阅读说明：本技术 一种镍基合金双性能整体叶盘的制造方法 (Manufacturing method of nickel-based alloy dual-performance blisk ) 是由 兰博 张国栋 张学军 方爽 陈由红 于秋颖 李凯 于 2019-08-02 设计创作，主要内容包括：本发明是一种镍基合金双性能整体叶盘的制造方法,本发明制造方法首先经大变形量等温锻造制造出细晶盘毂毛坯3,然后在盘毂毛坯3上采用电子束熔丝增材制造方法制备出粗大柱状晶的叶片毛坯4,再对整体叶盘毛坯进行小变形量的等温锻造变形,该种小变形量的等温锻造能够有效消除电子束熔丝沉积叶片毛坯内部的气孔及未熔合等缺陷,使整体叶盘毛坯致密化；同时有利于合金元素在盘毂毛坯3和叶片毛坯4界面处的均匀扩散,强化盘毂毛坯3和叶片毛坯4之间的界面结合；而且通过对整体叶盘毛坯的局部梯度变形,可以实现双性能整体叶盘的盘毂毛坯3与叶片毛坯4结合界面处两种显著差异组织之间的渐变过渡,能够大幅提高镍基合金双性能整体叶盘的耐久性和可靠性,得到整体叶盘锻件5。(The invention relates to a manufacturing method of a nickel-based alloy dual-performance blisk, which comprises the steps of firstly manufacturing a fine-grain blisk blank 3 through isothermal forging with large deformation, then preparing a thick columnar-grain blade blank 4 on the blisk blank 3 through an electron beam fuse wire additive manufacturing method, and then performing isothermal forging deformation with small deformation on the blisk blank, wherein the isothermal forging with small deformation can effectively eliminate the defects of air holes, unfused fusion and the like in the electron beam fuse wire deposition blade blank so as to densify the blisk blank; meanwhile, the uniform diffusion of alloy elements at the interface of the hub blank 3 and the blade blank 4 is facilitated, and the interface combination between the hub blank 3 and the blade blank 4 is strengthened; and through local gradient deformation of the blisk blank, gradual transition between two significant difference structures at the joint interface of the hub blank 3 and the blade blank 4 of the dual-performance blisk can be realized, the durability and the reliability of the nickel-based alloy dual-performance blisk can be greatly improved, and the blisk forged piece 5 is obtained.)

1. A manufacturing method of a nickel-based alloy dual-performance blisk is characterized in that: the manufacturing method comprises the following steps:

step one, preparing a disc hub blank

Aiming at a nickel-based alloy bar in a forging state or a rolling state, preparing a fine-grain hub blank (3) of the dual-performance blisk by adopting an isothermal forging method, wherein the hub blank (3) is in a disc shape;

step two, preparing a blade blank at the periphery of the disk hub blank

Fusing and depositing a blade blank (4) layer by layer on the periphery of the hub blank (3) according to the profiles of the air inlet and outlet edges of the blade to obtain a blisk blank;

the radial section of the blade blank (4) along the hub blank (3) is an isosceles trapezoid, the long side dimension H1 of the isosceles trapezoid is the same as the thickness of the hub blank (3), the short side dimension of the isosceles trapezoid is H2, the difference between H1 and H2 is H, and the difference is defined as the rolling reduction;

step three, carrying out small-deformation isothermal die forging on the integral leaf disc

Carrying out isothermal die forging on the blisk along the axial direction, wherein the reduction is h, and thus obtaining a blisk forge piece (5);

step four, blisk processing

And (4) machining the blisk forge piece (5) to the final size of the part according to a drawing to obtain the nickel-based alloy dual-performance blisk part (6).

2. The method of making a nickel-base alloy dual performance blisk as recited in claim 1. The method is characterized in that: the heating temperature of the die in the first step is consistent with that of the nickel-based alloy bar, the forging speed is 0.01-0.05 mm/s, and the deformation is 60-70%.

3. The method of making a nickel-base alloy dual performance blisk as recited in claim 1. The method is characterized in that: in the second step, the diameter of the welding wire (2) of the blade blank (4) is deposited by fusing wires layer by layer

4. The method of making a nickel-base alloy dual performance blisk as recited in claim 1. The method is characterized in that: in the second step, the rolling reduction H is 10% -20% of the thickness H1 of the hub blank (3).

5. The method of making a nickel-base alloy dual performance blisk as recited in claim 1. The method is characterized in that: in the third step, before isothermal die forging, coating a glass lubricant on the surface of the blisk, heating the blisk and a forging die to 1000-1100 ℃, and preserving heat, wherein the heat preservation time is calculated according to the following formula:

T_{time of heat preservation}＝H1×0.8～1.2min/mm。

6. The method of manufacturing a nickel-base alloy dual-performance blisk according to claim 1 or 5. The method is characterized in that: in the third step, the pressing speed of the isothermal die forging is 0.5 mm/s-1.0 mm/s.

7. The method of making a nickel-base alloy dual performance blisk as recited in claim 1. The method is characterized in that: the nickel-based alloy is of the grade GH 4169.

8. The method of manufacturing a nickel-base alloy dual-performance blisk according to claim 1 or 7. The method is characterized in that: in the fourth step, before machining and forming, heat treatment strengthening is carried out on the integral leaf disc forging (5), and the heat treatment system is as follows: solution treatment: keeping the temperature at 960 ℃ for 1h, and cooling in air; aging treatment: keeping the temperature of 720 ℃ for 8h, furnace-cooling to 620 ℃ at the speed of 50 ℃/h, keeping the temperature for 8h, and air-cooling.

9. The method of manufacturing a nickel-base alloy dual-performance blisk according to claim 1 or 7. The method is characterized in that: in the second step, the deposition direction of the blade blank (4) is along the radial direction of the hub blank (3), and the crystal grains inside the blade blank (4) are large-size columnar crystals along the direction.

Technical Field

The invention relates to a method for manufacturing a nickel-based alloy dual-performance blisk, belonging to the technical field of plastic forming.

Background

The turbine disc is one of the key parts of the hot end of the aircraft engine, generally works at 540-840 ℃, so the material is required to have excellent mechanical property and hot workability, and the nickel-based high-temperature alloy shows a series of excellent properties at high temperature, so the reliability and durability of the engine are effectively ensured, and the nickel-based high-temperature alloy becomes the preferred material for manufacturing the key hot end parts of the high-pressure turbine disc of the advanced aircraft engine and the like.

With the increase of thrust-weight ratio of aero-engines, the structure of aero-engine components is developing towards light weight and integration. The integral vane disc is a novel structural part of a modern aeroengine, the vane and the wheel disc of a traditional structure are designed into an integral structure, a tenon, a mortise and a locking device adopted by a traditional connection mode are omitted, the structural quality is reduced, the number of parts is reduced, the air flow loss of the tenon is avoided, the integral structure of the engine is greatly simplified, and the thrust-weight ratio and the reliability are obviously improved. However, the service environments (such as temperature, load bearing and the like) of different parts of the integral component have obvious difference, and the blades of the blade disc simultaneously bear the effects of high temperature, gas corrosion, centrifugal force, vibration, thermal fatigue and the like, so that the blades are required to have good high-temperature oxidation resistance and corrosion resistance, and also need coarse-grained structures to ensure sufficient high-temperature durability, creep deformation resistance and fatigue crack propagation resistance. Although the working temperature of the disk core part (hub) is lower than that of the blade, the disk core part (hub) is correspondingly subjected to the twisting action of the turbine shaft, a fine crystal structure is required to ensure sufficient tensile strength and fatigue resistance, the grain size level of the disk core part is more than 8 levels, and thus different areas of the turbine disk part are required to have microstructures with different grain sizes so as to meet different performances of the blade and the disk which meet the requirements of service environments.

The grain sizes of different parts are changed to obtain a fine grain structure of a disk core and a coarse grain structure of a disk edge, and the conventional manufacturing method of the nickel-based alloy dual-performance blisk mainly comprises hot isostatic pressing diffusion welding, local deformation heat treatment, dual-structure gradient heat treatment and the like. The hot isostatic pressing diffusion welding process is low in maturity, the interface of the hub and the blade material is unstable, and the service life and reliability of parts are seriously affected. The local thermomechanical treatment and double-structure gradient heat treatment methods have complex forming process, need to accurately control the dynamic changes of deformation, heating time and temperature, have great difficulty in controlling the process, can only prepare one disc at a time, and have low production efficiency. In addition, each dual-performance turbine disk of one material and one size is manufactured, and a mold or a heat conducting block matched with the dual-performance turbine disk is specially designed and manufactured, so that the production cost is high.

Disclosure of Invention

The invention provides a manufacturing method of a nickel-based alloy dual-performance blisk aiming at the prior technical situation in China, and aims to fully utilize the unique advantages of isothermal forging and electron beam fuse wire additive to prepare the dual-performance blisk with high performance, high reliability and long service life.

The technical scheme of the method is as follows:

the manufacturing method of the nickel-based alloy dual-performance blisk comprises the following steps:

step one, preparing a disc hub blank

Aiming at a nickel-based alloy bar in a forging state or a rolling state, preparing a fine-grain hub blank 3 of the dual-performance blisk by adopting an isothermal forging method, wherein the hub blank 3 is in a disc shape;

step two, preparing a blade blank at the periphery of the disk hub blank

Fusing and depositing a blade blank 4 layer by layer on the periphery of the hub blank 3 according to the profiles of the air inlet and outlet edges of the blade to obtain a blisk blank;

the radial section of the blade blank 4 along the hub blank 3 is an isosceles trapezoid, the long side dimension H1 of the isosceles trapezoid is the same as the thickness of the hub blank 3, the short side dimension of the isosceles trapezoid is H2, the difference between H1 and H2 is H, and the difference is defined as the rolling reduction;

step three, carrying out small-deformation isothermal die forging on the integral leaf disc

Carrying out isothermal die forging on the blisk along the axial direction, wherein the reduction is h, and thus obtaining a blisk forge piece 5;

step four, blisk processing

And (4) machining the blisk forged piece 5 to the final size of the part according to the drawing to obtain the nickel-based alloy dual-performance blisk part 6.

In one implementation, the heating temperature of the die in the step one is consistent with that of the nickel-based alloy bar, the forging speed is 0.01-0.05 mm/s, and the deformation is 60-70%.

In one implementation, in step two, the diameter of the welding wire 2 for fusing and depositing the blade blank 4 layer by layer is as follows

In one implementation, in the second step, the reduction H is 10% to 20% of the thickness H1 of the hub blank 3. The deformation can avoid complete dynamic recrystallization of the blank structure of the blade, is beneficial to the diffusion of alloy elements at the interface of the disk hub and the blade, improves the quality of a transition region of the dual-performance disk, can effectively close the defects of air holes, incomplete fusion and the like existing in the blank of the electron beam fuse deposition blade, improves the residual stress distribution in parts, and improves the durability and reliability of the nickel-based alloy dual-performance integral blade disk;

in one implementation, in the third step, before the isothermal die forging, the surface of the blisk is coated with a glass lubricant, and the blisk is heated to 1000-1100 ℃ together with a forging die for heat preservation, wherein the heat preservation time is calculated according to the following formula:

T_{time of heat preservation}H1 × 0.8-1.2 min/mm formula 1.

In one implementation, in the third step, the pressing speed of the isothermal die forging is 0.5 mm/s-1.0 mm/s.

In one implementation, the nickel-based alloy is of the designation GH 4169.

In one embodiment, in step four, before machining, the integral blisk forging 5 is heat treated to strengthen, wherein the heat treatment system is as follows: solution treatment: keeping the temperature at 960 ℃ for 1h, and cooling in air; aging treatment: keeping the temperature of 720 ℃ for 8h, furnace-cooling to 620 ℃ at the speed of 50 ℃/h, keeping the temperature for 8h, and air-cooling.

In one implementation, in the second step, the deposition direction of the blade blank 4 is along the radial direction of the disk hub blank 3, and the crystal grains inside the blade blank 4 are large-size columnar crystals along the direction, and almost consistent with the bearing direction of the disk piece, so that the service life of the blisk can be obviously prolonged.

The manufacturing method comprises the steps of firstly manufacturing a fine-grain disc hub blank 3 through isothermal forging with large deformation, then preparing a blade blank 4 with large columnar grains on the disc hub blank 3 through an electron beam fuse wire additive manufacturing method, and then carrying out isothermal forging deformation with small deformation on the whole blade disc blank, wherein the isothermal forging with small deformation can effectively eliminate the defects of air holes, incomplete fusion and the like in the blade blank deposited through electron beam fuses, so that the whole blade disc blank is densified; meanwhile, the uniform diffusion of alloy elements at the interface of the hub blank 3 and the blade blank 4 is facilitated, and the interface combination between the hub blank 3 and the blade blank 4 is strengthened; and through local gradient deformation of the blisk blank, gradual transition between two significant difference structures at the joint interface of the hub blank 3 and the blade blank 4 of the dual-performance blisk can be realized, the durability and the reliability of the nickel-based alloy dual-performance blisk can be greatly improved, and the blisk forged piece 5 is obtained.

The technical scheme of the invention has the following advantages:

compared with the existing commonly used isothermal forging and double-structure gradient heat treatment process, the manufacturing method of the nickel-based alloy double-performance blisk has the technical advantages that the isothermal forging and electron beam fuse wire additive manufacturing technology are adopted to respectively prepare the fine-grain hub and the coarse-grain rim, the blisk forge piece 5 with double-structure double-performance is directly obtained, the complex double-structure gradient heat treatment process is omitted, the process flow is simplified, the process stability is improved, the production and manufacturing cost is reduced, and the obvious economic benefit is achieved.

Drawings

FIG. 1 is a schematic diagram of an electron beam fuse additive manufacturing process of a blade blank according to an embodiment of the present invention

FIG. 2 is a schematic structural view of an additive manufactured blisk blank according to an embodiment of the method of the present invention

FIG. 3 is a schematic structural view of a blisk forging in an embodiment of the method of the present invention

FIG. 4 is a schematic structural view of a blisk part in an embodiment of the method of the present invention

Detailed Description

The technical scheme of the invention is further explained by combining the drawings and the embodiment as follows:

step one, preparing a disc hub blank 3

For the forged stateAdopting isothermal forging to perform upsetting on GH4169 alloy bars, wherein the isothermal forging speed is 0.02mm/s, the deformation is 60%, the heating temperature of a die and the heating temperature of the nickel-based alloy bars are both 1010 ℃, preparing a uniform fine-grain GH4169 alloy disc hub blank 3 of the dual-performance blisk, and the size of the blank after mechanical processing is

Step two, preparing a blade blank 4

By using

Under the focusing action of an electron beam gun 1, a GH4169 alloy welding wire 2 performs fuse deposition on a GH4169 alloy disk hub blank 3 layer by layer according to the profiles of the air inlet and outlet edges of the blade to obtain a blisk blank; the matching coupling control of the movement of the disc hub blank 3, the welding wire 2 and the electron beam gun 1 is completed by a numerical control movement system;

step three: heating blisk blank

Heating a blisk blank of additive manufacturing GH4169 alloy with a surface coated with a glass lubricant to 1010 ℃, and preserving heat, wherein the preserving heat time is calculated according to the following formula:

T_{time of heat preservation}H1 × 1min/mm equation 1

In the formula: h1 ═ 50 mm;

step four: isothermal forging of blisk blanks

And (3) placing the blisk blank subjected to heat preservation into a forging die for isothermal forging forming, wherein the heating temperature of the die is consistent with that of the blank. The forging speed is 0.6mm/s, the reduction h is 8mm, the deformation is 16%, and the blisk forging 5 is obtained after isothermal forging is completed;

step five: machining treatment of blisk forging 5

Carrying out heat treatment strengthening on the blisk forged piece 5, wherein the heat treatment system is as follows: solution treatment: keeping the temperature at 960 ℃ for 1h, and cooling in air; aging treatment: keeping the temperature at 720 ℃ for 8h, furnace-cooling to 620 ℃ at the speed of 50 ℃/h, keeping the temperature for 8h, and air-cooling;

and (3) performing finish machining on the surface of the forging, processing the required size of the manufactured part according to a drawing after the forging is qualified through nondestructive inspection, and obtaining the GH4169 alloy dual-performance blisk part 6.