A method for manufacturing a composite cover plate for finger components

Abstract

This application relates to the field of nuclear fusion reactor technology, specifically to a method for manufacturing a composite cover plate for a finger component. It includes the following steps: providing a bimetallic composite plate, the bimetallic composite plate comprising a heat sink material layer and a structural material layer stacked together; creating stress relief grooves on the surface of the heat sink material layer and subjecting it to vibration aging treatment; pressing the bimetallic composite plate to form an inner conical arc surface on the structural material layer and an outer conical arc surface on the heat sink material layer; subjecting the pressed bimetallic composite plate to natural aging treatment; and machining the pressed bimetallic composite plate to obtain the composite cover plate. This application can more precisely control the shape, interface, and edge dimensions of the composite cover plate, thus relatively reducing the manufacturing difficulty of the composite cover plate.

Description

Technical Field

[0001] This application relates to the field of nuclear fusion reactor technology, specifically to a method for manufacturing a composite cover plate for a finger component. Background Technology

[0002] The first wall is the component in the vacuum chamber of the International Thermonuclear Experimental Reactor (ITER) that directly faces the high-temperature plasma. The enhanced heat load type first wall needs to withstand 4.7 MW / m². 2 The heat load is mainly borne by the finger components located on the upper part of the first wall, and their structure is shown below. The finger components mainly consist of three parts: armor, composite cover plate, and back plate. The armor directly bears the heat load. The upper part of the composite cover plate is welded to the armor. The inner "washboard" structure utilizes the principle of boiling heat transfer to efficiently remove heat from the armor. The back plate is the load-bearing carrier of the finger structure and forms an internal cooling channel together with the composite cover plate.

[0003] The raw materials for manufacturing composite cover plates are bimetallic composite plates made by hot isostatic pressing of heat sink materials and structural materials. These raw materials are then machined into composite cover plates. For example... Figure 8 The structure shown is called an edge finger composite cover plate. The main feature of the edge finger composite cover plate is that the entire structure is conical, including the upper surface of the heat sink material, the lower surface of the structural material, and the outer contour formed by the inner "washboard" structure. However, the outer and inner surfaces of the composite cover plate are not perpendicular to the conical surface (acute or obtuse angles), making the entire composite cover plate structure more complex. Furthermore, the interface dimensions between the heat sink material and the structural material in the final product have high requirements. Taking the thickness of the structural material as an example, since the total thickness of the structural material and the heat sink material on the finger is a fixed value, if the structural material is too thick, the heat sink material will inevitably be too thin. This significantly increases the probability of cracking during high-heat load testing of the finger or high-heat load operation in the vacuum chamber of a fusion reactor, leading to coolant leakage. If the structural material is too thin, the heat generated during the subsequent welding of the composite cover plate and the back plate will directly affect the connection performance of the interface between the heat sink material and the structural material of the composite cover plate. This will also increase the risk of cracking under high-heat load conditions. Based on the experience of several prototype edge finger composite cover plates, due to the high-temperature and high-pressure environment, bending, pressing, and machining processes involved in the manufacturing process (including the raw material manufacturing process), the composite cover plate inevitably deforms due to reduced stiffness after material removal and residual stress, resulting in the dimensions of the interface between the heat sink material and the structural material exceeding the tolerance requirements. In conclusion, the manufacturing of composite cover plates for edge fingers is extremely difficult. Summary of the Invention

[0004] This application aims to solve at least one of the technical problems existing in the background art by providing a method for manufacturing a composite cover plate for finger components.

[0005] This application is achieved through the following technical solution: A method for manufacturing a composite cover plate for a finger component includes the following: A bimetallic composite plate is provided, the bimetallic composite plate comprising a heat sink material layer and a structural material layer stacked together, the material is cut according to the shape after the conical component is unfolded into a planar state, and a certain allowance is left in the dimensions around the perimeter; Stress relief grooves are formed on the surface of the heat sink material layer and vibration aging treatment is performed. The bimetallic composite plate is pressed to form an inner conical arc surface on the structural material layer and an outer conical arc surface on the heat sink material layer; Natural aging treatment is applied to the pressed bimetallic composite plate. The pressed bimetallic composite plate is assembled on a clamping seat and then machined to obtain a composite cover plate.

[0006] The method for manufacturing composite cover plates for finger components provided in this application effectively alleviates residual stress caused by high-temperature and high-pressure environments and machining processes during the manufacturing process of the composite cover plate by opening stress relief grooves on the surface of the heat sink material layer and performing vibration aging treatment, thereby reducing the risk of deformation. At the same time, pressing the bimetallic composite plate to form inner and outer conical arc surfaces ensures the structural accuracy of the composite cover plate and effectively reduces the amount of raw materials used and cutting. This method can precisely control the interface dimensions between the heat sink material and the structural material, avoiding the risk of coolant leakage and cracking due to excessively thick or thin structural materials, improving the fatigue life of the composite cover plate under high heat load conditions, and effectively solving the problem of high manufacturing difficulty of edge finger composite cover plates.

[0007] In some optional embodiments, the vibration aging treatment time after creating stress relief grooves on the surface of the heat sink material layer is 20 to 40 minutes.

[0008] In some alternative embodiments, the stress relief groove is a straight through groove.

[0009] In some alternative embodiments, a conical die is used to press the bimetallic composite plate. The conical die includes a first conical die and a second conical die. The first conical die has a first arc-shaped conical surface adapted to the composite cover plate structural material layer, and the second conical die has a second arc-shaped conical surface adapted to the composite cover plate heat sink material layer. A pressing gap adapted to the composite cover plate is formed between the first arc-shaped conical surface and the second arc-shaped conical surface.

[0010] In some optional embodiments, after the bimetallic composite plate is pressed, a shaping mold is used to shape the sides of the bimetallic composite plate. The shaping mold includes a first shaping mold and a second shaping mold. The first shaping mold has a first pressing working surface, and the second shaping mold has a second pressing working surface. A pressing gap is formed between the first pressing working surface and the second pressing working surface. A conical groove is formed on the second pressing working surface. The depth of the conical groove is less than the width of the composite cover plate, and the width of the conical groove is greater than the thickness of the composite cover plate.

[0011] In some alternative embodiments, the depth of the conical groove is 0.5 to 1 mm less than the width of the composite cover plate.

[0012] In some optional embodiments, the width of the conical groove is 0.3 to 0.5 mm greater than the thickness of the composite cover plate.

[0013] In some optional embodiments, the shaped bimetallic composite plate is subjected to natural aging treatment for 24 to 48 hours.

[0014] In some optional embodiments, a clamping base is used to position the bimetallic composite plate during machining of the pressed plate. The clamping base includes: A base, the base being configured to mate with the clamping structure of a machine tool; Support legs, multiple support legs are located on the base and arranged at intervals, and the end face of the support legs is used to connect the bimetallic composite plate; A pressure block, which is connected to the base by a bolt assembly and is located between two adjacent legs, is configured to press the other end of the leg against the base; A pad, which is connected to the base, is located on both sides of all the legs in the direction of the leg arrangement.

[0015] In some alternative embodiments, one end of the support leg has a reserved gap with the edge of the bimetallic composite plate.

[0016] Compared with the prior art, this application has the following advantages and beneficial effects: The method for manufacturing composite cover plates for finger components provided in this application effectively alleviates residual stress caused by high-temperature and high-pressure environments and machining processes during the manufacturing process of the composite cover plate by opening stress relief grooves on the surface of the heat sink material layer and performing vibration aging treatment, thereby reducing the risk of deformation. At the same time, pressing the bimetallic composite plate to form inner and outer conical arc surfaces ensures the structural accuracy of the composite cover plate and effectively reduces the amount of raw materials used and cutting. This method can precisely control the interface dimensions between the heat sink material and the structural material, avoiding the risk of coolant leakage and cracking due to excessively thick or thin structural materials, improving the fatigue life of the composite cover plate under high heat load conditions, and effectively solving the problem of high manufacturing difficulty of edge finger composite cover plates. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the exemplary embodiments of this application, the accompanying drawings used in the embodiments will be briefly described below. It should be understood that the following drawings only show some embodiments of this application and should not be considered as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort. In the drawings: Figure 1 This is a schematic diagram of the manufacturing process of the composite cover plate for the finger component provided in an embodiment of this application; Figure 2 This is a schematic diagram of the bimetallic composite plate structure provided in the embodiments of this application; Figure 3 A schematic diagram of the state structure of a bimetallic composite plate when a conical die is used to press the bimetallic composite plate according to an embodiment of this application; Figure 4 A schematic diagram of the state structure of a bimetallic composite plate when the alignment mold provided in this application is used to align the bimetallic composite plate; Figure 5 A schematic diagram of the state structure of the bimetallic composite plate and the second forming mold provided in the embodiment of this application; Figure 6 A schematic diagram of the first-view state structure of the bimetallic composite plate and the clamping base when they are engaged, according to an embodiment of this application; Figure 7 This is a schematic diagram of the second-view state structure of the bimetallic composite plate and the clamping seat provided in the embodiment of this application; Figure 8 This is a reference schematic diagram of the edge finger composite cover plate structure.

[0018] The attached diagram shows the markings and corresponding component names: 1-Structural material layer, 2-Heat sink material layer, 3-Stress relief groove, 4-Second conical mold, 5-First conical mold, 6-Bimetallic composite plate, 7-First straightening mold, 8-Second straightening mold, 9-Conical groove, 10-Base, 11-Support leg, 12-Pressure block, 13-Padded block, 14-Sheath material, 15-Bolt assembly. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the embodiments and accompanying drawings. The illustrative embodiments and descriptions of this application are only for explaining this application and are not intended to limit this application.

[0020] For composite cover plates, the usual practice is to directly perform precision machining using a five-axis CNC machine tool. However, this method has the problem of high cost, and since the composite cover plate is irregularly shaped, it is not easy to guarantee the contour accuracy of the composite cover plate during the machining process.

[0021] Due to the limitations of existing processing methods, the inventors previously attempted the following processing methods: The first method involves processing the internal "washboard" toothed structure and other water channel structures of the raw material bimetallic composite plate in a flat state. The side of the composite cover plate along its length and the lower surface welded to the back plate are also milled in place. Then, a special forming mold is made, and the cover plate in the flat state is pressed into a conical shape using the mold and a hydraulic press. Then, according to the length after pressing, the two ends of the composite cover plate are milled in place using a milling machine.

[0022] The advantages of this approach are excellent control over the thickness of the structural and heat sink materials. However, its disadvantages include: First, while most of the structure is completed during the flat plate stage, the difference between the structural form in the straight plate stage and the final stage is significant. This results in substantial deformation of the entire workpiece during subsequent pressing. Phased array ultrasonic testing revealed that the echo at the interface between the structural and heat sink materials exceeded the allowable range, indicating a significant defect. Second, the entire composite cover plate always exhibits some springback and deformation after pressing. When transferred from the hydraulic press to the milling machine, the overall shape of the composite cover plate changes, leading to significant errors after milling the two end faces. This does not meet the requirement that misalignment and gaps between the composite cover plate and the back plate should not exceed 0.1mm during welding.

[0023] The second method involves milling the interface between the structural material and the heat sink material during the raw material manufacturing stage, leaving the other surfaces flat to ensure good rigidity for both materials. The two are then directly assembled using hot isostatic pressing (HIP), ensuring the interface meets the requirements of the drawings and 3D model. A five-axis CNC machine tool is used to remove excess material from the lower part of the composite cover plate's heat sink and structural materials, and then a clamping device is used to remove excess material from the upper part of the composite cover plate's heat sink material, completing the entire composite cover plate manufacturing process. The advantages of this approach are that the finished composite cover plate has minimal deformation, good conformity after assembly with the back plate, and high dimensional accuracy at the interface between the heat sink material and the structural material, fully meeting product requirements. However, the disadvantages are that the material requirement for the composite cover plate with the edge fingers is almost four times that of the first approach due to its large conical curvature, resulting in significant material waste. Another crucial issue is that there are very few domestic manufacturers capable of providing thick heat sink materials that meet performance requirements (especially grain size and strength), and currently, there are almost none, necessitating further research and development. Based on the above, please refer to the following: Figure 1 and Figure 2 This application provides a method for manufacturing a composite cover plate for a finger component, which includes the following: S1. Provide a bimetallic composite plate 6, the bimetallic composite plate 6 comprising a heat sink material layer 2 and a structural material layer 1 arranged in layers.

[0024] Typically, explosive welding or hot isostatic pressing welding is used to connect the structural material layer 1 and the heat sink material layer 2 to form a bimetallic composite plate 6. In this embodiment, hot isostatic pressing welding is used to connect the structural material layer 1 and the heat sink material layer 2. During the fabrication of the bimetallic composite plate 6, a processing allowance of 1 to 3 mm is reserved for the thickness of both the structural material layer 1 and the heat sink material layer 2.

[0025] After the bimetallic composite plate 6 is manufactured, the next step is to cut it into blanks. Typically, the model of the composite cover plate is created in 3D modeling software. The 3D model of the composite cover plate is unfolded using the unfolding function in the 3D modeling software. The shape and size of the unfolded 3D model are measured. The shape of the unfolded 3D model is roughly an arc shape (where two opposite sides have an angle with the plate surface, and these two sides correspond to the sides at both ends of the width direction of the final formed composite plate). Based on the measured dimensional parameters, the bimetallic composite plate 6 is cut into blanks with a 1-3mm allowance on all four sides. After cutting, a bimetallic composite plate blank is obtained.

[0026] It should be noted that composite cover plates refer to components that are finally processed and shaped, and whose various shapes and dimensions are as expected.

[0027] S2. Stress relief grooves 3 are opened on the surface of the heat sink material layer 2 and vibration aging treatment is performed.

[0028] In this embodiment, when the bimetallic composite plate is manufactured, the connection between the structural material layer 1 and the heat sink material layer 2 is achieved by hot isostatic pressing (HIP) welding, leaving a retaining material 14 on the heat sink material layer 2. The bimetallic composite plate 6, after being cut, needs to be pressed to obtain its unique arc shape. To prevent springback after pressing, a slit can be cut into the retaining material 14, extending towards the heat sink material layer 2 to form a shallow stress relief groove 3 on the surface of the heat sink material layer 2. After the bimetallic composite plate 6 is pressed, stress can be quickly released through this stress relief groove 3. As described above... After cutting, the bimetallic composite plate 6 is generally annular in shape. The stress relief groove 3 is usually a straight through groove. The extension direction of the stress relief groove 3 is parallel to the width direction of the bimetallic composite plate 6. There are usually multiple stress relief grooves 3, which are arranged at intervals along the length of the bimetallic composite plate 6. Of course, after the stress relief groove 3 is opened, the bimetallic composite plate 6 can be subjected to vibration aging treatment, thereby further reducing the residual stress of the bimetallic composite plate produced by hot isostatic pressing under high temperature and high pressure. The aging time of vibration aging treatment is usually 20 min to 40 min.

[0029] S3. Press the bimetallic composite plate 6 to form an inner conical arc surface on the structural material layer 1 and an outer conical arc surface on the heat sink material layer 2.

[0030] After the stress relief groove 3 of the bimetallic composite plate 6 is created, the next step is to press the bimetallic composite plate 6. The overall shape of the formed composite cover plate is an irregular plate with a conical arc surface. It is difficult to press directly with a hydraulic press, and the resulting outline shape and dimensions will vary greatly, making subsequent processing difficult. Therefore, before pressing the bimetallic composite plate 6, the conical mold is first made. Please refer to [reference needed]. Figure 3The conical mold includes a first conical mold 5 and a second conical mold 4, both of which are block shapes. The first conical mold 5 has a first arc-shaped conical surface adapted to the structural material layer 1 of the composite cover plate, and the second conical mold 4 has a second arc-shaped conical surface adapted to the heat sink material layer 2 of the composite cover plate. A pressing gap adapted to the composite cover plate is formed between the first and second arc-shaped conical surfaces. The widths of both the first and second arc-shaped conical surfaces are greater than the width of the bimetallic composite plate 6, ensuring that the bimetallic composite plate 6 remains within the pressing gap during bending deformation. During pressing, the first conical mold 5 and the second conical mold 4 are... The face molds 4 are fixed to the hydraulic press. After the first conical face mold 5 and the second conical face mold 4 are fixed, they are arranged in an up-down position. For example, the first conical face mold 5 is located at the bottom and the second conical face mold 4 is located at the top. The first arc-shaped conical surface and the second arc-shaped conical surface are opposite each other. The bimetallic composite plate 6 is placed on the first arc-shaped conical surface of the first conical face mold 5. The second conical face mold 4 moves downward and contacts the bimetallic composite plate 6 through the second arc-shaped conical surface to press the bimetallic composite plate 6 tightly against the first arc-shaped conical surface. During the pressing process, the pressure parameters of the hydraulic press are controlled at 30~50t to ensure that the contour of the pressed bimetallic composite plate 6 has an error of no more than 0.3mm relative to the contour of the theoretical model.

[0031] Because two sides of the bimetallic composite plate 6 are irregularly shaped and cannot be fixed, the shape of the two sides in the width direction of the bimetallic composite plate 6 needs to be corrected after it is pressed within the pressing gap to ensure that the shape and size of the bimetallic composite plate 6 are within the expected range. Therefore, after pressing the bimetallic composite plate 6, a correction mold is used to correct the sides of the bimetallic composite plate 6. (See reference...) Figure 4 and Figure 5The forming mold includes a first forming mold 7 and a second forming mold 8. The first forming mold 7 can be designed as a rectangular block, with one plane of the first forming mold 7 serving as the first pressing working surface. The second forming mold 8 can also be a rectangular block, with one plane of the second forming mold 8 serving as the second pressing working surface. The first pressing working surface and the second pressing working surface are parallel to each other, forming a pressing gap between them. A conical groove 9 is formed on the second pressing working surface, extending into a through groove. The shapes of the two opposite groove walls of the conical groove 9 are respectively adapted to the inner and outer arc-shaped conical surfaces of the composite cover plate. The depth of the conical groove 9 is less than the width of the composite cover plate, meaning that when the composite cover plate is placed in the conical groove 9, part of the composite cover plate structure can be exposed above the second pressing working surface to contact the first pressing working surface. In actual implementation, the depth of the conical groove 9 is 0.5~1mm less than the width of the composite cover plate, and the width of the conical groove 9 is greater than the width of the composite cover plate. The thickness of the cover plate indicates that when the composite cover plate is placed in the conical groove 9, it can move a small distance in the width direction of the groove 9. This is to prevent the composite cover plate from getting stuck in the conical groove 9 during the pressing process. In practice, the width of the conical groove 9 is 0.3~0.5mm greater than the thickness of the composite cover plate. During pressing, the first shaping mold 7 and the second shaping mold 8 are fixed to the hydraulic press respectively. The first shaping mold 7 and the second shaping mold 8 are arranged in an up-down position, for example, the first shaping mold 7 is on top and the second shaping mold 8 is on the bottom. The groove opening of the conical groove 9 of the second shaping mold 8 faces the first pressing working surface. The hydraulic press drives the first shaping mold 7 to move downward and contact the composite cover plate to achieve the shaping of the bimetallic composite plate 6 until the gap between the first pressing working surface and the second pressing working surface is the theoretical value of the width of the bimetallic composite plate. During the pressing process, the parameters of the hydraulic press are controlled between 10~25t, so that the side flatness of the bimetallic composite plate 6 in the width direction is not greater than 0.5mm after pressing.

[0032] S4. Perform natural aging treatment on the pressed bimetallic composite plate 6.

[0033] After pressing the bimetallic composite cover plate using a conical die and a straightening die, the shape and size of the bimetallic composite plate 6 are within the expected range. However, the pressing process generates new residual stress. To prevent the bimetallic composite cover plate from springing back and deforming later, the bimetallic composite cover plate is subjected to natural aging treatment for 24 to 48 hours. After the aging treatment is completed, the flatness of the conical profile and the side surface in the width direction of the bimetallic composite plate 6 needs to be measured. If the requirements are not met, the pressing process is repeated, and the aging and measurement processes are repeated until the requirements are met.

[0034] S5. The pressed bimetallic composite plate 6 is machined to obtain a composite cover plate.

[0035] The processed bimetallic composite plate 6 will have the same shape and dimensions as the composite cover plate. Typically, a five-axis CNC machine tool is used to process the edges and tapered arc surfaces of the bimetallic composite plate 6. Because the bimetallic composite plate 6 is irregularly shaped, it is not directly clamped by a five-axis CNC machine tool during processing. Instead, a clamping seat is used to fix the bimetallic composite plate 6 to adjust the interface dimensions between the structural material and the heat sink material of the bimetallic composite plate. (See reference...) Figure 6 and Figure 7The clamping base specifically includes a base 10, support legs 11, pressure blocks 12, pads 13, and bolt assemblies 15. The base 10 is configured to cooperate with the clamping structure of the machine tool. For example, the base 10 can be designed as a plate structure, and several through holes can be opened on the base 10 to facilitate connection to a five-axis linkage machine tool. For example, the shape of the base 10 is roughly rectangular plate-shaped, the thickness of the base 10 is set to 20~30mm, the length of the base 10 is 100~150mm longer than the length of the bimetallic composite plate 6 after pressing, the width is designed to be 200~300mm, and multiple threaded holes with a diameter of M are provided in the length direction. The base 10 has a diameter of 12~M20, and the number of perforations is 4~8. Multiple perforations are arranged in two rows on the base 10, symmetrically. The diameter of the perforations is designed to be 16~24mm. The support legs 11 are T-shaped, with multiple legs 11 located on the base 10 and spaced apart, between the two rows of perforations. Each support leg 11 is also located between two adjacent threaded holes. The support legs 11 are attached to the plate surface of the base 10 through their flat surfaces. One end of each support leg 11 is connected to the bimetallic composite plate 6. Specifically, one end of the support leg 11 is connected to the sheathing material 14 of the bimetallic composite plate 6. Low-power... The connection between the support leg 11 and the bimetallic composite plate 6 is achieved using a low-heat laser welding machine or high-strength metal bonding adhesive. Since the sheathing material 14 has a conical arc surface, the end face of the support leg 11 that connects to the bimetallic composite plate 6 is an irregular arc shape, ensuring a full fit between this end face and the sheathing material 14. The heights of each support leg 11 are different; in the arrangement direction of the support legs 11, the height of the middle support leg 11 is lower than that of the support legs 11 on both sides. The height difference between adjacent support legs 11 is adapted to the composite cover plate, meaning that when the support leg 11 is positioned on the base, it is connected by the pressure block 12, the pad block 13, and the bolt assembly 1. 5. After fixing in place, the bimetallic composite plate 6 can be adjusted to the theoretical processing position. In the width direction of the bimetallic composite plate 6, the width of the support leg 11 is 2~4mm less than the width of the bimetallic composite plate 6 as a reserved processing space. That is, in the width direction of the bimetallic composite plate 6, the support leg 11 has a gap of 1~2mm from the two sides respectively. The interval between two adjacent support legs 11 should be set to 150~200mm. The number of support legs 11 is usually more than 3. In the length direction of the bimetallic composite plate 6, the support legs 11 at both ends have a distance of 10~20mm from the end face of the bimetallic composite plate 6 respectively.The pressure block 12 is connected to the base 10 and located between two adjacent support legs 11. The pressure block 12 is roughly rectangular in shape, and its length and width are adapted to the spacing between the support legs 11. In actual implementation, the length of the pressure block 12 is 6-10 mm less than the spacing between the support legs 11, and the width of the pressure block 12 is 2-6 mm greater than the corresponding width of the support legs 11. The pressure block 12 is located between the two support legs 11 to press down on the other end of the support legs 11. Pads 13 are designed on both sides of the support legs 11 at both ends of the arrangement direction. The pads 13 are spaced apart from the end support legs 11, and the pads 13 are spaced apart from the support legs. A pressure block 12 is also provided between the legs 11. A through hole is formed in the center of the pressure block 12, the diameter of which is 0.5-1 mm larger than the diameter of the threaded hole. One surface of the pressure block 12 (facing the bimetallic composite plate 6 in the working state) is designed with an inverted conical structure, an angle of 10-15°, and a length of 20-30 mm. The pressure block 12 is connected to the threaded hole on the base 10 via bolt assembly 15, thereby pressing the support leg 11 firmly onto the base 10. The clamping seat is then clamped onto a five-axis CNC machine tool through a through hole on the base 10. The bimetallic composite plate 6 is then processed by the five-axis CNC machine tool to obtain the composite cover plate.

[0036] When machining with a five-axis CNC machine tool, the feed rate of the machine tool is usually based on the theoretical design dimensions of the composite cover plate. If the bending shape of the bimetallic composite plate 6 differs significantly from the designed bending shape of the composite cover plate, some parts of the bimetallic composite plate 6 may be over-machined or under-machined. For example, when milling a conical arc surface, the milling thickness of each part may be different, ultimately resulting in the interface dimensions of the heat sink material and the structural material not meeting the requirements.

[0037] In this embodiment, since the height of each support leg 11 is adapted to the composite cover plate with the sheathing material 14, each support leg 11 is connected to the sheathing material 14 on the bimetallic composite plate 6, and then the support leg 11 is pressed onto the base 10 by the pressure block so that the plane on the support leg 11 is fully in contact with the plate surface of the base 10. During the pressing of the support leg 11, if the bending shape of the bimetallic composite plate 6 and the composite cover plate is significantly different, each support leg 11 can exert different degrees of tension on the bimetallic composite plate 6. After the support leg 11 is fully pressed, the bending shape of the bimetallic composite plate 6 is consistent with the bending shape of the composite cover plate, which means that each support leg 11, together with the pressure block 12, can correct the bending shape of the bimetallic composite plate 6. At this time, when processing the bimetallic composite plate 6, the processing dimensions of each part of the bimetallic composite plate 6 can meet the requirements.

[0038] Compared to existing manufacturing methods, the method for manufacturing the composite cover plate for the finger component provided in this application embodiment is as follows: 1. Using a bimetallic composite plate 6 with minimal machining allowance, the material is cut to the dimensions of the conical surface of the edge finger composite cover after planar unfolding. Then, the conical surface is bent, the sides are slightly shaped, the conical legs 11 are connected and clamped, the plate is clamped, and the material is processed on a five-axis CNC machine tool. This process completes the manufacturing of the edge finger composite cover without damaging the connection interface of the bimetallic composite plate 6, and the overall dimensions and the dimensions of the bimetallic materials on both sides of the connection interface meet the design requirements. This process results in almost no material waste and high process repeatability. 2. Multiple methods are employed to reduce residual stress and springback that may occur during bending. During the blanking stage, the material is cut to the dimensions after the conical surface is unfolded. During subsequent bending, the material only undergoes free bending deformation, avoiding excessive compression and stretching that could lead to significant plastic deformation and damage to the bimetallic plate connection interface, as well as residual stress. Grooving along the width direction on the upper part of the heat sink material (or the upper part of the sheathing material 14 remaining from the hot isostatic pressing connection), vibration aging treatment after blanking, and natural aging treatment after bending can all reduce residual stress and springback to a certain extent after bending. 3. A specialized combination mold is used for bending. The conical mold can directly press the bimetallic composite plate 6 into the conical surface required for the edge finger composite cover plate while maintaining a free state around its edges, ensuring that the thickness of the structural material and heat sink material meets the requirements during subsequent five-axis precision machining. The straightening mold can correct the shape and size of the bimetallic composite plate 6 in the width direction, reducing the amount of material removed during the five-axis machine tool machining stage, and ensuring that the edge dimensions of the machined composite cover plate meet the requirements. The straightening mold has space in both the thickness and length directions of the bimetallic composite plate 6, allowing it to be in a free state. The mold design takes into account unnecessary extrusion and deformation of the bimetallic composite plate 6.

[0039] 4. A complete set of specialized fixtures, including a base 10, legs 11, pressure blocks 12, pads 13, and bolt assemblies 15, is used to ensure that the conical shape of the bimetallic composite plate 6 is basically consistent with the theoretical shape. After bending, the bimetallic composite plate 6 inevitably experiences a small amount of springback. The legs 11, with their precise dimensions and high rigidity, are connected to the bent bimetallic composite plate 6 with high strength. Then, all the legs 11 are fixed to the rigid base 10, which pulls the springback and other deformations of the bimetallic composite plate 6 back to the theoretical conical surface. Furthermore, in the mass production stage of the edge cover plate composite cover, this complete set of fixtures has two usage methods. The first method is to pre-fix the base 10 on the machine tool, and then install the bimetallic composite plate 6 with legs 11 onto the base 10 on the machine tool using fasteners such as pressure blocks 12. The second method is to complete the clamping and fixing of the complete set of fixtures with the bimetallic composite plate 6 outside the machine tool, and then transport the entire assembly to the machine tool for installation and fixing via the base 10. Since mounting the base 10 onto the machine tool is relatively simple, while mounting and fixing the bimetallic composite plate 6 onto the base 10 is relatively complex, the second method can be chosen for mass production to save time on the five-axis machine tool, requiring only two sets of this complete set of fixtures. Method 1 requires only one set of the base 10 and pressure block 12, saving at least one set of manufacturing costs for this component.

[0040] 5. The connection between the support leg 11 and the bimetallic composite plate 6 has machining allowance gaps in both length and width directions. When clamped, all features of the bimetallic composite plate 6, except for the upper part of the heat sink material, including the "washboard" shape, surrounding contours, and structural material dimensions, can be machined to their final state. This means that all critical parts can be machined in a single clamping operation, reducing errors caused by repeated clamping. After disassembling the clamp, the support leg 11 can be removed using wire cutting. Then, a general-purpose clamp can be used to mount the bimetallic composite plate 6 onto a five-axis machine tool via a side clamping method to remove the upper part of the heat sink material. Although a small amount of springback occurs in the bimetallic composite plate 6 at this stage, resulting in minor dimensional errors in the heat sink material, subsequent machining processes will refine the heat sink material to its final state after the edge finger composite cover is welded to the back plate.

[0041] Based on the above embodiments, the following is an application example of a method for manufacturing a composite cover plate for a finger component: (1) The finger cover plate of the first wall edge of the ITER enhanced heat load is made of bimetallic composite plate 6 by hot isostatic pressing welding. The machining allowance for the structural material thickness is 1mm, and the machining allowance for the heat sink material thickness is 2mm. The conical surface of the three-dimensional model of the composite cover plate is unfolded to a planar state using software, and the raw material of bimetallic composite plate 6 is cut using this planar state model, with a 2mm allowance left around the raw material. Grooves are cut along the width direction on the upper part of the residual sheath material 14 of the hot isostatic pressing connection, and the groove spacing in the length direction is 100mm. Finally, the material is subjected to vibration aging treatment for 40min. (2) The bimetallic composite plate 6 was pressed using a conical mold. The hydraulic press pressure was 45t. After pressing, the conical surface of the bimetallic composite plate 6 had a relative profile of 0.15mm to the theoretical model. (3) The width dimension of the bimetallic composite plate 6 was corrected using a forming mold. The hydraulic press pressure parameters were 12t, and the flatness of the side surface of the bimetallic composite plate 6 after pressing was 0.5mm. (4) Perform natural aging treatment on the bimetallic composite plate 6 for 24 hours. (5) Fabricate support legs 11 designed according to the conical dimensions of the bimetallic composite plate 6. The overall width of support legs 11 is 45mm and the thickness of support legs 11 is 20mm. The top of support legs 11 is connected to one side of the heat sink material of the pressed bimetallic composite plate 6 using high-strength metal bonding adhesive. Leave a 2mm gap on each side in the width direction of the bimetallic composite plate 6. The support legs 11 are evenly arranged with a spacing of 155mm in the length direction. There are 5 support legs 11. Leave a 20mm gap between the end support legs 11 and the end face. (6) Fabricate the base 10 of the clamping seat, which is 30mm thick, 880mm long, and 230mm wide. There are 6 threaded holes with a diameter of M16 along the length direction. There are also 6 symmetrical through holes with a diameter of Φ20mm along the width direction. The position of the through holes is determined by the clamping position of the five-axis linkage machine tool. (7) Make 6 pressure blocks 12 with a thickness of 20mm, a length of 125mm (of which, the length of the pressure blocks 12 at both ends is 80mm), a width of 49mm, a through hole in the center of the pressure block 12 with a diameter of 20mm, and the two ends of the pressure block 12 have an inverted cone structure with an angle of 10° and a length of 30mm; make pad block 13 and prepare bolt assembly 15.

[0042] (8) Use pressure block 12, pad block 13 and bolt assembly 15 to clamp the bimetallic composite plate 6 with support leg 11 onto the clamping seat, and observe the contact surface between all support leg 11 and base 10. They should be in close contact.

[0043] (9) The clamping seat is clamped onto the five-axis linkage machine tool using fasteners such as bolts and washers.

[0044] (10) Use a five-axis linkage machine tool to process the features of the bimetallic composite plate 6 structural material side and the surrounding features, and process the dimensions to the required level.

[0045] (11) Disassemble the base 10 and the pressure block 12, and use the side clamping method to process the features of the heat sink material side of the bimetallic composite plate 6. Once the dimensions are processed to the required level, the composite cover plate can be obtained. The misalignment and gap of the composite cover plate during the welding and assembly with the subsequent back plate should not exceed 0.1mm in length, thickness, and outline.

[0046] The specific embodiments described above illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. Although the description of this application is presented in conjunction with some embodiments, this does not mean that the features of this application are limited to this embodiment. On the contrary, the purpose of describing the application in conjunction with embodiments is to cover other options or modifications that may be derived based on the claims of this application. To provide a thorough understanding of this application, many specific details are included in the above description. This application may also be implemented without using these details. Furthermore, to avoid confusion or obscuring the focus of this application, some specific details will be omitted in the description. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other.

[0047] It should be noted that in this specification, similar reference numerals and letters in the above figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the figures, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. In the description of this application, it should be noted that unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two elements. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0048] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if such modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. A method for manufacturing a composite cover plate for finger components, characterized in that, Includes the following: A bimetallic composite plate (6) is provided, the bimetallic composite plate (6) comprising a heat sink material layer (2) and a structural material layer (1) arranged in layers. Stress relief grooves (3) are opened on the surface of the heat sink material layer (2) and vibration aging treatment is performed; Press the bimetallic composite plate (6) to form an inner conical arc surface on the structural material layer (1) and an outer conical arc surface on the heat sink material layer (2); The sides of the pressed bimetallic composite plate (6) are shaped using a shaping mold; Natural aging treatment was applied to the corrected bimetallic composite plate (6); The age-treated bimetallic composite plate (6) is machined to obtain a composite cover plate.

2. The method for manufacturing the composite cover plate for the finger component according to claim 1, characterized in that, The vibration aging treatment time after opening the stress relief groove (3) on the surface of the heat sink material layer (2) is 20~40 minutes.

3. The method for manufacturing a composite cover plate for finger components according to claim 1, characterized in that, The stress relief groove (3) is a straight through groove.

4. The method for manufacturing a composite cover plate for finger components according to claim 1, characterized in that, When pressing the bimetallic composite plate (6), a conical mold is used for pressing. The conical mold includes a first conical mold (5) and a second conical mold (4). The first conical mold (5) has a first arc-shaped conical surface adapted to the composite cover plate structural material layer (1), and the second conical mold (4) has a second arc-shaped conical surface adapted to the composite cover plate heat sink material layer (2). A pressing gap adapted to the composite cover plate is formed between the first arc-shaped conical surface and the second arc-shaped conical surface.

5. The method for manufacturing a composite cover plate for a finger component according to claim 1, characterized in that, The shaping mold includes a first shaping mold (7) and a second shaping mold (8), wherein the first shaping mold (7) has a first pressing working surface, the second shaping mold (8) has a second pressing working surface, a pressing gap is formed between the first pressing working surface and the second pressing working surface, and a conical groove (9) is provided on the second pressing working surface. The depth of the conical groove (9) is less than the width of the composite cover plate, and the width of the conical groove (9) is greater than the thickness of the composite cover plate.

6. The method for manufacturing a composite cover plate for a finger component according to claim 5, characterized in that, The depth of the conical groove (9) is less than the width of the composite cover plate by 0.5~1mm.

7. The method for manufacturing a composite cover plate for a finger component according to claim 5, characterized in that, The width of the conical groove (9) is 0.3~0.5mm greater than the thickness of the composite cover plate.

8. The method for manufacturing a composite cover plate for a finger component according to claim 5, characterized in that, The natural aging process takes 24 to 48 hours.

9. The method for manufacturing a composite cover plate for a finger component according to claim 1, characterized in that, When machining the pressed bimetallic composite plate (6), a clamping base is used to position the bimetallic composite plate (6), the clamping base comprising: A base (10) is configured to engage with the clamping structure of a machine tool; Support legs (11), multiple support legs (11) are located on the base (10) and arranged at intervals, one end of the support leg (11) is used to connect the bimetallic composite plate (6). A pressure block (12) is connected to the base (10) by a bolt assembly (15) and is located between two adjacent legs (11). The pressure block (12) is configured to press the other end of the leg (11) against the base (10). Pad (13), the pad (13) is connected to the base (10), and in the arrangement direction of the legs (11), the two pads (13) are located on both sides of all the legs (11).

10. The method for manufacturing a composite cover plate for a finger component according to claim 9, characterized in that, The end face of the support leg (11) has a reserved gap with the edge of the bimetallic composite plate (6).

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