Atomic cluster powder, manufacturing method thereof and high-temperature alloy crack defect repairing method

Abstract

The invention provides atomic cluster powder, a manufacturing method thereof and a high-temperature alloy crack defect repairing method, high-frequency pulse discharge impact is continuously performed on a target material through a high-frequency pulse power supply, atomic-scale cluster powder is generated, and the atomic cluster powder is obtained. The repairing method comprises the following steps: cleaning and drying a high-temperature alloy material component with a crack defect, and putting the high-temperature alloy material component in a glove box; the atomic cluster powder is piled above the crack defects of the high-temperature alloy material component, and vibration treatment is carried out, so that the atomic cluster powder fully permeates into the crack defects of the high-temperature alloy material component; and the high-temperature alloy material component is put into a heat treatment furnace, the atomic cluster powder is melted, and metallurgical repair of the crack defect is achieved. According to the method, high-temperature alloy crack defect repair and the size of a connecting material are reduced to the atomic scale, same-material repair of crack defects of a high-temperature alloy material component can be achieved at the low temperature, and the method has the advantages that the process is simple, energy consumption is low, and the high-performance high-temperature alloy material is high in applicability.

Description

Technical Field

[0001] The present invention relates to the technical field of high-temperature alloy thermal processing, and in particular to an atomic cluster powder and a manufacturing method thereof, and a high-temperature alloy crack defect repairing method. Background Art

[0002] High-temperature alloys are indispensable and irreplaceable in the field of advanced aero engines and hypersonic aircraft. In order to improve the thrust-to-weight ratio of aero engines and the speed of hypersonic aircraft and other technical and combat indicators, it is necessary to use high-temperature alloy materials with higher service temperatures and higher performance. The strengthening phase content of high-performance high-temperature alloy materials is very high. In addition, the structural design of components is becoming more and more complex, and the stress state of the hot working process is becoming more and more complex, which is very easy to produce crack defects. For example, in three typical hot working processes, a batch of high-γ′ content nickel-based casting high-temperature alloys such as K418B, K447A and K4002 are very likely to have loose and hot and cold crack defects in the precision casting process, and CM247LC, IN939 and IN738 are prone to hot and cold crack defects in the additive manufacturing process. GH4720Li and GH4099 are very prone to cracking defects in the forging process. In fact, high-performance high-temperature alloy materials often cannot be repaired by traditional welding repair methods. This not only reduces the qualification rate and increases the development cost, but also causes some large and complex thin-walled components to be unable to be formed, resulting in "no parts available" for major aerospace projects. In addition, high-performance high-temperature alloys will also produce microcracks during long-term service due to complex alternating stresses. How to repair these cracks is a long-standing problem in the field of high-temperature alloy hot processing, which seriously restricts the development and upgrading of major equipment.

[0003] After searching the literature of the prior art, it was found that the Chinese invention patent with application number 201110067815.8 involves a vacuum brazing repair method for cracks in high-temperature alloy thin-walled parts. The method achieves crack defect repair by processing repair inserts, positioning inserts, powder filling, brazing and other processes. This patent can better solve the crack repair of high-temperature alloy thin-walled parts with high Al and Ti content. Its disadvantage is that the brazing material used for brazing is large in size and cannot penetrate into the micro-crack defects for repair; in addition, the composition of the brazing material and the base material is often different. In the subsequent service process, due to the different thermal expansion coefficients of the weld and the base material, cracking defects are easily generated, affecting the long-term service life.

[0004] The Chinese invention patent with application number 202110548934.9 relates to a method for repairing microcracks on the surface of a nickel-based high-temperature alloy forging die. This method fills the dried surface microcracks with the same metal powder as the matrix, and uses a needle-shaped tool to compact it appropriately. The filling height is slightly higher than the surface of the matrix, and then an electron beam heating device is used to locally heat and melt the microcracks filled with metal powder, naturally cool them, and finally perform local grinding and polishing to remove the repair traces. This method has the advantages of repairing with the same material as the parent material, good crack filling, and no obvious repair traces. The disadvantage is that the microcracks are complex in shape and different in width, and it is difficult to achieve high-density filling of powder at the microcracks by needle pressure. In addition, for high-performance high-temperature alloys, they are extremely sensitive to thermal gradients. The use of electron beam local heating method will cause cracks in the heat-affected zone, and the problem of cracking defects cannot be fundamentally solved. Summary of the invention

[0005] In view of the defects in the prior art, the purpose of the present invention is to provide an atomic cluster powder and a method for manufacturing it, and a method for repairing crack defects in high-temperature alloys, so as to provide technical support for the defect-free development of high-performance high-temperature alloy components and the repair of micro-cracks in the service process, so as to solve the problem that crack defects in existing high-performance high-temperature alloy materials are difficult to repair, resulting in the problem of "no parts available" in major aerospace projects.

[0006] The objective of the present invention is achieved through the following technical solutions:

[0007] According to a first aspect of the present invention, a method for manufacturing atomic cluster powder is provided, wherein a high-frequency pulse power supply is used to continuously perform high-frequency pulse discharge shock on a target material to generate atomic-level cluster powder, thereby obtaining atomic cluster powder.

[0008] Optionally, the target material is Ni.

[0009] Optionally, the material of the target also includes rare earth elements.

[0010] Optionally, the rare earth element is any one of rare earth Y, rare earth La and rare earth Sc.

[0011] According to a second aspect of the present invention, there is provided an atomic cluster powder, which is prepared by the method for manufacturing the atomic cluster powder according to the first aspect, and the atomic cluster powder is used for repairing crack defects in high-temperature alloys.

[0012] According to a third aspect of the present invention, there is provided a method for repairing a high temperature alloy crack defect, comprising:

[0013] After cleaning and drying, the high-temperature alloy material component with crack defects is placed in the glove box;

[0014] Providing the atomic cluster powder prepared by the method of the first aspect or the atomic cluster powder of the second aspect, piling the atomic cluster powder on the crack defect of the high-temperature alloy material component, and then performing a vibration treatment to allow the atomic cluster powder to fully penetrate into the crack defect of the high-temperature alloy material component;

[0015] Then the high-temperature alloy material component is placed in a heat treatment furnace to melt the atomic cluster powder to achieve metallurgical repair of the crack defects of the high-temperature alloy material component.

[0016] Optionally, the method further comprises: repairing the fluorescence defects on the surface of the high-temperature alloy material component by melting the atomic cluster powder.

[0017] Optionally, the vibration treatment is performed to allow the atomic cluster powder to fully penetrate into the crack defects of the high-temperature alloy material component, wherein the vibration treatment time is 8-12 minutes.

[0018] Optionally, the melting of the atomic cluster powder to achieve metallurgical repair of crack defects in high-temperature alloy material components includes: heating at a temperature lower than the melting point of the base material under the protection of a protective atmosphere for a heating time of 10-60 minutes.

[0019] Optionally, the step of cleaning and drying the high-temperature alloy material component with crack defects comprises:

[0020] The high-temperature alloy material component with crack defects is immersed in alcohol upside down for ultrasonic cleaning for 5-10 minutes;

[0021] Then put it in a drying oven and heat it to 120-200℃ and dry it for 10-20 minutes.

[0022] Compared with the prior art, the present invention has at least one of the following beneficial effects:

[0023] 1. The present invention uses atomic cluster powders to reduce the size of high-temperature alloy crack defect repair and connection materials to the atomic level. By utilizing the characteristic of the sharp drop in the melting point of atomic clusters, stress-free, ultra-stable, and highly reliable repair and connection are achieved by manipulating atoms, realizing the transition from "top-down" material precision processing to the "bottom-up" atomic-level construction era.

[0024] 2. The present invention utilizes low-melting-point atomic cluster powders to achieve the same-material repair of crack defects in high-performance high-temperature alloy components at a relatively low temperature, which can avoid the problem that existing brazing repair methods cannot achieve the same-material repair, and can also better solve the secondary crack problem that occurs during the repair process of electron beam, argon arc welding and other methods. In addition, the method has a simple process, low energy consumption, and strong applicability to high-performance high-temperature alloy materials. It can not only greatly improve the qualification rate of its development process, but also help solve the problem of "no parts available" for complex thin-walled components of high-performance high-temperature alloy materials. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Other features, objects and advantages of the present invention will become more apparent from the detailed description of non-limiting embodiments made with reference to the following drawings:

[0026] Figure 1 The figure is a schematic flow chart of a method for repairing crack defects in a high-temperature alloy according to an embodiment of the present invention. DETAILED DESCRIPTION

[0027] The present invention is described in detail below in conjunction with specific embodiments. The following embodiments will help those skilled in the art to further understand the present invention, but are not intended to limit the present invention in any form. It should be noted that, for those of ordinary skill in the art, several variations and improvements may be made without departing from the concept of the present invention. These all belong to the protection scope of the present invention.

[0028] Metal bulk materials have a high melting point, and as the metal particle size is reduced to nanometer and atomic cluster size, its melting point is greatly reduced. Based on the low-temperature melting property of atomic clusters, it is possible to develop a new type of low-temperature atomic manufacturing repair connection method for high-performance high-temperature alloy materials, avoiding the high heat input problem that cannot be avoided by all current welding repair technologies.

[0029] A method for manufacturing atomic cluster powders provided in one embodiment of the present invention continuously performs high-frequency pulse discharge impact on a target material through a high-frequency pulse power supply to generate atomic-level cluster powders, thereby obtaining atomic cluster powders.

[0030] In the embodiment of the present invention, the target material is the same as the prepared atomic cluster powder material, and the bulk target material is converted into powdered atomic clusters by pulse discharge shock, and the prepared atomic cluster powder composition is consistent with the target material. As an example, the high-frequency pulse power supply output voltage is 200 to 7000V and the frequency is 100 to 2000Hz.

[0031] The main element in the high-temperature alloy is Ni, and the composition range is wide. In order to prepare atomic cluster powder for repairing crack defects in high-temperature alloys, in some embodiments, the material of the target material is Ni.

[0032] In a further embodiment, in order to enhance the bonding of the connection interface, the target material also includes rare earth elements, and rare earth element atomic powder is used to form a rare earth precipitate phase with other alloy elements of the base material to compensate for the insufficient strength of pure Ni after connection and enhance the toughness of the repaired connection.

[0033] Exemplarily, the rare earth element may be any one of rare earth Y, rare earth La and rare earth Sc. Preferably, the rare earth element is rare earth Y.

[0034] The embodiment of the present invention uses a high-frequency pulse power source to continuously discharge high-frequency pulses on target materials such as Ni, rare earth elements and high-temperature alloys to produce atomic-level cluster powder preparation, thereby realizing atomic manufacturing of crack repair materials.

[0035] Another embodiment of the present invention provides an atomic cluster powder, which is prepared using the above-mentioned atomic cluster powder manufacturing method. The atomic cluster powder is used to repair high-temperature alloy crack defects. The melting point of the atomic cluster powder is 900-1200°C, which is specifically determined according to the type and state of the atomic cluster powder.

[0036] Based on the same inventive concept, another embodiment of the present invention provides a method for repairing crack defects in a high temperature alloy, referring to Figure 1 As shown, the method comprises the following steps:

[0037] S1. After cleaning and drying, the high-temperature alloy material component with crack defects is placed in a glove box;

[0038] S2. Providing atomic cluster powder, piling the atomic cluster powder on the crack defect of the high-temperature alloy material component, and then performing vibration treatment to allow the atomic cluster powder to fully penetrate into the crack defect of the high-temperature alloy material component;

[0039] S3. Then, the high-temperature alloy material component is placed in a heat treatment furnace to melt the atomic cluster powder at a low temperature to achieve metallurgical repair of the crack defects of the high-temperature alloy material component.

[0040] In some embodiments, in step S1, the high-temperature alloy material component with crack defects is inverted and immersed in alcohol for ultrasonic cleaning for 5-10 minutes to fully clean the dust particles in the cracks; then it is placed in a drying oven and heated to 120-200°C and dried for 10-20 minutes to fully dry the moisture in the cracks.

[0041] In some embodiments, in order to allow the atomic cluster powder to fully penetrate into the crack defects of the high-temperature alloy material component, the vibration treatment time is 8-12 minutes. As an example, the vibration treatment time is 10 minutes, which is determined according to the width and depth of the crack and the complexity of the component structure.

[0042] In some embodiments, the atomic cluster powder is melted at a low temperature to achieve metallurgical repair of crack defects in a high-temperature alloy material component, including: under the protection of a protective atmosphere such as argon or helium, heating is performed at a temperature lower than the melting point of the parent material, i.e., the high-temperature alloy material component to be repaired (900-1200°C), and the heating temperature and time are mainly determined based on the type and state of the atomic cluster powder and the grade of the parent material, so as to achieve complete melting of the atomic cluster powder without melting the parent material, and to achieve metallurgical bonding of the atomic cluster powder and the parent material. Exemplarily, the heating temperature is 1000-1300°C and the heating time is 10-60 minutes.

[0043] High-temperature alloy cracks include cracks that can be observed by the naked eye and surface fluorescent defects. Surface fluorescent defects mainly include sesame-sized pit defects on the surface of the component. Some of these defects are caused by the precipitation of trace gases, and some are caused by the reaction between the casting and the metal. The pits are small and can only be seen with the help of fluorescent developers. In some embodiments, the above method also includes: placing atomic cluster powder in the pit of the surface fluorescent defect and heating it, and repairing the surface fluorescent defects of the high-temperature alloy material component by melting the atomic cluster powder.

[0044] In the above-mentioned embodiments of the present invention, atomic cluster powder is used as a connecting material, and atomic clusters are used to fill gaps and melt them, so as to repair hot and cold cracks or microcracks defects of components caused by casting or service processes, realize metallurgical repair, and realize surface fluorescent defect repair of high-temperature alloy components, reduce the size of high-performance high-temperature alloy repair and connection materials to the atomic level, utilize the characteristics of the drastic drop in the melting point of atomic clusters, and realize stress-free, ultra-stable, and highly reliable repair and connection by manipulating atoms, realizing the transition from "top-down" material precision processing to "bottom-up" atomic-level construction.

[0045] The above-mentioned embodiment of the present invention utilizes low-melting-point atomic cluster powders to achieve the same-material repair of crack defects in high-performance high-temperature alloy components at a relatively low temperature, which can avoid the problem that the existing brazing repair method cannot achieve the same-material repair, and can also better solve the secondary crack problem that occurs during the repair process of electron beam, argon arc welding and other methods. In addition, the method has a simple process, low energy consumption, and strong applicability to high-performance high-temperature alloy materials. It can not only greatly improve the qualification rate of its development process, but also help solve the problem of "no parts available" for complex thin-walled components of high-performance high-temperature alloy materials.

[0046] The scheme of the present application will be explained below in conjunction with specific embodiments. It will be appreciated by those skilled in the art that the following embodiments are only used to illustrate the present application and should not be considered as limiting the scope of the present application. If specific techniques or conditions are not indicated in the embodiments, the techniques or conditions described in the documents in this area or the product specifications are carried out. The reagents used or the instruments that do not indicate the manufacturer are all conventional products that can be obtained through commercial channels.

[0047] Example 1

[0048] A certain aerospace rare earth high-temperature alloy casting is about 800mm long and 60mm high. It has an internal structure and is formed in one piece using traditional precision casting technology. Crack defects were discovered during later cleaning.

[0049] The high-performance rare earth superalloy casting with crack defects was inverted and immersed in alcohol for ultrasonic cleaning for 10 minutes to fully clean the dust particles in the cracks, and then placed in a drying oven and heated to 200°C for 20 minutes to fully dry the moisture in the cracks. The cleaned, dried and clean high-performance rare earth superalloy casting with crack defects was placed in a glove box, and the prepared Ni and rare earth Y mixed atomic cluster powders were mixed and piled on the cracks, and vibrated for 10 minutes to allow the mixed atomic cluster powder to fully penetrate into the crack defects. The high-performance superalloy casting with crack defects infiltrated by the mixed atomic cluster powder was placed in a heat treatment furnace, and was kept at 1100°C for 30 minutes under argon protection. The metallurgical repair of the crack defects was achieved by melting the mixed atomic cluster powder, and the strength and toughness of the repaired parts were improved by the rare earth precipitation phase enhancement effect formed with the alloying elements in the parent material. The polished rare earth superalloy casting had a good appearance and uniform structure, and no secondary crack defects were found.

[0050] Example 2

[0051] An aviation CM247LC high-temperature alloy additively manufactured component is about 250mm in length, 100mm in width, and 40mm in height. The overall structure is complex and irregular. After additive manufacturing, crack defects and surface fluorescence defects were detected.

[0052] The high-performance high-temperature alloy additive manufacturing component with crack defects and surface fluorescence defects was inverted and immersed in alcohol for ultrasonic cleaning for 5 minutes to fully clean the residual powder particles printed in the cracks, and then placed in a drying oven and heated to 120°C for 10 minutes to fully dry the moisture in the cracks. The cleaned and dried high-performance high-temperature alloy additive manufacturing component with crack defects was placed in a glove box, and the prepared high-temperature alloy atomic cluster powder (the specific composition is the same as CM247LC) was stacked on the crack and vibrated for 10 minutes to allow the atomic cluster powder to fully penetrate into the crack defect and evenly cover the atomic cluster powder in the fluorescent defect area. The high-performance high-temperature alloy additive manufacturing component was then placed in a heat treatment furnace and kept at 1200°C for 30 minutes under argon protection. The metallurgical repair of the crack defect and the surface fluorescence defect repair were achieved by melting the atomic cluster powder. The repaired high-performance high-temperature alloy additive manufacturing component had good quality, uniform microstructure, and disappeared surface fluorescence defects, indicating that the atomic manufacturing repair technology is also suitable for surface fluorescence defect repair.

[0053] Example 3

[0054] A high-temperature alloy blade for a gas turbine was about 200 mm wide and 400 mm high. During long-term service, microcrack defects appeared at the tenon, seriously affecting the reliability of the service process.

[0055] The high-temperature alloy blade with crack defects is inverted and immersed in alcohol for ultrasonic cleaning for 7 minutes to fully clean the impurities or dust particles in the crack, and then placed in a drying oven and heated to 150°C, dried for 15 minutes, and the moisture in the crack is fully dried. The cleaned and dried high-temperature alloy blade with crack defects is placed upright in a glove box, and the prepared Ni atomic cluster powder is piled on the crack and vibrated for 7 minutes to allow the Ni atomic cluster powder to fully penetrate into the crack defect. The high-temperature alloy blade with crack defects infiltrated by the atomic cluster powder is placed in a heat treatment furnace and kept at 1250°C for 10 minutes under argon protection. The metallurgical repair of micro-crack defects is achieved by melting the atomic cluster powder, and the high-temperature alloy blade has a good appearance after grinding and polishing.

[0056] It has been found through testing that the atomic cluster powder in the above embodiment can repair 1 micron cracks, while brazing can repair a minimum of 25 micron cracks. Compared with traditional brazing filling repair, after repair using the method in the above embodiment of the present invention, the atomic powder has better permeability at the microcracks and a higher density after repair.

[0057] The above describes the specific embodiments of the present invention. It should be understood that the present invention is not limited to the above specific embodiments, and those skilled in the art can make various modifications or variations within the scope of the claims, which does not affect the essence of the present invention. The above preferred features can be used in any combination without conflicting with each other.

Claims

1. A method for producing atomic cluster powder, characterized in that: The target material is continuously subjected to high-frequency pulse discharge impact by a high-frequency pulse power supply to generate atomic-level cluster powders, thereby obtaining atomic cluster powders.

2. The method for producing atomic cluster powder according to claim 1, characterized in that: The target material is Ni.

3. The method for producing atomic cluster powder according to claim 2, characterized in that: The target material also includes rare earth elements.

4. The method for producing atomic cluster powder according to claim 3, characterized in that: The rare earth element is any one of rare earth Y, rare earth La and rare earth Sc.

5. An atomic cluster powder, characterized in that: The atomic cluster powder is prepared by the method for manufacturing the atomic cluster powder according to any one of claims 1 to 4, and the atomic cluster powder is used to repair crack defects in high-temperature alloys.

6. A method for repairing crack defects in high temperature alloys, characterized in that: include: After cleaning and drying, the high-temperature alloy material component with crack defects is placed in the glove box; Providing an atomic cluster powder prepared by the method according to any one of claims 1 to 4 or the atomic cluster powder according to claim 5, piling the atomic cluster powder on the crack defect of the high-temperature alloy material component, and then performing a vibration treatment to allow the atomic cluster powder to fully penetrate into the crack defect of the high-temperature alloy material component; Then the high-temperature alloy material component is placed in a heat treatment furnace to melt the atomic cluster powder to achieve metallurgical repair of the crack defects of the high-temperature alloy material component.

7. The high temperature alloy crack defect repairing method according to claim 6, characterized in that: The method further comprises: repairing the fluorescence defects on the surface of the high-temperature alloy material component by melting the atomic cluster powder.

8. The high temperature alloy crack defect repairing method according to claim 6, characterized in that: The vibration treatment is performed to allow the atomic cluster powder to fully penetrate into the crack defects of the high-temperature alloy material component, wherein the vibration treatment time is 8-12 minutes.

9. The high temperature alloy crack defect repairing method according to claim 6, characterized in that: The melting of the atomic cluster powder to achieve metallurgical repair of crack defects in high-temperature alloy material components includes: heating at a temperature lower than the melting point of the base material under the protection of a protective atmosphere for a heating time of 10-60 minutes.

10. The high temperature alloy crack defect repairing method according to claim 6, characterized in that: The method of cleaning and drying the high-temperature alloy material component with crack defects comprises: The high-temperature alloy material component with crack defects is inverted and immersed in alcohol for ultrasonic cleaning for 5-10 minutes; then placed in a drying oven, heated to 120-200°C, and dried for 10-20 minutes.

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