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摘要:
随着航空航天、能源动力和石油化工等领域的快速发展，镍基合金薄板焊接技术成为决定核心零部件使用性能的关键因素之一。镍基合金薄板焊接对热输入敏感，易出现元素偏析、脆性相析出导致焊缝性能降低及产生焊接变形等问题。本文介绍了镍基合金薄板激光焊接技术的研究进展，分别总结了镍基合金薄板的激光自熔焊接和激光填丝焊接两种焊接技术下的焊缝微观组织演变、力学性能和耐腐蚀性能变化以及焊接变形规律，提出了未来研究应重点考虑对焊缝微观组织的预测，并结合先进的算法，提出微观组织、力学性能和耐腐蚀性能的自适应调控策略，进而开发出新型智能化焊接工艺。
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关键词:
- 镍基合金 /
- 激光焊接 /
- 微观组织 /
- 力学性能和耐腐蚀性能 /
- 焊接变形
Abstract:With the rapid development of aerospace, energy power, petrochemical, and other fields, nickel-based alloy sheet welding technology has become one of the key factors determining the performance of core components. The welding of nickel base alloy sheet is sensitive to the heat input, and it is easy to cause element segregation and brittle phase precipitation, which will reduce the weld performance and produce welding deformation. This paper introduces the research progress of laser welding technology of nickel base alloy sheet, and summarizes the evolution of weld microstructure, changes of mechanical properties and corrosion resistance, and the rules of welding deformation under two kinds of welding technologies including laser autogenous welding and laser welding with filler wire of nickel base alloy sheet. It is proposed that the prediction of weld microstructure should be considered in the future research, which should combine with advanced algorithms to propose the adaptive control strategy of microstructure, mechanical properties and corrosion resistance, developing a new intelligent welding process.
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Overview: With the rapid development of aerospace, energy power, petrochemical, and other fields, nickel-based alloy sheet welding technology has become one of the key factors determining the performance of core components. The welding of nickel base alloy sheet is sensitive to the heat input, and it is easy to cause element segregation and brittle phase precipitation, which will reduce the weld performance and produce welding deformation. This paper introduces the research progress of laser welding technology of nickel base alloy sheet, and summarizes the evolution of weld microstructure, changes of mechanical properties and corrosion resistance, and the rules of welding deformation under two kinds of welding technologies including laser autogenous welding and laser welding with filler wire of nickel base alloy sheet. The research of the autogenous laser welding process focuses on Ni-Cr and Ni-Cr-Mo alloys. The grain morphology and element segregation are analyzed, including refining microstructure and inhibiting the formation of precipitates, by means of adjusting the process parameters, using ultrasonic vibration, and using a low-temperature cooling process. The microhardness of the two kinds of alloy welds is better than that of base metal, because of the finer grains in the welds. Tensile strength at room temperature can reach about 90% of the base metal, but high-temperature tensile performance is comparable to the base metal. Ni-Cr alloy welded joints show good high-temperature plasticity. The relatively lower tensile strength of the welded joints is relative to the worse morphology of the weld surfaces. The fatigue properties and corrosion resistance of the Ni-Cr-Mo alloy welds are comparable to those of the base metal. The research of laser welding of nickel-based alloy sheets with filler wire focuses on the Ni-Cr-Mo alloy, and the grain morphology, element segregation, and its regulation are still the focuses of the research. The microhardness and room temperature tensile strength of the welded joints with filler wire are better than those of the base metal. The better room temperature tensile strength of the welded joints benefits from both the finer weld grains and the occurrence of the reinforcement. Corrosion tests show that the welded joints have comparable corrosion resistance to the base metal. Welding deformation of nickel-based alloy sheets includes shrinkage deformation, deflection, and angular deformation. Compare with the traditional arc welding process, laser welding shows lower heat input, and thus, it leads to smaller deformation. At present, the research of welding deformation of nickel-based alloy sheet mainly concentrates on the prediction of deformation through the finite element method and reducing deformation through process parameters adjustment, restraint intensity control, and utilizing auxiliary processes. Future research should focus on the prediction of weld microstructure and the propose of various adaptive control strategies for microstructure, mechanical properties and corrosion resistance by combining with advanced algorithms. Besides, developing new types of intelligent welding processes is also an important part.
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图 1 Ni-Cr合金焊缝微观组织。(a) 熔合线附近和焊缝中心微观组织[19]; (b) 焊接速度对焊缝枝晶的影响[24]; (c) 激光功率对焊缝微观组织的影响[25]; (d) 微观组织预测[26]
Figure 1. Microstructure of Ni-Cr alloy welds. (a) Microstructure near the fusion line and in the weld center[19]; (b) The effect of welding velocity on weld dendrites[24]; (c) The effect of laser power on microstructure of welds[25]; (d) Prediction of microstructure[26]
图 2 Ni-Cr-Mo合金焊缝微观组织。(a) Hastelloy C-276母材、热影响区和焊缝中心处的微观组织[27-28]; (b) Hatelloy X焊缝边缘微观组织[29]; (c) 使用相场法模拟焊缝中的柱状晶[30]; (d) 母材及超声作用前后焊缝的微观组织EBSD图[31]
Figure 2. Microstructure of Ni-Cr-Mo alloy welds. (a) Microstructure of Hastelloy C-276 base metal, heat affected zone and weld center[27-28]; (b) Microstructure of Hastelloy X weld edge[29]; (c) The phase field simulation of columnar grains in weld [30]; (d) EBSD microstructure of base metal and the weld with or without ultrasonic vibration[31]
图 3 镍基合金焊缝析出相。(a) Inconel 718焊缝中的Laves相[33]; (b) 热输入变化对Inconel 617焊缝析出相的影响[24];(c) 超声振动对Hastelloy C-276焊缝析出相的影响[31]
Figure 3. The precipitation phase in nickel-based alloy welds. (a) The Laves phase in the Inconel 718 weld[33]; (b) The effect of heat input on the precipitation phase of the Inconel 617 weld[24]; (c) The effect of ultrasonic vibration on the precipitation phase in Hastelloy C-276 welds[31]
图 5 Ni-Cr-Mo合金焊接接头拉伸性能。(a) Ni-Cr合金的母材与焊缝拉伸断口形貌[46];(b) 通过调整热输入调控抗拉强度[23]; (c) Ni-Cr-Mo合金的母材与焊缝拉伸断口形貌[45]
Figure 5. Tensile properties of Ni-Cr-Mo alloy welded joints. (a) Fracture surfaces of Ni-Cr alloy base metal and weld[46]; (b) Tensile strength with different heat input[23]; (c) Fracture surfaces of Ni-Cr-Mo alloy base metal and weld[45]
图 6 镍基合金高温拉伸性能。(a) Ni-Cr合金高温拉伸前后焊缝中的Laves相[47];(b) Ni-Cr-Mo合金在不同温度下的拉伸曲线[43]; (c) Ni-Cr-Mo合金400 ℃拉伸断口[43]
Figure 6. High temperature tensile properties of nickel-based alloy. (a) The Laves phase in the weld of Ni-Cr alloy before and after high temperature tensile test[47]; (b) Curves of tensile strength of Ni-Cr-Mo alloy welded joints in different temperatures[43]; (c) Fracture surfaces of Ni-Cr-Mo alloy welded joint in 400 °C [43]
图 8 Ni-Cr-Mo合金腐蚀性能[27]。(a) 腐蚀后的母材和焊缝形貌(NaCl溶液); (b) NaCl溶液电化学极化曲线;(c) 酸性溶液电化学极化曲线; (d) 碱性溶液电化学极化曲线
Figure 8. Corrosion properties of Ni-Cr-Mo alloy[27]. (a) Corrosion morphology of the base metal and the weld (in NaCl solution); (b) Polarization curves in NaCl solution; (c) Polarization curves in acid solution; (d) Polarization curves in alkaline solution
图 9 Ni-Cr-Mo合金激光填丝焊接接头形貌与微观组织。(a) 焊缝整体形貌[57]; (b) 上、下余高边缘及中心处微观组织[57];(c) 焊缝中心、熔合线与过渡熔合区的微观组织[57]; (d) 脉冲宽度为4 ms时微观组织[46]; (e) 脉冲宽度为8 ms时微观组织[46]; (f) 脉冲频率为50 Hz时微观组织[46]; (g) 脉冲频率90 Hz时微观组织[46]
Figure 9. Morphology and microstructure of Ni-Cr-Mo alloy welded joints in laser welding with filler wire. (a) Morphology of the welded joint[57]; (b) Microstructure in edge and center of the reinforcement[57]; (c) Microstructure of the weld center, fusion line and transition fusion zone[57]; (d) Microstructure with the pulse duration of 4 ms[46]; (e) Microstructure with the pulse duration of 8 ms[46]; (f) Microstructure with the pulse frequency of 50 Hz[46]; (g) Microstructure with the pulse frequency of 90 Hz[46]
图 10 Ni-Cr-Mo激光填丝焊缝微观组织。(a) 焊缝中的链状析出物[61]; (b) 脉冲宽度对Mo元素偏析影响[61];(c) 脉冲频率对Mo元素偏析影响[61]; (d) 未施加低温冷却的焊缝微观组织[60]; (e) 施加低温冷却后的焊缝微观组织[60]
Figure 10. Microstructure of the Ni-Cr-Mo alloy weld of laser welding with filler wire. (a) Precipitate chain in the weld[61]; (b) The effect of pulse duration on the segregation of Mo[61]; (c) The effect of pulse frequency on segregation of Mo[61]; (d) Microstructure of the weld without low temperature cooling process[60]; (e) Microstructure of the weld with low temperature cooling process[60]
图 13 Ni-Cr-Mo焊接接头空蚀性能[66]。(a) 焊缝空蚀后形貌; (b) 发生空蚀的焊缝晶界; (c) 发生空蚀的母材孪晶界
Figure 13. Cavitation erosion property of Ni-Cr-Mo alloy welded joint [66]. (a) The morphology of the weld after cavitation erosion; (b) Cavitation eroded grain boundary in the weld; (c) Cavitation eroded twin boundary in base metal
图 16 Hastelloy C-276薄板焊接变形。(a) 线能量密度对挠曲变形的影响[62]; (b) 相对送丝量对挠曲变形的影响[62];(c) 未施加热沉的残余变形[71]; (d) 冷却流量水流量48 mL/min的残余变形[71]; (e) 冷却流量水流量68 mL/min的残余变形[71]
Figure 16. Welding deformation of Hastelloy C-276 sheet. (a) Effect of linear energy density on deflection[62]; (b) Effect of the relative wire speed on the deflection[62]; (c) Residual deformation without heat sink[71]; (d) Residual deformation with the flow rate of 48 mL/min[71]; (e) Residual deformation with the flow rate of 68 mL/min[71]
表 1 自熔焊微观组织研究现状
Table 1. Research status of microstructure of autogenous
材料 微观组织 工艺方法 研究机构 GH 3044 细化焊缝晶粒，减小二次枝晶臂间距 提高焊接速度降低焊接热输入 南昌航空大学[23] Inconel 617 清华大学[24] GH 118 进一步减小焊缝宽度和晶粒尺寸 降低激光功率 北京航空制造工程研究所[25] Hasetlloy C-276 焊缝晶粒显著细化，微观偏析程度降低，脆性相得到抑制 脉冲激光焊接快速凝固 大连理工大学[28] Hasetlloy C-276 减小焊缝晶粒及析出相的尺寸，元素分布更加均匀 施加随焊超声振动调控微观组织 大连理工大学[31] Inconel 617 有效降低了焊缝元素偏析程度，减小脆性相的析出 降低热输入 清华大学[24] Inconel 718 二次枝晶臂间距的预测误差<1.5 μm 数值模型预测焊缝几何形貌和微观组织 巴斯克大学(西班牙)[26] Hatelloy X 初生枝晶臂间距大于3 μm时，会有裂纹产生 德黑兰大学(伊朗)[29] Inconel 718 减少焊缝中的Nb偏析和相应Laves相发展 使用高能量密度的激光焊接 安纳马莱大学(印度)[1] 
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