials.

[0015] Preferably, the arrangement step includes: selecting a part section perpendicular to the wire section, calculating the cross-sectional area of ​​the part, determining the wire diameter of the raw material, determining the stacking positions of different raw material wires on the part section, and calculating the number of stacking layers on the part section according to the wire diameter of the raw material, and then winding.

[0016] Preferably, the winding method includes: splicing the raw materials according to the stacking position and the number of stacking layers, and after all the raw materials are spliced ​​into a wire, winding is performed with the center line of the part as the axis.

[0017] A multi-material variable gradient part manufactured by the above manufacturing method.

[0018] Preferably, the multi-material variable gradient part includes an outer shell and an inner core, the outer shell is provided with a groove A, and the inner core is placed in the groove A. The outer shell and the inner core are prepared by arranging and winding the raw materials in a mold and then heat treating them. The heat treatment step includes: keeping warm for 1-4 hours in an argon environment at 900-1300°C and a pressure of 100-150MPa, and then cooling to room temperature with the furnace.

[0019] Preferably, the raw materials include wire A and wire B, the outer shell is prepared by wire A whose material is material A, the inner core is prepared by wire B whose material includes material A and material B, and a groove B is provided on the mold.

[0020] Preferably, the preparation step of the wire B includes: depositing material A on the surface of wire C made of material B by EB-PVD to obtain wire B coated with a layer of material A, the wire A and wire B have the same diameter, the material A is SiC, and the material B is TC17.

[0021] Preferably, the stacking sequence in the groove B from bottom to top is: wire A layer, transition zone A, wire B layer, transition zone B and wire A layer.

[0022] The beneficial effects of the present invention are:

[0023] 1. The present invention realizes the manufacturing of multi-material variable gradient parts through the process of multi-material wire splicing-winding molding-hot isostatic pressing, which solves the problem of large gradient changes in the connection interface caused by sleeve or welding of two materials, and meets the design requirements of mechanical properties differences of different parts of a single part under harsh working environment.

[0024] 2. The present invention uses a multi-material variable gradient connection method and realizes it through the splicing and winding of wires, and achieves the designability of the material organization in the transition zone through the diameter, length and splicing sequence of the wires.

[0025] 3. The method of the present invention can be used for radial gradient design of rotating parts, and can also be used for axial gradient design of rotating parts.

[0026] 4. The parts produced by the method of the present invention realize the fusion and densification of adjacent wires through hot isostatic pressing, and finally form a multi-material part blank. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of the structure of preparing the integral blade ring of the compressor according to the present invention;

[0028] Figure 2 It is a structural schematic diagram of a mold for preparing an integral blade ring of a compressor according to the present invention;

[0029] Figure 3 It is a schematic diagram of the stacking of wires in the transition zone A for preparing the integral blade ring of the compressor according to the present invention;

[0030] Figure 4 Schematic diagram of the structure of the wire material B for preparing the integral blade ring of the compressor according to the present invention;

[0031] Figure 5 It is a schematic diagram of splicing four kinds of material ladder-changing parts prepared by the present invention;

[0032] Figure 6 It is a schematic diagram of the placement of material molds for preparing four types of material ladder-changing parts according to the present invention;

[0033] Figure 7 It is a schematic diagram of the process of preparing four kinds of material ladder-changing parts according to the present invention;

[0034] In the figure: 1-jacket, 11-slot A, 2-inner core, 3-mold, 31-slot B, 4-wire A, 5-wire B, 6-wire C, 7-wire A layer, 8-transition zone A, 81-transition zone B, 9-wire B layer, 10-blade. DETAILED DESCRIPTION

[0035] The technical solution of the present invention is further described below, but the scope of protection claimed is not limited to the description.

[0036] Example:

[0037] like Figures 1 to 4 As shown, a method for manufacturing a multi-material variable gradient part comprises the following steps:

[0038] S1: Analyze the working temperature and load of parts to evaluate the feasibility of dual-material or multi-material solutions;

[0039] S2: Raw material selection, wire diameter determination and wire pretreatment process;

[0040] S3: Design the mold, arrange and wrap the raw materials in the mold;

[0041] S4: prepare the heat treatment process of the blank after winding;

[0042] S5: Demolding and defect monitoring.

[0043] Step S4 can prepare different process parameters according to different materials, and step S5 is a prior art.

[0044] The number of types of the raw materials is greater than or equal to two, and the raw materials are added into the mold in the form of wires and arranged.

[0045] During the arrangement process, a transition zone is set between adjacent different raw materials, and the transition zone includes two or more of the adjacent different raw materials.

[0046] The arrangement step includes: selecting a part section perpendicular to the cross section of the wire, calculating the cross-sectional area at the center of the part, determining the wire diameter of the raw material, determining the stacking position of different raw material wires on the part section, and calculating the number of stacking layers on the part section according to the wire diameter of the raw material, and then winding.

[0047] The winding method includes: splicing the raw materials according to the stacking position and the number of stacking layers, and after all the raw materials are spliced ​​into a wire, winding is performed with the center line of the part as the axis.

[0048] A multi-material variable gradient part manufactured by the above manufacturing method, the part is an integral blade ring of a compressor, including an outer sleeve 1 and an inner core 2, the outer sleeve 1 is provided with a groove A11, the top of the outer sleeve 1 is connected to the blade 10, the inner core 2 is placed in the groove A11, the outer sleeve 1 and the inner core 2 are prepared by placing raw materials in a mold 3, including arranging and winding the raw materials and then heat treating them.

[0049] The raw materials include wire A4 and wire B5. The outer sleeve 1 is prepared by wire A4 made of material A. The inner core 2 is prepared by wire B5 made of material A and material B. A groove B31 is provided on the mold 3.

[0050] The preparation steps of the wire material B5 include: Figure 4 , material A is deposited with 25um thick TC17 titanium alloy on the surface of wire C6 with an average diameter of 100um made of material B by EB-PVD to obtain wire B5 coated with material A layer, the wire A4 has the same diameter as the wire B5, the diameter of the pretreated wire B5 is 150um, the outer sleeve 1 is made of TC17 wire, the diameter of the wire A4 is 150um, the material A is SiC, the material B is TC17, and embedded SiC (silicon carbide fiber) fiber is used for reinforcement, and the outer sleeve 1 is titanium alloy to reduce the weight of the overall blade ring of the compressor.

[0051] The stacking order in the groove B31 is from bottom to top: wire A layer 7, transition zone A8, wire B layer 9, transition zone B81 and wire A layer 7, and the wire A layer 7, transition zone A8, wire B layer 9 and transition zone B81 have the same width; from bottom to top: the thickness of wire A layer 7 is 6mm, the thickness of transition zone A8 is 3.4mm, the thickness of wire B layer 9 is 600, the thickness of transition zone B81 is 3.4mm, and the remainder is the top layer of wire A layer 7. Among them, the outer diameter of the blank used for the integral leaf ring is Φ370mm, the axial thickness of the mold 3 is 24mm, the width of the groove B31 is 5mm, and the depth is 29mm.

[0052] The heat treatment step includes: arranging and winding the raw materials in the mold 3, keeping the temperature at 900-1300° C. and 100-150 MPa of argon for 1-4 hours, and then cooling to room temperature with the furnace.

[0053] The number of wires that can be accommodated in a single layer in slot B31 can be calculated by using the wire diameter of 150um and the slot width of 5mm, that is, the number of wire turns contained in each stacked layer, which is 33. The thickness of transition zone A8 is 3.4mm, which can accommodate 23 stacked layers. Therefore, the winding arrangement of transition zone A8 is as follows: Figure 3As shown, the width is 3.4 mm, the length is 55 mm, R159.4, and the winding arrangement of transition zone B81 is symmetrical with that of transition zone A8. The number and length of fiber lines in each layer of transition zone A8 are shown in Table 1. The splicing order and length of SiC and TC17 wires obtained from Table 1 are shown in Table 2.

[0054] Table 1 Length of SiC and TC17 fibers in each layer of transition zone A

[0055]

[0056]

[0057] Table 2 Splicing length of SiC and TC17 wires in transition zone A

[0058]

[0059] According to the calculation method of linear transition zone A8, the other three regions, namely, wire A layer 7, wire B layer 9, transition zone B81 and wire A layer 7 region, are obtained, and the wire splicing sequence and length are connected into one wire. Figure 2 The left side of the groove bottom is the starting point for winding layer by layer.

[0060] like Figures 5 to 7 As shown, when the materials of the multi-material variable gradient part include four materials: material A, material B, material C, and material D, four material layers can be set in the corresponding mold, and heat treatment can be carried out under high temperature and high pressure through corresponding processes, and finally the part can be demolded.

Claims

1. A method for manufacturing a multi-material variable gradient part, characterized in that: The following steps are involved: S1: Analyze the working temperature and load of parts to evaluate the feasibility of dual-material or multi-material solutions; S2: Raw material selection, wire diameter determination and wire pretreatment process; S3: Design the mold, arrange and wrap the raw materials in the mold; S4: prepare the heat treatment process of the blank after winding; S5: Demolding and defect monitoring.

2. A method for manufacturing a multi-material variable gradient part according to claim 1, characterized in that: The number of types of the raw materials is greater than or equal to two, and the raw materials are added into the mold in the form of wires and arranged.

3. The method for manufacturing a multi-material variable gradient part according to claim 1, characterized in that: During the arrangement process, a transition zone is set between adjacent different raw materials, and the transition zone includes two or more of the adjacent different raw materials.

4. A method for manufacturing a multi-material variable gradient part according to claim 2, characterized in that: The arrangement step includes: selecting a part section perpendicular to the wire section, calculating the cross-sectional area of ​​the part, determining the wire diameter of the raw material, determining the stacking position of different raw material wires on the part section, and calculating the number of stacking layers on the part section according to the wire diameter of the raw material, and then winding.

5. A method for manufacturing a multi-material variable gradient part according to claim 4, characterized in that: The winding method includes: splicing the raw materials according to the stacking position and the number of stacking layers, and after all the raw materials are spliced ​​into a wire, winding is performed with the center line of the part as the axis.

6. A multi-material variable gradient part manufactured by the manufacturing method according to any one of claims 1 to 5.

7. A multi-material variable gradient component according to claim 6, characterized in that: The invention comprises an outer sleeve (1) and an inner core (2), wherein the outer sleeve (1) is provided with a groove A (11), and the inner core (2) is placed in the groove A (11). The outer sleeve (1) and the inner core (2) are prepared by arranging and winding raw materials in a mold (3) and then heat treating the raw materials. The heat treatment step comprises: keeping the temperature at 900-1300°C and a pressure of 100-150MPa in an argon environment for 1-4h, and then cooling the raw materials to room temperature with the furnace.

8. A multi-material variable gradient component according to claim 7, characterized in that: The raw materials include wire A (4) and wire B (5), the outer shell (1) is prepared by wire A (4) made of material A, the inner core (2) is prepared by wire B (5) made of material A and material B, and a groove B (31) is provided on the mold (3).

9. A multi-material variable gradient component according to claim 8, characterized in that: The preparation steps of the wire B (5) include: depositing material A on the surface of a wire C (6) made of material B by EB-PVD to obtain a wire B (5) coated with a layer of material A, wherein the wire A (4) has the same diameter as the wire B (5), the material A is SiC, and the material B is TC17.

10. A multi-material variable gradient component according to claim 8, characterized in that: The stacking sequence in the groove B (31) from bottom to top is: wire A layer (7), transition zone A (8), wire B layer (9), transition zone B (81) and wire A layer (7).

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