高强铝合金半固态触变-塑变复合近净成形技术及协调变形机制研究

Based on the integrated requirements of near net shaping and high performance products by modern industry, a novel processing technology is imminently needed which could not only bring out the potential properties of alloys but also produce the advantage of forming technology. In this project, a compound processing technology is presented by integrating the semi-solid thixoforming and plastic forming. The different regions on the billet are reheated to different temperatures and microstructures by electromagnetic induction heating, according to the shape and mechanical property requirements of the component. Then the region of the billet corresponding to forming the complex shape will be deformed in the semi-solid state, while other regions will be deformed plastically. Therefore, the advantages of semi-solid processing (near net shaping) and plastic forming (high performance) could be utilized. In this project, the mechanism and law in the compound forming of high performance aluminum alloys will be studied by experimental, numerical simulation and theoretical analyses. The distribution of temperature and microstructures under different reheating conditions will be revealed. Besides, the coordinated deforming mechanism of compound forming will be clarified, and the heat treatment mechanism will be studied. Moreover, the efficient connection of reheating system and forming system will be achieved. This research will provide a novel compound forming technology for the near net shaping of complex components, and it has important theoretical value and practical significance of application.

源于现代工业对近净成形(成形)和高性能构件(成性)的一体化要求，迫切需要能同时发挥出合金的性能潜力和成形技术优势的新型加工技术。本项目提出半固态触变成形-塑性成形集成的复合加工技术，采用电磁感应加热等高效加热方式将坯料的不同区域加热到不同的温度和组织状态，使成形复杂形状区域和相对简单形状区域的局部坯料分别进行触变成形和塑性成形，从而发挥出半固态成形的近净成形特点和塑性成形的高性能优势。本项目采用试验研究、数值模拟与理论分析相结合的方法，深入研究高强铝合金半固态触变-塑变复合成形的机理和规律，揭示坯料在不同加热条件下的温度和组织状态的区域化分布规律，阐明复合成形过程中的触变-塑变协调变形机制，探索适用于这种具有区域差异化组织构件的热处理强化机制，实现电磁感应加热系统与复合成形系统间的高效短流程衔接。项目研究可为复杂构件高性能近净成形提供一种新的复合成形技术，具有重要的理论价值和实际应用意义。

本项目研究的半固态触变-塑变复合成形技术将半固态触变成形和塑性成形在构件区域上有效集成，采用电磁感应加热方式将坯料的不同区域加热到不同的温度和组织状态，使成形复杂形状区域和相对简单形状区域的局部坯料分别进行触变成形和塑性成形，从而发挥出半固态成形的近净成形特点和塑性成形的高性能优势。本项目采用试验研究、数值模拟与理论分析相结合的方法，研究了高强铝合金半固态触变-塑变复合成形的机理和规律，揭示了坯料在不同加热条件下的温度和组织状态的区域化分布规律，实现了梯度铝合金坯料高效制备。开发了电磁感应加热系统与复合成形系统间的高效短流程衔接装置，实现了铝合金尾翼构件近净成形，阐明了复合成形过程中的触变-塑变协调变形机制，研究了适用于具有区域差异化组织构件的热处理强化机制。研究结果表明半固态触变-塑变复合成形技术可实现高性能复杂件近净成形，研究成果已通过某单位技术鉴定，在航空航天、兵器装备、汽车工业等领域具有广阔的应用前景。