Examination of superplastic forming combined with diffusion bonding for titanium: Perspective from experience

Superplastic forming (SPF) combined with diffusion bonding (DB) has been used successfully for the fabrication of titanium aerospace hardware. Many of these applications have been for military aircraft, whereby a complex built-up structure has been replaced with monolithic parts. Several methods for applying the two- and four-sheet titanium SPF/DB processes have been devised, including the welding of sheets prior to forming and the use of silk-screened stop-off (yttria) to prevent bonding where it is undesirable. Very little progress has been made in the past few years toward understanding and modeling the SPF/DB process using constitutive equations and data by laboratory testing. Concerns that engineers face in designing for fatigue life, acceptable design loads, and damage tolerance are currently being studied, but the database is very limited. This is a summary of past work found in the literature and forms the foundation for additional research. This paper was presented at the International Symposium on Superplasticity and Superplastic Forming sponsored by the Manufacturing Critical Sector at the ASM International AeroMat 2004 Conference and Exposition, June 8–9, 2004, in Seattle, WA. The symposium was organized by Daniel G. Sanders, The Boeing Company.     

MICROSTRUCTURAL EVOLUTION OF HIGHLY UNDERCOOLED EUTECTIC Ni78.6Si21.4 ALLOY

A large undercooling level up to 550K （0.386Te） was achieved in eutectic Ni78.6Si21.4melt by the combination of molten-glass and cyclic superheating. A microcrystaUine structure is obtained at large undercooling. Surprisingly, the morphology of ct（Ni） phase transits from the non-faceted phaseto faceted phase at large undercooling of 390K. Based on the classical nucleation theory and transient nucleation theory, the process of microstructure evolution and competitive nucleation was analyzed, and the refinement of crystal structure is determined by the high nucleation rate under large undercooling.     

激光表面熔凝处理对U-2Nb合金抗腐蚀性能的影响

利用波长1．06μm的激光对U-2Nb合金进行了表面熔化处理。结果表明；U-2Nb合金激光熔化层的显微硬度（HV）由处理前的2900MPa提高到3300MPa；合金基材为双相（α＋γ）珠光体，经激光处理后变成马氏体（α′），激光处理能细化显微组织，使Nb元素实现均匀分布。阳极极化试验与质量法腐蚀试验表明：激光处理能明显提高合金的抗腐蚀能力，在FeCl3·6H2O溶液中激光处理后合金的失重仅为处理前的1／5。     

非晶态SrTiO3薄膜的快速晶化处理

在Si(111)基片上采用脉冲激光沉积(PLD)方法,烘烤温度300℃,制备得到非晶态SrTiO3薄膜.采用快速晶化处理,将非晶态SrTiO3薄膜在不同温度、不同晶化处理时间下进行了晶化处理,采用GIXRD和AFM分析检验晶化的效果和表面形貌.结果表明,SrTiO3晶化程度强烈依赖处理温度,处理温度越高,晶化程度越高;在同一温度下,增加处理时间有助于提高晶化效果,并获得致密、表面平整、均匀的SrTiO3晶态薄膜;晶粒大小不随晶化处理时间明显变化.在快速晶化处理过程中,非晶态SrTiO3薄膜在极短时间内达到晶化温度,并形成大量晶核,从而使晶粒生长受到限制,有利于获得更好的晶化效果.     

非晶态Fe－B－Si合金的退火脆化

非晶态Ｆｅ－Ｂ－Ｓｉ合金的退火脆化具有明显的成分依赖性，并且对制备条件和退火方式比较敏感；近共晶成分的合金（如Ｆｅ８０Ｂ１１．５Ｓｉ８．５和Ｆｅ７９Ｂ１１．５Ｓｉ９．５等）和适当液淬工艺条件下制备的非晶合金薄带具有相对较小的脆化倾向。与常规退火工艺相比，脉冲电流加热快速退火，可在保持延性基本不变的情况下，明显改善合金的磁性；是获得非晶态Ｆｅ－Ｂ－Ｓｉ合金磁性优化与良好延性配合的有效途径之一     

Tb在快速凝固Ag合金中固溶度扩展

采用电弧熔化快速锤砧急冷技术制备含Tb直到10at.-%的Ag-Tb合金箔,厚度0.05—0.08mm,其冷却速度为10~6K/s数量级,采用晶格参数法确定Tb在快速凝固Ag-Tb合金中亚稳扩展固溶度可达到5at-%,确定亚稳共晶中的第二相为Ag_3Tb,观察了快凝Ag-Tb合金的显微结构与缺陷。     

激光快速修复Ti-6Al-4V合金的显微组织与力学性能

针对Ti-6Al-4V合金在加工和服役过程中的损伤特点,对Ti-6Al-4V合金锻件的3种典型误加工缺陷——槽缺陷、面缺陷和体缺陷进行了激光快速修复研究。激光修复区与锻件基体形成致密冶金结合,Al、V合金元素由锻件基体到激光修复区均匀分布,无宏观偏析。激光修复区组织为粗大原始β晶粒内分布细长的α针及编织细密的α+β板条组织,呈现典型的魏氏结构,热影响区组织从锻件的等轴α+转变β组织逐步过渡到魏氏(α+β)组织。对预制有3种类型缺陷的激光修复试样进行室温静载拉伸试验和硬度测试,结果表明修复试样的拉伸性能达到锻件标准(HB5224-1982)。激光修复试样的硬度和强度高于锻件基体,而塑性则低于锻件基体。因此,激光修复区和锻件基体可看作是一种“强+弱”的组合,这与二者的显微组织是相对应的。     

Rapidly solidified hypereutectic Al-Si alloys prepared by powder hot extrusion

Rapidly solidified hypereutectic Al-Si alloys were prepared by powder hot extrusion.By eliminating vacuum degassing procedure.the fabrication routine was simplified.The tensile fracture mechanisms at room temperature and elevated temperature were investigated by SEM fractography.Compared with KS282 casting material,the tensile strength of rapidly solidified Al-Si alloy is greatly improved due to silicon particles refining while its density and coefficient of thermal expansion are lower.than those of KS282.The wear resistance of RS AlSi is better than that of KS282.     

热压快速凝固Fe0.92Mn0.08Six半导体的热电性能

采用快速凝固和热压的方法制备了p型热电材料Fe0.92Mn0.08Six(x=1.9, 2.0, 2.1, 2.3, 2.5).X射线衍射分析表明,热压试样退火24 h后,完全转变为β半导体相.所有试样的致密度均高于90%.测量试样的电学性能发现,原料配比为Fe0.92Mn0.08Si2.1的试样在整个测量温度范围内的功率因子最大,550℃时达到了400 μW·m-1·K-1以上.     

基于焊接机器人的三维快速成形的方法研究

将RP技术与熔焊技术结合．依据焊接工艺的特点对切片和多径规划算法进行了研究，得出了根据不同类型零件使用不同路径规划算法的结论。据此。使用Visual C^ 基于UniGraphics二次开发的方式实现了切片、路径规划算法，完成了面向焊接机器人性速成形软件的编写，实现UG实体模型的切片、路径规划以及机器人数控代码的生成。利用MotoMan机器人远程控制接口软件包MotoCom32编写了用于机器人快速成形的远程成形控制软件。采用CO2气体保护焊成功实现了基于焊接机器人的典型零件的快速成形。