Hot deformation behavior and ring rolling process of SiCp/Al composites used in aircraft manufacturing
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摘要: 为了研究航空用高强韧碳化硅颗粒增强铝基复合材料（SiCp/Al）的热变形行为，为环轧制备航空用大尺寸环件提供工艺依据，采用粉末冶金工艺制备了17%SiCp/Al复合材料（体积分数）。通过不同温度与不同变形速率的热压缩实验，获得了复合材料在不同热变形条件下的应力应变关系，并根据这一关系建立了复合材料的热加工图。研究结果表明，SiCp/Al复合材料随着变形量的增加，在低于440 ℃或高于490 ℃以及高于0.100 s‒1的变形速率下易发生失稳变形。SiCp/Al复合材料在变形温度与变形速率不适宜时，除了发生传统金属的失稳变形等工艺缺陷外，还会出现颗粒损伤引起的表面开裂，这种开裂无法通过机加工去除，应予以避免。最后，在热加工图的指导以及环轧实验验证下，给出了适宜SiCp/Al复合材料环轧成型的工艺参数，完成了外径达1200 mm的SiCp/Al复合材料环件制备。
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关键词:
- 粉末冶金 /
- 颗粒增强铝基复合材料 /
- 热变形行为 /
- 环轧
Abstract: To study the thermal deformation behavior of high-strength and high-toughness SiC particle reinforced aluminum matrix composites (SiCp/Al) used in aircraft manufacturing and to provide the technical basis for the preparation of large size rings by ring rolling used for the aviation, the 17%SiCp/Al composites (volume fraction) were prepared by powder metallurgy process. The stress-strain relationships of the SiCp/Al composites under the different thermal deformation conditions were obtained through the thermal compression experiments at the different temperatures and deformation rates, and the thermal working diagram was established according to the relationship. In the results, with the increase of deformation, the SiCp/Al composites are prone to the instability deformation at the deformation temperature lower than 440 ℃ or higher than 490 ℃ and the deformation rates higher than 0.100 s‒1. When the deformation temperature and deformation rate of the SiCp/Al composite are not suitable, besides the traditional process defects such as the instability deformation but also the surface cracking caused by the particle damage may occur, which cannot be removed by machining and should be avoided. Finally, under the guidance of the hot working diagram and the verification of the ring rolling experiment, the process parameters suitable for the ring rolling of the SiCp/Al composite are given, and the circular workpieces prepared using the SiCp/Al composites with the outer diameter of 1200 mm are prepared. -
图 1 SiCp/Al复合材料金相组织和能谱分析:（a）显微组织；（b）Cu能谱分析；（c）Mg能谱分析；（d）Al能谱分析；（e）Si能谱分析
Figure 1. Microstructure and EDS mapping of the SiCp/Al composites: (a) microstructure; (b) EDS of Cu; (c) EDS of Mg; (d) EDS of Al; (e) EDS of Si
图 2 SiCp/Al复合材料热压缩试样压缩前（a）与压缩后（b）宏观形貌
Figure 2. Macro appearance of the SiCp/Al composite specimens before (a) and after (b) hot compressing
图 4 不同变形量下SiCp/Al复合材料logσ与
$ \log \dot \varepsilon $ 函数关系拟合图：（a）0.1；（b）0.3；（c）0.5；（d）0.7Figure 4. Fitting results of logσ and
$ \log \dot \varepsilon $ for the SiCp/Al composites at the different deformation: (a) 0.1; (b) 0.3; (c) 0.5; (d) 0.7
图 5 不同变形量下SiCp/Al复合材料热加工图：（a）0.1；（b）0.3；（c）0.5；（d）0.7
Figure 5. Hot processing maps of the SiCp/Al composites at the different deformation: (a) 0.1; (b) 0.3; (c) 0.5; (d) 0.7
图 6 1#样件扩孔时发生多次开裂后的裂纹宏观形貌（a），1#样件裂纹附近微观组织（b），2#样件在环轧过程中发生失稳变形的宏观形貌（c）及3#样件完成环轧后宏观形貌（d）
Figure 6. Cracking macro appearance of 1# part (a), the microstructure near the cracks of 1# part (b), the macro appearance of 2# part after the buckling deformation during rolling (c), and the macro appearance of 3# part finished the ring rolling process (d)
表 1 Al‒Cu‒Mg合金化学成分（质量分数）
Table 1. Chemical composition of the Al‒Cu‒Mg alloys
% Cu Mg Al 4.8 2.0 93.2 
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表 2 SiCp/Al复合材料环轧工艺方案
Table 2. Processing parameter of ring rolling for the SiCp/Al composites
样件编号 变形速率 / s‒1 变形温度 / ℃ 单次变形量 1# 0.100 450 0.3 2# 0.010 480 0.1 3# 0.010 450 0.1
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