Super-Ni/NiCr叠层复合材料TIG接头区微观结构及应力分布研究
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摘要
叠层复合材料是适应当代航空发动机对材料提出的特殊性能要求而发展起来的一种新型材料。Super-Ni/NiCr叠层复合材料由于其独特的高温性能使其在航空、航天等高科技领域具有很好的应用前景。但由于其特殊的合金组分及叠层复合结构,焊接时焊缝成形难度大,并且接头处易产生很大的热应力,导致焊接裂纹等。因此,焊接问题成为阻碍Super-Ni/NiCr叠层复合材料推广应用的关键。
采用填丝钨极氩弧焊(TIG)工艺对Super-Ni/NiCr叠层复合材料与1Cr18Ni9Ti钢的焊接进行研究。并对接头的微观组织、元素分布、精细相结构以及应力分布等进行研究,建立焊接工艺参数-焊缝组织结构-接头区微观裂纹-应力分布的关系,揭示其内在规律性。
本文提出Super-Ni叠层复合材料接头特征区划分方案,包括：Ni复层与焊缝过渡区、Ni80Cr20基层与焊缝过渡区、焊缝中心区。Ni复层与焊缝过渡区包括Ni复层侧熔合区及Ni复层热影响区；Ni80Cr20基层与焊缝过渡区包括Ni80Cr20基层熔合区及Ni80Cr20热影响区；焊缝中心区包括柱状晶区及等轴晶区。随焊接热输入不同(3.3-4.6、5.0-11.0、12.6.13.8kJ／cm),焊缝中心等轴晶由细小变得粗大。小焊接热输入时能形成良好的焊接接头,热输入高于11kJ／cm时焊缝成形变差。
采用X射线衍射仪(XRD)、电子探针(EPMA)和透射电镜(TEM)对Super-Ni叠层复合材料接头区的微观相结构及元素分布进行分析。结果表明,Super-Ni叠层复合材料接头区由γ-Fe、δ-Fe、γ-Ni(Cr,Fe)、γ-Ni和FeNi构成。NiCr基层熔合区呈锯齿状,NiCr基层熔合区形成了宽约83μm的元素过渡区,Fe元素从焊缝向母材扩散,而Ni元素相反,从母材向焊缝中扩散,Cr元素无明显的扩散现象,Super-Ni复层熔合区的宽度约为30μm。叠层复合材料侧形成了Ni含量40%的焊缝组织,Creq／Nieq<1.52,凝固模式为AF凝固模式,柱状晶方向性明显,有热裂纹倾向。
衍射分析发现焊缝组织的内应力较大,Super-Ni叠层复合材料焊缝中以γ奥氏体相为主,少量δ铁素体相分布于γ相晶界,并存在((?)11)γ／／(1(?)0)δ、[211]γ／／[111]δ的位相关系。焊缝中形成了面心立方结构的有序相Ni3Fe。Super-Ni叠层复合材料熔合区的γ奥氏体与α铁素体相之间存在(1(?)0)α／／((?)11)γ、[111]α／／[211]γ的位相关系,熔合区存在γ-Fe相与γ-Ni(Fe,Cr)相共存的形态。
在组织结构分析的基础上,对Super-Ni叠层复合材料接头的应力分布进行研究。发现Super-Ni叠层复合材料侧熔合区应力集中严重,主要承受纵向拉应力σx和横向拉应力σy。NiCr基层与Ni复层界面为Super-Ni叠层复合材料焊接时的薄弱区域,Ni复层与NiCr基层界面的最大拉应力为纵向应力29.1MPa,横向应力40.1MPa,出现在母材热影响区。沿焊接方向,Super-Ni叠层复合材料侧熔合区先焊位置为σx压应力区,后焊位置为σx拉应力区,σx拉应力最大值为40MPa左右,出现在叠层复合材料底层。
本文首次研究了Super-Ni叠层复合材料焊接区的微观组织结构及接头应力分布。该研究工作为Super-Ni叠层复合材料的应用提供了实验依据和理论基础。所得出的研究成果对进一步开展包括Super-Ni叠层复合材料在内的高温复合材料的焊接研究奠定了重要基础。
Laminated composite material is a kind of new materials that could meet the particular performance of modern aircraft engines. Due to its special high temperature performance, Super-Ni/NiCr laminated composite has a luciferous prospect in aviation, aerospace and other high-tech fields. However, Super-Ni/NiCr is difficult to be welded and easy to induce thermal stress due to its unique composition and the laminated composite structure. Therefore the welding problem of Super-Ni/NiCr is the key to block its wide application.
The weldability of Super-Ni/NiCr laminated composite was studied via TIG with filler alloy. The microstructure, elements distribution, fine phase structure and stress distribution of the TIG joint were researched to reveal the relationship of welding parameter, microstructure, microcracks and stress distribution.
The division of the characteristic zone of Super-Ni/NiCr TIG joint was put forward to include transition zone of Ni cover layer with weld, transition zone of Ni80Cr20 base layer with weld and weld center. The transition zone of Ni cover layer with weld included fusion zone(FZ) and heat affect zone(HAZ) of Ni cover layer. The transition zone of Ni80Cr20 base layer with weld included FZ and HAZ of Ni80Cr20 base layer. The weld center included columnar grain zone and equiaxed grain zone. With the welding heat input increasing, the equiaxed grains in weld center became gross. A sound joint could be formed with small heat input. However, its difficult to get a good joint with heat input above 11kJ/cm.
The fine phase structure and element distribution of Super-Ni/NiCr TIG joint was analyzed by means of X-ray diffraction (XRD), electron probe microanalysis (EPM A) and transmission electron microscopy (TEM). The results indicated that the joint zone was constituted ofγ-Fe,δ-Fe,γ-Ni (Cr, Fe), }-Ni and FeNi intermetallic compound. Fusion zone of NiCr base layer was jagged and elements transition zone about 83μm was formed with Fe element transited from weld to the base metal, while Ni transited in the contrary and Cr not transited obviously. The element transition zone of Ni cover layer fusion zone was about 30μm. The Ni content in the weld near Super-Ni/NiCr side was about 40%, Creq/Nieq＜1.52, with AF solidification mode. Directional columnar grains was formed, and the weld meat has tendency to hot cracking.
Diffraction analysis indicated that the internal stress of weld metal was high. The main phase in the Super-Ni/NiCr TIG joint wasγaustenite with a small amount ofδferrite phase distributed in the y-phase grain boundaries, and the lattice orientation betweenγaustenite and 8 ferrite phases was (111)γ//(110)δ、[211]γ//[111]δ.The ordered phase Ni3Fe with FCC structure was formed in the weld. In the fusion of Super-Ni/NiCr, the lattice orientation between y austenite and a ferrite phases was (110)α//(111)γ、[111]α//[211]γ. Theγ-Fe andγ-Ni (Fe, Cr) coexisted in the fusion zone of the laminated composite.
The stress fields of Super-Ni/NiCr and 1Cr18Ni9Ti steel TIG joint were studied based on the analysis of microstructure. The results indicated that the stress concentrated seriously in the fusion zone of Super-Ni/NiCr, mainly affected byσx andσy stress. The interface of NiCr base layer and Ni cover layer was the weakness region while the laminated composite being welded. The peak value ofσx tensile stress was 29.1 MPa andσx tensile stress was 40.1MPa, in the HAZ of the laminated composite. Along the welding direction, in first welding position of the fusion zone of the laminated composite was mainly affected byσx compression stress, in the behind position was mainly affected byσx tensile stress.
The microstructure and stress distribution of Super-Ni/NiCr TIG joint was firstly studied in this paper, which provided experimental and theoretical basis for improving the application of Super-Ni laminated composite. The conclusions obtained from this paper have established an important foundation to study deeply the weldability of high temperature composites.
采用填丝钨极氩弧焊(TIG)工艺对Super-Ni/NiCr叠层复合材料与1Cr18Ni9Ti钢的焊接进行研究。并对接头的微观组织、元素分布、精细相结构以及应力分布等进行研究,建立焊接工艺参数-焊缝组织结构-接头区微观裂纹-应力分布的关系,揭示其内在规律性。
本文提出Super-Ni叠层复合材料接头特征区划分方案,包括：Ni复层与焊缝过渡区、Ni80Cr20基层与焊缝过渡区、焊缝中心区。Ni复层与焊缝过渡区包括Ni复层侧熔合区及Ni复层热影响区；Ni80Cr20基层与焊缝过渡区包括Ni80Cr20基层熔合区及Ni80Cr20热影响区；焊缝中心区包括柱状晶区及等轴晶区。随焊接热输入不同(3.3-4.6、5.0-11.0、12.6.13.8kJ／cm),焊缝中心等轴晶由细小变得粗大。小焊接热输入时能形成良好的焊接接头,热输入高于11kJ／cm时焊缝成形变差。
采用X射线衍射仪(XRD)、电子探针(EPMA)和透射电镜(TEM)对Super-Ni叠层复合材料接头区的微观相结构及元素分布进行分析。结果表明,Super-Ni叠层复合材料接头区由γ-Fe、δ-Fe、γ-Ni(Cr,Fe)、γ-Ni和FeNi构成。NiCr基层熔合区呈锯齿状,NiCr基层熔合区形成了宽约83μm的元素过渡区,Fe元素从焊缝向母材扩散,而Ni元素相反,从母材向焊缝中扩散,Cr元素无明显的扩散现象,Super-Ni复层熔合区的宽度约为30μm。叠层复合材料侧形成了Ni含量40%的焊缝组织,Creq／Nieq<1.52,凝固模式为AF凝固模式,柱状晶方向性明显,有热裂纹倾向。
衍射分析发现焊缝组织的内应力较大,Super-Ni叠层复合材料焊缝中以γ奥氏体相为主,少量δ铁素体相分布于γ相晶界,并存在((?)11)γ／／(1(?)0)δ、[211]γ／／[111]δ的位相关系。焊缝中形成了面心立方结构的有序相Ni3Fe。Super-Ni叠层复合材料熔合区的γ奥氏体与α铁素体相之间存在(1(?)0)α／／((?)11)γ、[111]α／／[211]γ的位相关系,熔合区存在γ-Fe相与γ-Ni(Fe,Cr)相共存的形态。
在组织结构分析的基础上,对Super-Ni叠层复合材料接头的应力分布进行研究。发现Super-Ni叠层复合材料侧熔合区应力集中严重,主要承受纵向拉应力σx和横向拉应力σy。NiCr基层与Ni复层界面为Super-Ni叠层复合材料焊接时的薄弱区域,Ni复层与NiCr基层界面的最大拉应力为纵向应力29.1MPa,横向应力40.1MPa,出现在母材热影响区。沿焊接方向,Super-Ni叠层复合材料侧熔合区先焊位置为σx压应力区,后焊位置为σx拉应力区,σx拉应力最大值为40MPa左右,出现在叠层复合材料底层。
本文首次研究了Super-Ni叠层复合材料焊接区的微观组织结构及接头应力分布。该研究工作为Super-Ni叠层复合材料的应用提供了实验依据和理论基础。所得出的研究成果对进一步开展包括Super-Ni叠层复合材料在内的高温复合材料的焊接研究奠定了重要基础。
Laminated composite material is a kind of new materials that could meet the particular performance of modern aircraft engines. Due to its special high temperature performance, Super-Ni/NiCr laminated composite has a luciferous prospect in aviation, aerospace and other high-tech fields. However, Super-Ni/NiCr is difficult to be welded and easy to induce thermal stress due to its unique composition and the laminated composite structure. Therefore the welding problem of Super-Ni/NiCr is the key to block its wide application.
The weldability of Super-Ni/NiCr laminated composite was studied via TIG with filler alloy. The microstructure, elements distribution, fine phase structure and stress distribution of the TIG joint were researched to reveal the relationship of welding parameter, microstructure, microcracks and stress distribution.
The division of the characteristic zone of Super-Ni/NiCr TIG joint was put forward to include transition zone of Ni cover layer with weld, transition zone of Ni80Cr20 base layer with weld and weld center. The transition zone of Ni cover layer with weld included fusion zone(FZ) and heat affect zone(HAZ) of Ni cover layer. The transition zone of Ni80Cr20 base layer with weld included FZ and HAZ of Ni80Cr20 base layer. The weld center included columnar grain zone and equiaxed grain zone. With the welding heat input increasing, the equiaxed grains in weld center became gross. A sound joint could be formed with small heat input. However, its difficult to get a good joint with heat input above 11kJ/cm.
The fine phase structure and element distribution of Super-Ni/NiCr TIG joint was analyzed by means of X-ray diffraction (XRD), electron probe microanalysis (EPM A) and transmission electron microscopy (TEM). The results indicated that the joint zone was constituted ofγ-Fe,δ-Fe,γ-Ni (Cr, Fe), }-Ni and FeNi intermetallic compound. Fusion zone of NiCr base layer was jagged and elements transition zone about 83μm was formed with Fe element transited from weld to the base metal, while Ni transited in the contrary and Cr not transited obviously. The element transition zone of Ni cover layer fusion zone was about 30μm. The Ni content in the weld near Super-Ni/NiCr side was about 40%, Creq/Nieq＜1.52, with AF solidification mode. Directional columnar grains was formed, and the weld meat has tendency to hot cracking.
Diffraction analysis indicated that the internal stress of weld metal was high. The main phase in the Super-Ni/NiCr TIG joint wasγaustenite with a small amount ofδferrite phase distributed in the y-phase grain boundaries, and the lattice orientation betweenγaustenite and 8 ferrite phases was (111)γ//(110)δ、[211]γ//[111]δ.The ordered phase Ni3Fe with FCC structure was formed in the weld. In the fusion of Super-Ni/NiCr, the lattice orientation between y austenite and a ferrite phases was (110)α//(111)γ、[111]α//[211]γ. Theγ-Fe andγ-Ni (Fe, Cr) coexisted in the fusion zone of the laminated composite.
The stress fields of Super-Ni/NiCr and 1Cr18Ni9Ti steel TIG joint were studied based on the analysis of microstructure. The results indicated that the stress concentrated seriously in the fusion zone of Super-Ni/NiCr, mainly affected byσx andσy stress. The interface of NiCr base layer and Ni cover layer was the weakness region while the laminated composite being welded. The peak value ofσx tensile stress was 29.1 MPa andσx tensile stress was 40.1MPa, in the HAZ of the laminated composite. Along the welding direction, in first welding position of the fusion zone of the laminated composite was mainly affected byσx compression stress, in the behind position was mainly affected byσx tensile stress.
The microstructure and stress distribution of Super-Ni/NiCr TIG joint was firstly studied in this paper, which provided experimental and theoretical basis for improving the application of Super-Ni laminated composite. The conclusions obtained from this paper have established an important foundation to study deeply the weldability of high temperature composites.
引文
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