Super-Ni/NiCr叠层复合材料与Cr18-Ni8钢高温钎焊接头组织结构研究
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摘要
超级镍叠层复合材料(Super-Ni/NiCr)是近年来开发的一种新型材料,由两侧的Super-Ni复层和中间的Ni80-Cr20粉末通过真空压制而成。Super-Ni复层具有较好的耐腐蚀性、抗氧化性和韧性；Super-Ni复层包覆在NiCr基层表面,能够抑制NiCr基层的裂纹扩展,防止零部件存在裂纹和缺陷时发生瞬间破坏,提高叠层材料的整体强度。Super-Ni/NiCr叠层材料具有低密度、耐腐蚀、耐高温等优点,在航空航天、能源动力等领域具有广阔的应用前景。由于Super-Ni/NiCr叠层复合材料特殊的合金成分和结构形式,焊接时既要使Super-Ni复层和NiCr基层与焊缝之间结合良好,又要保证Super-Ni复层和NiCr基层之间的复合结构完整。因此,焊接问题是阻碍Super-Ni/NiCr叠层复合材料推广应用的关键。
采用Ni-Cr-P系和Ni-Cr-Si-B系镍基钎料对Super-Ni/NiCr叠层复合材料与Cr18-Ni8不锈钢进行真空钎焊,控制真空度1.33×10-4～1.33×10-5Pa、保温时间20min、钎焊温度980～1060℃和1040～1120℃,获得了成型良好的Super-Ni/NiCr叠层复合材料与Crl8-Ni8不锈钢钎焊接头,剪切强度最高可达143MPa和195MPa。通过扫描电镜(SEM)、能谱分析仪(EDS)、X射线衍射仪(XRD)对不同钎焊参数获得的叠层材料/Cr18-Ni8钢钎焊接头的显微组织、元素分布、物相组成以及接头的剪切断裂行为进行研究,建立钎焊工艺参数、接头组织结构及断裂机制之间的关系,揭示钎焊接头的扩散-凝固规律。
采用Ni-Cr-P钎料连接Super-Ni/NiCr叠层材料与Cr18-Ni8钢时,钎缝区主要由靠近两侧母材的γ-Ni固溶体、中心的γ-Ni+Ni3P共晶和少量FeNi3相组成。P元素沿晶界扩散至Super-Ni复层,形成Ni3P或Ni-P共晶；NiCr基层与Ni-Cr-P钎料之间发生固溶反应,没有形成脆性扩散反应层。
采用Ni-Cr-Si-B钎料钎焊Super-Ni/NiCr叠层复合材料与Cr18-Ni8钢时,B元素是控制钎缝区凝固结晶及界面反应的关键。B元素扩散至叠层材料和Cr18-Ni8钢并析出硼化物,析出相形态、数量及分布受钎焊温度影响。钎焊温度为1040℃时,钎缝区由γ-Ni固溶体、Ni3Si.Ni3B以及CrB颗粒等组成,Ni3Si弥散分布在γ-Ni固溶体中。钎焊温度升高至1060～1100℃时,钎缝由γ-Ni固溶体、Ni3Si.Ni3B.CrB块状相以及Ni6Si2B等组成。钎焊温度升高至1120℃时,钎缝区由γ-Ni固溶体、Ni3Si.Ni3B等组成。非等温凝固阶段可归纳为：①剩余液相凝固形成γ-Ni(Si),剩余液相L1富B;②Ni-B二元共晶反应：L1→γ-Ni+Ni3B,剩余液相L2富Cr;③Ni-Cr-B三元共晶反应：L2→γ-Ni+Ni3B+CrB,剩余液相L3富Si;④Ni-Si-B三元共晶反应：L3→γ-Ni+Ni3B+Ni6Si2B.
等温凝固阶段在NiCr基层孔隙端口形成γ-Ni固溶体,抑制液态钎料渗入孔隙,削弱钎缝与NiCr基层之间的结合面积。对叠层材料／Cr18-Ni8(?)钢钎焊接头的剪切强度及断口形貌进行分析,采用Ni-Cr-P钎料时,钎焊接头断裂于钎缝区Ni-P共晶。采用Ni-Cr-Si-B钎料时,Super-Ni复层钎缝区沿钎缝区与复层之间的Ni3B扩散反应层断裂,呈沿晶脆性断裂；NiCr基层钎缝区呈沿钎缝区共晶组织及界面附近NiCr基层的混合断裂方式。
Super-Ni/NiCr laminated composite is a newly developed material composed of super-Ni cover layer and Ni80-Cr20powder by vacuum pressing. Super-Ni cover layer is featured with good toughness, oxidation resistance and corrosion resistance at elevated high temperature. Super-Ni cover layer is able to suppress crack propagation in NiCr base layer, which will prevent instantaneous destruction of the components. Super-Ni/NiCr laminated composite is an attractive candidate in aerospace, energy and power industries due to its low density, good oxidation resistance and corrosion resistance. Two main difficulties in the welding of Super-Ni/NiCr laminated composite were identified. First, both Super-Ni cover layer and NiCr base layer should have good combination with weld metal. Second, it is important to keep the structure integrity of Super-Ni/NiCr laminated composite after welding. Therefore, welding is the key problem impeding the engineering application of Super-Ni/NiCr laminated composite.
The joints of Super-Ni/NiCr laminated composite to Cr18-Ni8steel were established by vacuum brazing technology using Ni-Cr-P and Ni-Cr-Si-B nickel-based filler metal. Good combination between Super-Ni/NiCr laminated composite and Cr18-Ni8steel was prepared at980～1060℃and1040～1120℃for20min under a vacuum of1.33×10-4～1.33×10-5Pa. Shear strength of the brazed joints reached143MPa and195MPa. Microstructure, elemental distribution, phase constitution and shear strength were investigated by means of scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), X-ray diffraction (XRD) and electromechanical universal testing machine. The relationship between brazing parameters, microstructure and fracture mechanism was proposed. The diffusion-solidification behavior of the brazed joint was revealed.
The brazed region was mainly composed of γ-Ni solid solution, eutectic of γ-Ni(P) and M3P, and some FeNi3when Super-Ni/NiCr laminated composite and Cr18-Ni8steel was brazed with Ni-Cr-P filler metal. P diffused into Super-Ni cover layer along grain boundaries leading to the precipitation of Ni-P eutectic. There was only solution reaction without brittle reaction layer between Ni-Cr-P filler metal and NiCr base layer.
When Super-Ni/NiCr laminated composite and Cr18-Ni8steel was brazed with Ni-Cr-Si-B filler metal, element B was the key factor controlling the solidification and interface reaction. When the brazing temperature was1040℃, the brazed region constituted of γ-Ni, Ni3Si, Ni3B, CrB particles. And the Ni3Si dispersed in y-Ni. When the brazing temperature was1060～1100℃, the brazed region constituted of γ-Ni, Ni3Si, Ni3B, blocky CrB and Ni6Si2B. When the brazing temperature was1120℃, the brazed region constituted of γ-Ni, Ni3Si, Ni3B. The athermally solidified stage was concluded as following:①the residual luquid solidified into y-Ni solid solution and the residual luquid L1was rich in B;②Ni-B binary eutectic reaction:L1→γ-Ni+Ni3B and the residual luquid L2was rich in Cr;③Ni-Cr-B ternary eutectic reaction:L2→γ-Ni+Ni3B+CrB and the residual luquid L3was rich in Si;④Ni-Si-B ternary eutectic reaction:L3→γ-Ni+Ni3B+Ni6Si2B.
γ-Ni solid solution forming in the isothermally solidified stage prevented the infiltration of liquid filler metal into porosities of NiCr base layer, which decreased the combination area between the brazed region and NiCr base layer. The shear strength test and fracture morphology analysis was conducted. The Super-Ni/NiCr laminate/Cr18-Ni8brazed joint fractured along the Ni-P eutectic in the brazed region when brazed with Ni-Cr-P filler metal. When brazed with Ni-Cr-Si-B filler metal, the brazed region of Super-Ni cover layer fractured along the Ni3B interface displaying intergranular brittle fracture. The brazed region of NiCr base layer fractured along a mixed path along eutectic in brazed region and NiCr base layer near the interface.
采用Ni-Cr-P系和Ni-Cr-Si-B系镍基钎料对Super-Ni/NiCr叠层复合材料与Cr18-Ni8不锈钢进行真空钎焊,控制真空度1.33×10-4～1.33×10-5Pa、保温时间20min、钎焊温度980～1060℃和1040～1120℃,获得了成型良好的Super-Ni/NiCr叠层复合材料与Crl8-Ni8不锈钢钎焊接头,剪切强度最高可达143MPa和195MPa。通过扫描电镜(SEM)、能谱分析仪(EDS)、X射线衍射仪(XRD)对不同钎焊参数获得的叠层材料/Cr18-Ni8钢钎焊接头的显微组织、元素分布、物相组成以及接头的剪切断裂行为进行研究,建立钎焊工艺参数、接头组织结构及断裂机制之间的关系,揭示钎焊接头的扩散-凝固规律。
采用Ni-Cr-P钎料连接Super-Ni/NiCr叠层材料与Cr18-Ni8钢时,钎缝区主要由靠近两侧母材的γ-Ni固溶体、中心的γ-Ni+Ni3P共晶和少量FeNi3相组成。P元素沿晶界扩散至Super-Ni复层,形成Ni3P或Ni-P共晶；NiCr基层与Ni-Cr-P钎料之间发生固溶反应,没有形成脆性扩散反应层。
采用Ni-Cr-Si-B钎料钎焊Super-Ni/NiCr叠层复合材料与Cr18-Ni8钢时,B元素是控制钎缝区凝固结晶及界面反应的关键。B元素扩散至叠层材料和Cr18-Ni8钢并析出硼化物,析出相形态、数量及分布受钎焊温度影响。钎焊温度为1040℃时,钎缝区由γ-Ni固溶体、Ni3Si.Ni3B以及CrB颗粒等组成,Ni3Si弥散分布在γ-Ni固溶体中。钎焊温度升高至1060～1100℃时,钎缝由γ-Ni固溶体、Ni3Si.Ni3B.CrB块状相以及Ni6Si2B等组成。钎焊温度升高至1120℃时,钎缝区由γ-Ni固溶体、Ni3Si.Ni3B等组成。非等温凝固阶段可归纳为：①剩余液相凝固形成γ-Ni(Si),剩余液相L1富B;②Ni-B二元共晶反应：L1→γ-Ni+Ni3B,剩余液相L2富Cr;③Ni-Cr-B三元共晶反应：L2→γ-Ni+Ni3B+CrB,剩余液相L3富Si;④Ni-Si-B三元共晶反应：L3→γ-Ni+Ni3B+Ni6Si2B.
等温凝固阶段在NiCr基层孔隙端口形成γ-Ni固溶体,抑制液态钎料渗入孔隙,削弱钎缝与NiCr基层之间的结合面积。对叠层材料／Cr18-Ni8(?)钢钎焊接头的剪切强度及断口形貌进行分析,采用Ni-Cr-P钎料时,钎焊接头断裂于钎缝区Ni-P共晶。采用Ni-Cr-Si-B钎料时,Super-Ni复层钎缝区沿钎缝区与复层之间的Ni3B扩散反应层断裂,呈沿晶脆性断裂；NiCr基层钎缝区呈沿钎缝区共晶组织及界面附近NiCr基层的混合断裂方式。
Super-Ni/NiCr laminated composite is a newly developed material composed of super-Ni cover layer and Ni80-Cr20powder by vacuum pressing. Super-Ni cover layer is featured with good toughness, oxidation resistance and corrosion resistance at elevated high temperature. Super-Ni cover layer is able to suppress crack propagation in NiCr base layer, which will prevent instantaneous destruction of the components. Super-Ni/NiCr laminated composite is an attractive candidate in aerospace, energy and power industries due to its low density, good oxidation resistance and corrosion resistance. Two main difficulties in the welding of Super-Ni/NiCr laminated composite were identified. First, both Super-Ni cover layer and NiCr base layer should have good combination with weld metal. Second, it is important to keep the structure integrity of Super-Ni/NiCr laminated composite after welding. Therefore, welding is the key problem impeding the engineering application of Super-Ni/NiCr laminated composite.
The joints of Super-Ni/NiCr laminated composite to Cr18-Ni8steel were established by vacuum brazing technology using Ni-Cr-P and Ni-Cr-Si-B nickel-based filler metal. Good combination between Super-Ni/NiCr laminated composite and Cr18-Ni8steel was prepared at980～1060℃and1040～1120℃for20min under a vacuum of1.33×10-4～1.33×10-5Pa. Shear strength of the brazed joints reached143MPa and195MPa. Microstructure, elemental distribution, phase constitution and shear strength were investigated by means of scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), X-ray diffraction (XRD) and electromechanical universal testing machine. The relationship between brazing parameters, microstructure and fracture mechanism was proposed. The diffusion-solidification behavior of the brazed joint was revealed.
The brazed region was mainly composed of γ-Ni solid solution, eutectic of γ-Ni(P) and M3P, and some FeNi3when Super-Ni/NiCr laminated composite and Cr18-Ni8steel was brazed with Ni-Cr-P filler metal. P diffused into Super-Ni cover layer along grain boundaries leading to the precipitation of Ni-P eutectic. There was only solution reaction without brittle reaction layer between Ni-Cr-P filler metal and NiCr base layer.
When Super-Ni/NiCr laminated composite and Cr18-Ni8steel was brazed with Ni-Cr-Si-B filler metal, element B was the key factor controlling the solidification and interface reaction. When the brazing temperature was1040℃, the brazed region constituted of γ-Ni, Ni3Si, Ni3B, CrB particles. And the Ni3Si dispersed in y-Ni. When the brazing temperature was1060～1100℃, the brazed region constituted of γ-Ni, Ni3Si, Ni3B, blocky CrB and Ni6Si2B. When the brazing temperature was1120℃, the brazed region constituted of γ-Ni, Ni3Si, Ni3B. The athermally solidified stage was concluded as following:①the residual luquid solidified into y-Ni solid solution and the residual luquid L1was rich in B;②Ni-B binary eutectic reaction:L1→γ-Ni+Ni3B and the residual luquid L2was rich in Cr;③Ni-Cr-B ternary eutectic reaction:L2→γ-Ni+Ni3B+CrB and the residual luquid L3was rich in Si;④Ni-Si-B ternary eutectic reaction:L3→γ-Ni+Ni3B+Ni6Si2B.
γ-Ni solid solution forming in the isothermally solidified stage prevented the infiltration of liquid filler metal into porosities of NiCr base layer, which decreased the combination area between the brazed region and NiCr base layer. The shear strength test and fracture morphology analysis was conducted. The Super-Ni/NiCr laminate/Cr18-Ni8brazed joint fractured along the Ni-P eutectic in the brazed region when brazed with Ni-Cr-P filler metal. When brazed with Ni-Cr-Si-B filler metal, the brazed region of Super-Ni cover layer fractured along the Ni3B interface displaying intergranular brittle fracture. The brazed region of NiCr base layer fractured along a mixed path along eutectic in brazed region and NiCr base layer near the interface.
引文
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