大径厚比异质高温合金惯性摩擦焊接特征物理行为研究

惯性摩擦焊技术是目前高性能航空发动机动力传动部件制造的主导性工艺方法。对于大径厚比异质高温合金惯性摩擦焊，工件结构及材料性能的特殊性使焊接过程产生诸如接头失稳变形、“粉末型飞溅”、“咬边”等特征物理行为，其对焊接成形及接头质量产生重要影响。本项目以航空用异质镍基高温合金材料为例，通过工艺试验方法研究工件结构、材料热物理性能、工艺参数多因素耦合作用对大径厚比异质镍基高温合金惯性摩擦焊接成形过程的影响，并通过推导及开发离散-连续有限元法及有限元子程序，模拟惯性摩擦焊接过程连续变形及非连续变形行为。基于工艺试验与数值模拟相结合的方法系统揭示大径厚比异质高温合金惯性摩擦焊接特征物理行为形成机理。该项目研究成果将进一步丰富异质高温合金惯性摩擦焊接基础研究，更将为高性能航空发动机大径厚比异质高温合金动力传动部件的惯性摩擦焊接制造提供技术支撑，促进我国航空发动机制造技术水平的进步和提高。

Inertia friction welding (IFW) technology has become the dominant manufacturing technology of hot-end components in high-performance aero-engine. For large diameter-thickness ratio dissimilar superalloy, the particularity of workpiece structure and material properties results in the formation of characteristic physical behaviors during IFW such as instability deformation of joint, spatter and undercut, etc. which seriously affect the joint forming and quality. This project focuses on the dissimilar superalloys used in aircraft, and studies the influences of coupling effect of multiple factors such as workpiece structure, material thermal physical properties and welding parameters on welding forming through experiments. Through the derivation of discrete-continuous finite element method and the development of subroutine, the non-continuous and continuous deformation behaviors during IFW are solved. Bases on the experimental and numerical studies, the forming mechanics of characteristic physical behaviors in IFW of large diameter-thickness ratio dissimilar superalloy can be revealed systematically. The results not only further develop basic researches of dissimilar superalloy IFW, but also provide the support for IFW manufacturing of large diameter-thickness ratio dissimilar superalloy hot-end componnets in advanced aero-engine, and promote the development and improvement of aero-engine manufacturing technology in China.