A method for applying a low melting filler for repairing aluminum alloy honeycomb damage

Abstract

The present application relates to a kind of low melting point filler metal for repairing aluminum alloy honeycomb damage and its application method, and the mass percentage of the chemical composition of low melting point filler metal is respectively: Mg: 5~12%, Cu: 5~13%, Zn: 10~40%, Sn: 1.5~4.5%, Ge: 2.0~6.0%, Si: 4.5~12.5%, the balance is Al.Preparation method includes the following steps: low melting point repair filler is made into amorphous thin slice, powder or solder paste.Use method includes: cleaning damaged part, making repair parts, using low melting point repair filler to carry out brazing repair.The present application is conducive to the effect of reducing the melting point of Mg, Cu, Zn, Sn, Ge, Si element, and a kind of low melting point filler metal can be used to repair aluminum alloy honeycomb, compared with traditional glue filling repair method, the strength and light weight of honeycomb after repair are guaranteed simultaneously.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of metal brazing, in particular to an application method of low-melting filler metal for repairing damage of an aluminum alloy honeycomb. BACKGROUND

[0002] The density of the honeycomb material is very small, so the weight is very light, which is beneficial to reducing the overall weight of the airplane, and the honeycomb material has high strength and can withstand large pressure and impact, and the corrosion resistance of the honeycomb material is very excellent, so that the airplane can be used for a long time in a harsh environment, and in addition, the honeycomb is very easy to process, so that the honeycomb is very suitable for parts with complex shapes. Due to these advantages, the honeycomb material is widely used on the airplane.

[0003] However, in the long-term use process, the honeycomb part is inevitably hit by external objects, and damage, honeycomb collapse and corrosion occur. At present, the honeycomb core is filled with glue for repair, and such a repair method cannot meet the strength requirement of the original honeycomb material, and the weight of the airplane is greatly increased, so it is very important to find a new repair method which can balance the weight and strength. SUMMARY

[0004] To solve the above technical problems, the application provides a preparation method of low-melting filler metal for repairing an aluminum alloy honeycomb and an application method thereof.

[0005] A preparation method of low-melting filler metal for repairing damage of a honeycomb, comprising the following steps:

[0006] Step one: the mass percentage of the chemical composition of the low-melting filler metal is as follows: Mg: 5-12%, Cu: 5-13%, Zn: 10-40%, Sn: 1.5-4.5%, Ge: 2.0-6.0%, Si: 4.5-12.5%, and the balance is Al;

[0007] According to the mass percentage of the chemical composition of the filler metal, various high-purity raw materials are weighed, and the purity of the various high-purity raw materials is not less than 99.99%;

[0008] Step two: the Al raw material is divided into three parts, namely a first part, a second part and a third part; the first part is made into an Al-Ge compound with Ge, and the second part is made into an Al-Si compound with Si;

[0009] Step three: the third part of the Al raw material, the Mg raw material, the Cu raw material, the Zn raw material, the Sn raw material, the Al-Ge compound and the Al-Si compound are uniformly mixed, heated and melted in an electric arc furnace under the protection of argon atmosphere, and a blocky alloy, namely the above-mentioned low-melting repair filler metal, is obtained.

[0010] The preparation method of the low-melting filler for repairing the honeycomb damage has the preferred scheme that in step two, the mass ratio of the first part of Al raw material, the second part of Al raw material and the third part of Al raw material depends on the specific composition of the filler.

[0011] The preparation method of the low-melting filler for repairing the honeycomb damage has the preferred scheme that in step three, the melting temperature of the electric arc furnace is 700 DEG C, and the melting time is 5 min-10 min, so that the elements are fully diffused and fused, and meanwhile, the loss of the elements is avoided.

[0012] The preparation method of the low-melting filler for repairing the honeycomb damage has the preferred scheme that in step three, the bulk alloy is made into amorphous flakes, the preparation method of the amorphous flakes is a single-roller rapid cooling method, and the thickness of the amorphous flakes is 50 mu m.

[0013] An application method of the low-melting filler for repairing the honeycomb damage comprises the following steps.

[0014] Step one: the area to be repaired is cleaned by using a cutting machine to obtain the area to be repaired, and a corresponding repair patch is processed, wherein the size of the patch is larger than that of the area to be repaired, but should not be too large, wherein L is 0.3-0.5 times the radius of the honeycomb;

[0015] Step two: the area to be repaired and the patch are cleaned, polished and pickled to remove the oil stains and oxide films on the surface of the materials;

[0016] Step three: the patch is installed on the area to be repaired, the position is carefully adjusted, and the solder paste is applied or the filler foil is put into the gap between the patch and the original honeycomb;

[0017] Step four: the brazing is performed by using a special repair tool or by using a flame, a hot air gun or an induction coil, and when other heating methods are used, the temperature and the time should be controlled to prevent the damage to the honeycomb itself;

[0018] Step five: after the brazing is completed, the brazing seam is cleaned to remove the residual filler and flux. Beneficial effects

[0019] Compared with the prior art, the application has the following beneficial technical effects:

[0020] The technical scheme adopted by the application is that the melting point of Mg, Cu, Zn, Sn, Ge and Si elements is reduced, and a low-melting filler for repairing the alloy honeycomb is prepared, compared with the traditional glue filling repair method, the strength and light weight of the repaired honeycomb are ensured, and the blank of repairing the alloy honeycomb of the aircraft is made up. BRIEF DESCRIPTION OF DRAWINGS

[0021] Fig. 1A schematic diagram of cleaning the damaged area and making the repair patch for the embodiment;

[0022] Fig. 2 A schematic diagram of assembling the repair patch and filling the solder for the embodiment;

[0023] Fig. 3 A special welding tool for the embodiment. DETAILED DESCRIPTION

[0024] The application will be described in detail below with reference to the accompanying drawings. Figs. 1-3 The application will be described in detail below with reference to the accompanying drawings. Embodiment 1

[0025] A preparation method of a low-melting-point solder for repairing honeycomb damage, comprising the following steps:

[0026] Step one: preparing the solder, the components are Mg: 7.8%, Cu: 6.3%, Zn: 33.5%, Sn: 2.5%, Ge: 4.25%, Si: 6.25%, and the balance is Al. According to the above mass percentage, various high-purity raw materials are weighed, and the purity of each high-purity raw material is not less than 99.99%;

[0027] Step two: mixing the first part of Al raw material with Ge raw material to prepare Al-Ge compound, and mixing the second part of Al raw material with Si raw material to prepare Al-Si compound;

[0028] Step three: uniformly mixing the third part of Al raw material, Mg raw material, Cu raw material, Zn raw material, Sn raw material, Al-Ge compound and Al-Si compound, and heating and smelting in an arc furnace under the protection of argon atmosphere, the smelting temperature is 650℃, and the smelting time is 5 minutes, to obtain a blocky alloy;

[0029] Step four: preparing the blocky alloy into an amorphous sheet, the preparation method of the amorphous sheet is single-roll rapid cooling method, and the thickness of the amorphous sheet is 50μm.

[0030] The application method of the low-melting-point solder for repairing honeycomb damage, comprising the following steps:

[0031] Step one: cleaning the area to be repaired using a cutting machine to clean the area to be repaired, and processing the corresponding repair patch, wherein the size of the patch should be larger than the size of the area to be repaired, but should not be too large, and L is 0.3-0.5 times the radius of the honeycomb;

[0032] Step two: cleaning, polishing and pickling the area to be repaired and the patch to remove oil stains and oxidation film on the surface of the material;

[0033] Step three: install the patch to the area to be repaired, carefully adjust the position, and apply solder paste or put in the solder foil into the gap between the patch and the original honeycomb, as shown in Fig. 2. Fig. 2

[0034] Step four: use the solder to perform brazing test on the aluminum foil, use the special repair tool, select the heating head width of 5 mm, the temperature of 475℃, and the welding time of 45s.

[0035] Step five: clean the brazing seam after brazing, and remove the residual solder and flux.

[0036] After welding, the tensile test is performed on the sample, all samples are broken at the base material, which shows that the welding quality is good, and the weld strength is higher than the base material. Example 2

[0037] A preparation method of a low-melting-point solder for repairing honeycomb damage, comprising the following steps:

[0038] Step one: prepare the solder, the composition is Mg: 7.8%, Cu: 6.3%, Zn: 33.5%, Sn: 2.5%, Ge: 4.25%, Si: 6.25%, and the balance is Al. According to the above mass percentage, various high-purity raw materials are weighed, and the purity of each high-purity raw material is not less than 99.99%.

[0039] Step two: mix the first part of Al raw material with Ge raw material to prepare Al-Ge compound, and mix the second part of Al raw material with Si raw material to prepare Al-Si compound.

[0040] Step three: mix the third part of Al raw material, Mg raw material, Cu raw material, Zn raw material, Sn raw material, Al-Ge compound and Al-Si compound uniformly, heat and melt in the arc furnace under the protection of argon atmosphere, the melting temperature is 650℃, and the melting time is 5 minutes, to obtain a blocky alloy.

[0041] Step four: prepare the blocky alloy into an amorphous sheet, the preparation method of the amorphous sheet is single-roll rapid cooling method, and the thickness of the amorphous sheet is 50μm.

[0042] An application method of the low-melting-point solder for repairing honeycomb damage, comprising the following steps:

[0043] Step one: use a cutting machine to clean the area to be repaired, and make a welding test block: the size of the aluminum honeycomb test block is 100 x 100 mm, the size of the area to be repaired is 50 x 50 mm, and the size of the honeycomb is 12.8 mm; the size of the patch is 55 x 55 mm, and the size of the honeycomb is consistent with the material to be repaired.

[0044] ​Step two: clean, polish and acid wash the repair area and patch to remove surface oil and oxidation film;

[0045] Step three: assemble the patch and the honeycomb to be repaired, adjust the position and place the foil filler between the two test blocks;

[0046] Step four: use the special repair tool in Fig. 3 , select the heating head width of 5mm, the temperature of 475℃, and the welding time of 45s, and sequentially weld the honeycomb weld.

[0047] Step five: clean the weld after brazing to remove residual filler and flux.

[0048] After welding, test the quality of the weld, and all the welds are free of cracking, with good welding quality.

Claims

1. A method of using a low melting filler metal for repairing aluminum alloy honeycomb damage, characterized by: The method comprises the following steps: Step 1: use a cutting machine to clean the area to be repaired and process a corresponding repair patch, the size of the repair patch is larger than that of the area to be repaired, and the size of the repair patch is larger than the width of the area to be repaired, wherein the value of the area larger than the area to be repaired is l, and l is 0.3-0.5 times the radius of the honeycomb; Step 2: clean, polish and pickle the area to be repaired and the patch to remove oil stains and oxide films on the surface of the material; Step 3: install the patch in the area to be repaired, carefully adjust the position, and put low-melting filler sheet into the gap between the patch and the original honeycomb; Step 4: use a special repair tool or use a flame, hot air gun, induction coil to perform brazing by heating method, and attention should be paid to control the temperature and time when using other heating methods to prevent damage to the honeycomb itself; Step 5: clean the brazing seam after brazing to remove residual filler and flux; The low-melting filler sheet is obtained by the following preparation method, comprising the following steps: Step 1: the chemical composition of the low-melting filler is as follows: Mg: 5-12%, Cu: 5-13%, Zn: 10-40%, Sn: 1.5-4.5%, Ge: 2.0-6.0%, Si: 4.5-12.5%, and the balance is Al; Various high-purity raw materials are weighed according to the mass percentage of the chemical composition of the filler, and the purity of each high-purity raw material is not less than 99.99%; Step 2: divide the Al raw material into three parts, namely the first part, the second part and the third part; wherein the first part and Ge form an Al-Ge compound, and the second part and Si form an Al-Si compound; Step 3: mix the third part of Al raw material, Mg raw material, Cu raw material, Zn raw material, Sn raw material, Al-Ge compound and Al-Si compound uniformly, heat and melt in an arc furnace under the protection of argon atmosphere, and obtain a blocky alloy, i.e. the above low-melting filler; The blocky alloy is made into an amorphous sheet, and the preparation method of the amorphous sheet is single-roll rapid cooling method, and the thickness of the amorphous sheet is 50μm.

2. A method of using a low melting filler metal for repairing damage to aluminum alloy honeycomb according to claim 1, characterized in that: The mass ratio of the first part of Al raw material, the second part of Al raw material and the third part of Al raw material depends on the specific composition of the filler.

3. A method of using a low melting filler metal for repairing damage to aluminum alloy honeycomb according to claim 1, characterized in that: The melting temperature of the arc furnace is 700℃, and the melting time is 5-10min, so that the elements can be fully diffused and fused, and the loss of elements can be avoided.

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