[Abstract] The role of thermal processing technology in the aviation industry and its development trend are described. According to the needs of aviation product development and the development trend of the discipline, the key thermal processing technologies that need to be developed and promoted at the beginning of the next century are proposed.
The design, materials and manufacturing technologies of aviation products complement each other and promote each other and restrict each other.
The renewal of a generation of aircraft and its engines is accompanied by major breakthroughs in new materials, new structures and new processes. The replacement of thermal processing technology will certainly promote major changes in the performance and structure of aerospace products.
Thermal processing technology is an important part of the main technology of advanced manufacturing technology and is the basic technology to ensure the quality of aviation products. The role in the aviation industry can be summarized as follows:
(1) Significantly improve the performance of aviation products. Over the past 30 years, the turbine inlet temperature has increased by 450 ° C, 70% of which was achieved with the use of cast hollow vanes, which have become the key technology to determine the highest performance level of the engine.
(2) Significantly reduce the weight of aviation products and reduce manufacturing costs. Many examples at home and abroad have proven that the use of advanced thermal processing technology to manufacture large precision forgings and castings can reduce weight by 20% and reduce costs by about 30%. At the same time, it provides designers with design flexibility.
(3) Improve the service life and reliability of aviation products. For example, the use of multi-directional die forging, vacuum heat treatment, surface cadmium-plated titanium and shot peening and hole extrusion strengthening treatment and other advanced thermal processes to manufacture landing gear parts can make the landing gear and the aircraft the same life, one landing gear can replace the traditional production process Several landing gears are used.
At present, foreign countries have been able to mass-produce leaf precision forgings and oriented and single-crystal alloy hollow blade precision castings of various sizes without any margin. The United States Howmet Company has produced more than 100 kinds of more than 100 million pieces of precision cast single crystal blades; Large-scale die forgings of various materials with a projected area of ​​1.2-3.5 m2 have been mass-produced, and titanium alloy die forgings with a projected area of ​​5.16 m2 have been successfully developed; mass production of 1300 mm and wall thickness of 1-2 mm (thinest 0.5 mm) have been mass-produced. Titanium alloy casting machine, and is developing precision castings up to 2000mm in size.
China has been able to produce small and medium-sized titanium alloy blade precision forgings and oriented hollow blade precision castings in small batches, and has successfully developed single crystal alloy blade precision castings; titanium alloy casing castings with a diameter of 570 mm and die forgings with a projected area of ​​less than 1 m2 have been developed. . This situation is not only far from the international advanced level, but also compared with the demand for thermal processing technology in the development and production of advanced fighter aircraft, advanced civil aircraft and high-ratio engine and airborne equipment in the new century. Very big. Therefore, it is necessary to formulate plans, clarify goals, and concentrate on overcoming the key thermal processing technologies that are urgently needed for the development and production of new machines. In view of this situation, this paper looks forward to the key technologies of China's aviation thermal processing in the new century.
1 Trends in thermal processing technology
Most of the modern thermal processing technology is a comprehensive technology integrating multiple disciplines. It is an engineering technology compatible with many modern scientific and technological theories. It is one of the most technically intensive and highly representative areas of advanced manufacturing technology. It is characterized by technical difficulties, high cost and long research period, and is developing along the following new trends:
(1) New process methods are developing rapidly. Such as single crystal hollow blade precision casting, powder superalloy turbine disk superplastic forging, spray deposition forming and thermal insulation coating technology;
(2) Conventional thermal processing technology is gradually being transformed by modern technology. The ancient techniques of forging, casting, welding, heat, surface treatment and other technologies have been introduced into computers, vacuum and laser technology, and have been transformed into high-tech;
(3) There are more and more interpenetrating disciplines or combinations into composite forming processes. Such as superplastic forming / diffusion bonding and deformation heat treatment technology;
(4) The simulation technology of the thermal process is generally applied. Such as the numerical simulation of the solidification casting process of castings, the numerical simulation of the formation and prediction of forgings and casting defects, and the techniques of laser rapid prototyping;
(5) The hot processing technology and the new structure of the product develop simultaneously. Thermal processing techniques such as friction welding, hot isostatic pressing and liquid phase diffusion welding are developed simultaneously with new structures such as the overall turbine rotor, the integral blade disc structure and the large sandwich structure fan blades and split blades;
(6) New process methods and new materials are developed simultaneously. Such as hot isostatic pressing and superplastic forging, simultaneous development of powder superalloy and liquid metal rapid cooling rolling and amorphous materials;
(7) The processing materials (Processing Materials) play an increasingly important role in the thermal processing process. Such as titanium alloy forging glass lubricants, casting cores and shell materials and coatings.
2 Development focus of aviation thermal processing technology
According to the development needs of China's aviation industry in the new century and the development trend of thermal processing technology, the demand for thermal processing technology for fourth-generation fighters and advanced civil aircrafts and their associated high-push-weight ratio engines and airborne equipment, and consideration of disciplinary development It is recommended that the following aviation thermal processing technologies be developed at the beginning of the next century:
(1) Advanced casting technology. Research on complex structure blade precision casting technology, high temperature resistant core and shell material and its precision preparation technology and coating technology, and supporting electron beam physical vapor deposition (EB-PVD) to explore the efficient cooling of working temperature 2000~2100K Single crystal blade manufacturing technology; research on titanium alloy machine å¶ç‰‡-blade overall structural parts precision casting technology, high-temperature alloy machine 匣 precision casting technology, aluminum alloy lip and accessory shell and other large structural parts precision casting technology, large thin-wall high-strength wax type And shell-type manufacturing technology and coating technology, numerical simulation technology of casting process, etc., to fully grasp the precision casting technology of large-scale thin-walled structural parts. In order to meet the needs of the industrial production of aircraft and its engine parts in the research and development, the application of titanium alloy whole machine precision casting technology and its corresponding supporting technology will be promoted to develop the single crystal combined blade batch production technology and its corresponding supporting technology.
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