WO2019051979A1 - 模块式金属构筑成形方法 - Google Patents

模块式金属构筑成形方法 Download PDF

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Publication number
WO2019051979A1
WO2019051979A1 PCT/CN2017/110489 CN2017110489W WO2019051979A1 WO 2019051979 A1 WO2019051979 A1 WO 2019051979A1 CN 2017110489 W CN2017110489 W CN 2017110489W WO 2019051979 A1 WO2019051979 A1 WO 2019051979A1
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Prior art keywords
blank
module
forming method
forging
hourglass
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PCT/CN2017/110489
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English (en)
French (fr)
Inventor
燕春光
徐海涛
刘强
李雅平
孙刚
刘兆阳
王明政
杨孔雳
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China Institute Of Amomic Energy
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China Institute Of Amomic Energy
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Priority to EP17925195.4A priority Critical patent/EP3683006B1/en
Priority to JP2020515203A priority patent/JP6913239B2/ja
Priority to KR1020207010298A priority patent/KR102383823B1/ko
Publication of WO2019051979A1 publication Critical patent/WO2019051979A1/zh
Anticipated expiration legal-status Critical
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
    • B21J1/04—Shaping in the rough solely by forging or pressing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/08—Upsetting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
    • B21H1/00—Making articles shaped as bodies of revolution
    • B21H1/06—Making articles shaped as bodies of revolution rings of restricted axial length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
    • B21J1/02—Preliminary treatment of metal stock without particular shaping, e.g. salvaging segregated zones, forging or pressing in the rough
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
    • B21J1/06—Heating or cooling methods or arrangements specially adapted for performing forging or pressing operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/12—Forming profiles on internal or external surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/76—Making machine elements elements not mentioned in one of the preceding groups
    • B21K1/761—Making machine elements elements not mentioned in one of the preceding groups rings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/06—Electron-beam welding or cutting within a vacuum chamber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/02—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press ; Diffusion bonding
    • B23K20/023—Thermo-compression bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P13/00—Making metal objects by operations essentially involving machining but not covered by a single other subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P2700/00—Indexing scheme relating to the articles being treated, e.g. manufactured, repaired, assembled, connected or other operations covered in the subgroups
    • B23P2700/12—Laminated parts

Definitions

  • the invention relates to a method for manufacturing a metal material, in particular to a modular metal structure forming method.
  • the existing method proposes to use a slab, a forging slab, and a rolled blank as a basis, and after surface processing and cleaning, a plurality of primitives are packaged together, and the interior of the interface is kept high.
  • a forging process characterized by upsetting deformation, forging insulation, and multi-directional forging is then applied to finally prepare a large metal device.
  • the Chinese patent application 201511026272.X “homogeneous metal construction molding method”, 201511027492.4 “metal construction molding method”, 201511027686.4 “cylinder metal construction molding method”, all of which are manufactured by a one-time construction molding method.
  • the object of the present invention is to provide a more feasible, reliable and safe manufacturing method for the formation of large metals.
  • the intermediate blank prepared in the step (S4) is welded in the vacuum chamber, further forming a multi-stage module, and heating the multi-stage module to perform height along the height Directional upset deformation and forging insulation, repeating this step one or more times until one blank is made;
  • the preform described in the step (S1) is constructed by a cast slab, a forging blank or a rolled blank element, and is sealed and forged; or the forging blank is machined. The way is made directly.
  • the preform in the step (S2), is formed into a frustum shape unit, and then the facets of the two frustum shape units are stacked together to perform vacuum electrons.
  • the frustum shape unit may have a truncated cone shape or a quadrangular frustum shape, and the intermediate interface of the two frustum shape units smoothly transitions.
  • the vacuum electron beam welding has a welding depth of 20 to 50 mm.
  • the hourglass-shaped module has an aspect ratio of between 1 and 3.
  • the reduction amount of the upset deformation of the hourglass-shaped module in the steps (S3), (S4), and (S5) is 30% to 55% of the total height of the blank.
  • the billet after the upsetting is subjected to high-temperature diffusion bonding, the heating temperature is not lower than 1200 ° C, and the heat preservation after the temperature is uniform.
  • the time is no less than 12 hours.
  • step (S6) the blank is roughed, punched, reamed, and flattened to form a ring forging; or the blank is subjected to upsetting, rounding, and reaming to form a tube.
  • the billet; or the blank is subjected to upsetting, rounding and upsetting to form a cube-shaped slab.
  • the beneficial effects of the present invention are as follows:
  • the modular metal structure forming method provided by the present invention is more reliable and controllable in quality.
  • Each module can be inspected after forging, and it can be reused after being qualified. It can be used for multiple items during feeding, which can effectively guarantee the construction period.
  • the hourglass-shaped framing blank can concentrate the deformation of the upsetting process at the interface position, and avoid the generation of surface tensile stress, so that the blank is uniformly subjected to large compressive stress, and the tensile stress state of the surface of the blank is obviously improved.
  • the hourglass shaped blank has a small minimum cross-sectional area, which can effectively reduce the pressure required for forging.
  • the invention can improve the finished product rate of the large metal structure forming, can greatly improve the production efficiency under the condition of using the same specification press, and solves the bottleneck problem in the manufacturing process of the large-structure forming and forming forging, and reduces the production cost.
  • FIG. 1 is a flow chart of a method for forming a modular metal structure according to the present invention
  • FIG. 2 is a schematic flow chart of a metal construction forming method according to Embodiment 1 of the present invention.
  • Embodiment 3 is a schematic flow chart of a metal construction forming method according to Embodiment 2 of the present invention.
  • the method for forming a modular metal structure provided by the present invention includes:
  • Step (1) preparing 2 N preforms, N being an integer greater than or equal to 2;
  • Step (2) preparation of a multi-level module
  • Step (3) forming the intermediate blank into a blank
  • Step (4) processes the blank into parts or parts.
  • the first-class module made of the preform and the second-stage module or the multi-stage module made of the intermediate blank are all hourglass-shaped modules, and the advantages of the hourglass-shaped module are fully utilized, and the volume and weight of the intermediate blank are continuously expanded. Finally, the blank is made.
  • the preform according to the present invention can be constructed, sealed and forged from a billet, a billet or a billet element (for a specific method, see the description in 201511026272.X "Homogeneous Metal Construction Method”); or It is made directly from the forging blank by mechanical processing.
  • a feature of the invention is the use of multi-stage modular manufacturing Art, the large forgings are divided into multiple modules for construction. This kind of process can invest more than one part when feeding, which can effectively improve production efficiency and ensure the construction period.
  • the number of stages of the module is determined by the number of preforms.
  • the preforms or intermediate blanks are welded together in a vacuum chamber to form a profiled module, and then the profiled module is subjected to upset deformation in the height direction and forging insulation. This process step is repeated one by one, and finally one blank is produced.
  • Another aspect of the present invention is embodied in a profiled module structure used in a blank manufacturing process.
  • a preform into a multi-stage hourglass-shaped module
  • an hourglass-shaped structured blank can concentrate the deformation of the upsetting process at the interface position and avoid The surface tensile stress is generated, so that the blank is uniformly subjected to a large compressive stress, and the tensile stress state of the surface of the blank is remarkably improved.
  • the invention firstly produces the preform or intermediate blank into a frustum shape unit which can be produced by forging and/or machining. Then, the facets of the two frustum-shaped unit units are stacked together and subjected to vacuum electron beam welding to form an hourglass-shaped module.
  • the frustum shape unit may have a truncated cone shape or a quadrangular frustum shape (other frustum shapes such as a hexagonal frustum, an octagonal frustum, etc.) may also be used. Since the hourglass shaped blank has a small minimum cross-sectional area, the pressure required for forging can be effectively reduced. However, when the middle depression is narrow, wrinkle defects are generated during the forging process; when the middle depression is wider, the effect of lowering the forging pressure is weakened.
  • the angle between the lower base and the waist of the longitudinal trapezoidal section of the frustum-shaped unit should be considered, so that the position is in a more ideal range.
  • the joining of the two frustum-shaped units is achieved by vacuum electron beam welding.
  • the welded surface is processed and cleaned first, and then vacuum electron beam sealing is performed around the blank to be welded in the vacuum chamber, and vacuum electron beam welding is performed.
  • the depth is 20-50mm.
  • the hourglass-shaped module formed after welding has an aspect ratio of between 1-3.
  • the aspect ratio referred to herein refers to the ratio of the total height of the hourglass-shaped module to the diameter of the bottom surface of the truncated cone (or the length of the bottom side of the quadrangular frustum).
  • the billet In the forging process of the blank, the billet is first heated, the maximum heating temperature is not lower than 1200 ° C, and then the hourglass-shaped billet is subjected to upsetting deformation in the height direction, and the heated billet is placed. On the press table, the upset is performed in the height direction, and the reduction of the upset deformation is 30%-55% of the total height of the blank. Next, the billet after the upsetting is subjected to high-temperature diffusion connection, and the billet after the thick pile is sent back to the heating furnace for heating, the heating temperature is not lower than 1200 ° C, and the holding time after the uniform temperature is not less than 12 hours.
  • the target product of this embodiment is a large ring forging.
  • the ingot is obtained by pouring, and the ingot is heated and blank forged to form a preform.
  • the size of the preform is 2100 mm in diameter and 1500 mm in height, as shown in Fig. 2(a).
  • the preform is heated before forging, and the maximum heating temperature is not lower than 1200 °C.
  • the preform is die-forged to form a Class I frustum shaped unit, see Figure 2(b).
  • the third step vacuum electron beam welding is performed on the class I frustum shape unit.
  • the superimposed I-stage frustum-shaped unit blank is subjected to vacuum electron beam sealing welding with a welding depth of 20-50 mm to form a Class I hourglass-shaped module, as shown in Fig. 2(c).
  • the welded Class I hourglass-shaped module is heated before forging, and the maximum heating temperature is not lower than 1200 °C.
  • the heated billet is placed on the press table so that the height of the billet is in the vertical direction.
  • the height of the pier is increased in the height direction, and the total height of the blank is reduced by 30-55%.
  • a high temperature diffusion joint is applied to the blank.
  • the billet after the thick pile is sent back to the heating furnace for heating, the heating temperature is not lower than 1200 ° C, and the holding time after the uniform temperature is not less than 12 hours.
  • the blank is then rounded, see Figure 2(d).
  • the billet is heated before forging, and the maximum heating temperature is not lower than 1200 °C.
  • the blank is die-forged to form a Class II frustum shaped unit, see Figure 2(e).
  • the sixth step vacuum electron beam welding is performed on the class II frustum shape unit.
  • the stacked II stage frustum shape unit blanks are vacuum electron beam sealed and welded to a depth of 20-50 mm to form a Class II hourglass shaped module, as shown in Fig. 2(f).
  • the welded Class II hourglass-shaped module is heated before forging, and the maximum heating temperature is not lower than 1200 °C.
  • the heated billet is placed on the press table so that the height of the billet is in the vertical direction.
  • the height of the pier is increased in the height direction, and the total height of the blank is reduced by 30-55%.
  • a high temperature diffusion joint is applied to the blank.
  • the billet after the thick pile is sent back to the heating furnace for heating, the heating temperature is not lower than 1200 ° C, and the holding time after the uniform temperature is not less than 12 hours.
  • the blank is then rounded to form a blank, see Figure 2(g).
  • the blank is roughed, punched, reamed, and leveled.
  • the blank was machined to the final size on a 16 meter ring mill, see Figure 2(h).
  • the fifth to seventh steps in this embodiment can be repeated, and the intermediate blank is formed into a multi-stage hourglass-shaped module and then formed into a blank.
  • the target product of this embodiment is a large tube blank.
  • the stainless steel continuous casting slab made by continuous casting was cut into 11 pieces of blanks of 1500 mm ⁇ 1500 mm ⁇ 200 mm.
  • the six faces of each slab are machined and the surface to be welded is cleaned to expose a fresh metal surface.
  • the blank is subjected to vacuum electron beam welding.
  • vacuum electron beam sealing is performed on the superimposed blanks, and the welding depth is 20-50 mm.
  • the dimensions after welding are: width 1500 mm, length 1500 mm, height 2200 mm, see Fig. 3(a).
  • the welded blank is heated before forging, the maximum heating temperature is not lower than 1200 ° C, and the heating speed is required to be lower than 100 ° C / h.
  • the heated billet is placed on the press table so that the height of the billet is in the vertical direction.
  • the height of the pier is increased in the height direction, and the total height of the blank is reduced by 30-55%.
  • a high temperature diffusion joint is applied to the blank.
  • the billet after the thick pile is sent back to the heating furnace for heating, the heating temperature is not lower than 1200 ° C, and the holding time after the uniform temperature is not less than 12 hours.
  • the roughing of the blank in three directions is carried out, chamfering, chamfering and machining are performed to form a preform, as shown in Fig. 3(b).
  • the preform is heated before forging, and the maximum heating temperature is not lower than 1200 °C.
  • the preform is die-forged to form a Class I frustum shaped unit, see Figure 3(c).
  • vacuum electron beam welding is performed on the class I frustum shape unit.
  • the superimposed I-stage frustum-shaped unit blank is subjected to vacuum electron beam sealing welding with a welding depth of 20-50 mm to form a Class I hourglass-shaped module, as shown in Fig. 3(d).
  • the welded special-shaped module is heated before forging, and the maximum heating temperature is not lower than 1200 °C.
  • the heated billet is placed on the press table so that the height of the billet is in the vertical direction.
  • the height of the pier is increased in the height direction, and the total height of the blank is reduced by 30-55%.
  • a high temperature diffusion joint is applied to the blank.
  • the billet after the thick pile is sent back to the heating furnace for heating, the heating temperature is not lower than 1200 ° C, and the holding time after the uniform temperature is not less than 12 hours.
  • the blank is then rounded, see Figure 3(e).
  • the billet is heated before forging, and the maximum heating temperature is not lower than 1200 °C.
  • the blank is die-forged to form a Class II frustum shaped unit, see Figure 3(f).
  • the ninth step vacuum electron beam welding is performed on the class II frustum shape unit.
  • the superimposed II-stage frustum-shaped unit blank is subjected to vacuum electron beam sealing welding with a welding depth of 20-50 mm to form a Class II hourglass-shaped module, as shown in Fig. 3(g).
  • the welded II-shaped hourglass-shaped module is heated before forging, and the maximum heating temperature is not lower than 1200 °C.
  • the heated billet is placed on the press table so that the height of the billet is in the vertical direction.
  • the height of the pier is increased in the height direction, and the total height of the blank is reduced by 30-55%.
  • a high temperature diffusion joint is applied to the blank.
  • the billet after the thick pile is sent back to the heating furnace for heating, the heating temperature is not lower than 1200 ° C, and the holding time after the uniform temperature is not less than 12 hours.
  • the blank is then rounded to form a blank, see Figure 3(h).
  • the blank is subjected to upsetting, spheronization and reaming to form a final size of the tube blank, as shown in Fig. 3(i).
  • the eighth to tenth steps in this embodiment can be repeated, and the intermediate blank is formed into a multi-stage hourglass-shaped module and then formed into a blank.
  • the final product of the above embodiment is not limited to a large annular forging or tube blank, but may be processed into other parts or components such as a cubic shaped slab or the like.

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  • Mechanical Engineering (AREA)
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  • Welding Or Cutting Using Electron Beams (AREA)

Abstract

一种模块式金属构筑成形方法，该方法将大型锻件的预制坯依据具体情况分成多级模块分别构筑，最后制成毛坯并加工成部件或零件。该方法的构筑质量更加可靠、可控，各模块锻后可探伤，保证合格后再利用，投料时可投多件，可有效保证工期，该方法可以提高大型金属构筑成形的成材率。

Description

模块式金属构筑成形方法 技术领域
本发明涉及金属材料的制造方法，具体涉及一种模块式金属构筑成形方法。
背景技术
在制备大型金属材料或复合金属材料时，现有方法提出以铸坯、锻坯、轧坯为基元，通过表面加工和清洁后，将多个基元封装在一起，并使界面内部保持高真空状态，然后施加以镦粗变形、锻间保温、多向锻造为特点的锻焊工艺，最终制备大型金属器件。如中国专利申请201511026272.X“同质金属构筑成形方法”、201511027492.4“金属构筑成形方法”、201511027686.4“圆柱体金属构筑成形方法”，均是采用一次构筑成形方法对金属材料进行制造。但是，对于大型锻件(特别是百吨级以上)，一次构筑成形难度极大，对设备的要求高。构筑过程中焊缝一旦失效，将造成整体坯料的全部报废，损失较大。
发明内容
本发明的目的在于针对大型金属的构筑成形，提供一种更加可行、可靠和安全的制造方法。
本发明的技术方案如下：一种模块式金属构筑成形方法，包括如下步骤：
(S1)制备2N个预制坯，N≥2；
(S2)将预制坯在真空室内进行两两焊合，制成2N-1个Ⅰ级模块；
(S3)通过对Ⅰ级模块加热后实施沿高度方向的镦粗变形和锻间保温，制成中间坯料；
(S4)将中间坯料在真空室内进行两两焊合，制成2N-2个Ⅱ级模块，并对Ⅱ级模块加热后实施沿高度方向的镦粗变形和锻间保温；
(S5)如果2N-2＞1，则将步骤(S4)制成的中间坯料在真空室内进行两两焊合，进一步制成多级模块，并对所述多级模块加热后实施沿高度方向的镦粗变形和锻间保温，通过一次或多次重复该步骤，直至制成1个毛坯；
(S6)将毛坯加工成部件或零件。
进一步，如上所述的模块式金属构筑成形方法，其中，所述的Ⅰ级模块、Ⅱ级模块和多级模块均为沙漏形模块。
进一步，如上所述的模块式金属构筑成形方法，步骤(S1)中所述的预制坯由铸坯、锻坯或轧坯基元构筑并封焊、锻造而成；或者由锻坯通过机械加工方式直接制成。
进一步，如上所述的模块式金属构筑成形方法，步骤(S2)中，将所述预制坯制成锥台形状单元，然后将两个锥台形状单元的小面叠放在一起，进行真空电子束焊接，制成Ⅰ级沙漏形模块；步骤(S4)或(S5)中，将所述中间坯料制成锥台形状单元，然后将两个锥台形状单元的小面叠放在一起，进行真空电子束焊接，制成Ⅱ级沙漏形模块或多级沙漏形模块。所述锥台形状单元可以为圆锥台形状或四棱锥台形状，两个锥台形状单元的中间界面处平滑过渡。
进一步，如上所述的模块式金属构筑成形方法，所述真空电子束焊接的焊接深度为20-50mm。
进一步，如上所述的模块式金属构筑成形方法，所述沙漏形模块的高径比在1-3之间。
进一步，如上所述的模块式金属构筑成形方法，步骤(S3)、(S4)和(S5)中对沙漏形模块实施镦粗变形的压下量为坯料总高度的30％-55％。
进一步，如上所述的模块式金属构筑成形方法，步骤(S3)、(S4)和(S5)中将镦粗后的坯料实施高温扩散连接，加热温度不低于1200℃，均温后的保温时间不低于12小时。
进一步，如上所述的模块式金属构筑成形方法，步骤(S6)中对毛坯进行墩粗、冲孔、扩孔、平整形成环形锻件；或者对毛坯进行镦粗保压、滚圆及扩孔形成管坯；或者对毛坯进行镦粗保压、滚圆及镦粗压方形成立方体形状板坯。
本发明的有益效果如下：本发明所提供的模块式金属构筑成形方法，质量更加可靠、可控。各模块锻后可探伤，保证合格后再利用，投料时可投多件，可有效保证工期。沙漏形的构筑坯料可以使镦粗过程的变形集中于界面位置，且避免了表面拉应力的产生，使坯料均匀地受到较大压应力，明显改善坯料表面的拉应力状态。同时，沙漏形坯料最小截面积较小，可以有效降低锻造所需压力。本发明可以提高大型金属构筑成形的成材率，在使用同规格压机的条件下可以大幅提高生产效率，并且解决了大型构筑成形锻件在制造过程中的瓶颈问题，降低了生产成本。
附图说明
图1为本发明模块式金属构筑成形方法的流程图；
图2为本发明实施例1的金属构筑成形方法流程示意图；
图3为本发明实施例2的金属构筑成形方法流程示意图。
具体实施方式
下面结合附图和实施例对本发明进行详细的描述。
如图1所示，从总体工艺过程来描述，本发明提供的模块式金属构筑成形方法，包括：
步骤(1)制备2N个预制坯，N为大于等于2的整数；
步骤(2)多级模块的制备，
(2-1)首先将预制坯在真空室两两焊合，制成2N-1个Ⅰ级模块，
(2-2)然后通过对Ⅰ级模块加热后实施沿高度方向的镦粗变形和锻间保温，制成中间坯料，
(2-3)接下来将中间坯料在真空室内进行两两焊合，制成2N-2个Ⅱ级模块，并对Ⅱ级模块加热后实施沿高度方向的镦粗变形和锻间保温，根据预制坯的数量，该步骤可能要进行多次重复；
步骤(3)将中间坯料制成毛坯；
步骤(4)将毛坯加工成部件或零件。
本发明将预制坯制成的Ⅰ级模块，以及将中间坯料制成的Ⅱ级模块或多级模块都是沙漏形模块，充分利用沙漏形模块的优点，不断的扩大中间坯料的体积和重量，最后再制成毛坯。
本发明所述的预制坯可以由铸坯、锻坯或轧坯基元构筑并封焊、锻造而成(具体的方法可以参见201511026272.X“同质金属构筑成形方法”中的描述)；或者由锻坯通过机械加工方式直接制成。
在毛坯制造过程中，本发明的一个特点是采用了多级模块化的制造工 艺，将大型锻件分成多个模块进行构筑。这种工艺方法在投料时可投多件，能够有效的提高生产效率，保证工期。模块的级数由预制坯的数量来决定，通过将预制坯或中间坯料进行真空室内的两两焊合，形成异形模块，然后对异形模块实施沿高度方向的镦粗变形和锻间保温，多次重复此工艺步骤，最终制成1个毛坯。
本发明的特点另一方面体现在毛坯制造过程中采用的异形模块结构，通过将预制坯制成多级沙漏形模块，沙漏形的构筑坯料可以使镦粗过程的变形集中于界面位置，并且避免表面拉应力的产生，使坯料均匀地受到较大压应力，明显改善坯料表面的拉应力状态。为此，本发明首先要将所述预制坯或中间坯料制成锥台形状单元，锥台形状单元可以通过锻造和/或机械加工的方式制成。然后将两个锥台形状单元的小面叠放在一起，进行真空电子束焊接，制成沙漏形模块。在具体的实施方式中，所述锥台形状单元可以为圆锥台形状或四棱锥台形状(也可以采用其他锥台形状，如六棱锥台、八棱锥台等)。由于沙漏形坯料最小截面积较小，可以有效降低锻造所需压力。但当中间凹陷处较窄时，在锻造过程中会产生褶皱缺陷；中间凹陷处较宽时，降低锻造压力的作用又会被削弱。为此，在对沙漏形坯料进行设计时，应考虑锥台形状单元的纵向梯形截面的下底边与腰边的夹角大小，使之处在一个较为理想的范围。同时，为避免梯形坯料在中间界面处产生折叠，要使其平滑过渡，避免两梯形交界处的尖角产生。两个锥台形状单元的接合是通过真空电子束焊接的方式实现，先对待焊接表面进行加工、清洗，然后在真空室内对待焊合的坯料四周进行真空电子束封焊，真空电子束焊接的焊接深度为20-50mm。焊接后形成的沙漏形模块的高径比在1-3之间。此处所述的高径比是指沙漏形模块的总高度与圆锥台底面直径(或四棱锥台底面边长)的比值。
在毛坯的锻造过程中，首先要对坯料进行加热，最高加热温度不低于1200℃，然后对沙漏形坯料实施沿高度方向的镦粗变形，将加热后的坯料放 在压机操作台上，沿高度方向实施镦粗，镦粗变形的压下量为坯料总高度的30％-55％。接下来，将镦粗后的坯料实施高温扩散连接，将墩粗后的坯料送回加热炉加热，加热温度不低于1200℃，均温后的保温时间不低于12小时。
实施例1
本实施例的目标产品为大型环形锻件。
第一步，采用浇筑的方式获得钢锭，对钢锭进行加热并开坯锻造形成预制坯，预制坯的尺寸为：直径2100mm，高度1500mm，见图2(a)。
第二步，对预制坯进行锻造前加热，最高加热温度不低于1200℃。对预制坯进行模锻，形成I级锥台形状单元，见图2(b)。
第三步，对I级锥台形状单元进行真空电子束焊接。在真空室内，对叠加好的I级锥台形状单元坯料进行真空电子束封焊，焊接深度20-50mm，形成I级沙漏形模块，见图2(c)。
第四步，对焊接好的I级沙漏形模块进行锻造前加热，最高加热温度不低于1200℃。将加热后的坯料放在压机操作台上，使坯料高度方向沿竖直方向。沿高度方向实现墩粗，压下坯料总高度的30-55％。对坯料实施高温扩散连接。将墩粗后的坯料送回加热炉加热，加热温度不低于1200℃，均温后的保温时间不低于12小时。随后对坯料进行滚圆处理，见图2(d)。
第五步，对坯料进行锻造前加热，最高加热温度不低于1200℃。对坯料进行模锻，形成II级锥台形状单元，见图2(e)。
第六步，对II级锥台形状单元进行真空电子束焊接。在真空室内，对叠加好的II级锥台形状单元坯料进行真空电子束封焊，焊接深度20-50mm，形成II级沙漏形模块，见图2(f)。
第七步，对焊接好的II级沙漏形模块进行锻造前加热，最高加热温度不低于1200℃。将加热后的坯料放在压机操作台上，使坯料高度方向沿竖直方向。 沿高度方向实现墩粗，压下坯料总高度的30-55％。对坯料实施高温扩散连接。将墩粗后的坯料送回加热炉加热，加热温度不低于1200℃，均温后的保温时间不低于12小时。随后对坯料进行滚圆处理制成毛坯，见图2(g)。
第八步，将毛坯进行墩粗、冲孔、扩孔、平整。在16米碾环机上将坯料加工成最终尺寸，见图2(h)。
该实施例中第五步至第七步可以重复进行，将中间坯料制成多级沙漏形模块，然后再制成毛坯。
实施例2
本实施例的目标产品为大型管坯。
第一步，将采用连续浇筑方式制成的不锈钢连铸板坯切取成11块规格为1500mm×1500mm×200mm的坯料。对每块连铸坯的6个面进行机械加工、清洗待焊接表面，使其暴露出新鲜的金属表面。
第二步，对坯料进行真空电子束焊接。在真空室内，对叠加好的坯料四周进行真空电子束封焊，焊接深度20-50mm，焊接后的尺寸为：宽度1500mm，长度1500mm，高度为2200mm，见图3(a)。
第三步，对焊接好的坯料进行锻造前加热，最高加热温度不低于1200℃，加热速度要求低于100℃/h。将加热后的坯料放在压机操作台上，使坯料高度方向沿竖直方向。沿高度方向实现墩粗，压下坯料总高度的30-55％。对坯料实施高温扩散连接。将墩粗后的坯料送回加热炉加热，加热温度不低于1200℃，均温后的保温时间不低于12小时。
第四步，对坯料实施三个方向的墩粗，进行倒棱、倒角及机加工处理，形成预制坯，见图3(b)。
第五步，对预制坯进行锻造前加热，最高加热温度不低于1200℃。对预制坯进行模锻，形成I级锥台形状单元，见图3(c)。
第六步，对I级锥台形状单元进行真空电子束焊接。在真空室内，对叠加好的I级锥台形状单元坯料进行真空电子束封焊，焊接深度20-50mm，形成I级沙漏形模块，见图3(d)。
第七步，对焊接好的异形模块进行锻造前加热，最高加热温度不低于1200℃。将加热后的坯料放在压机操作台上，使坯料高度方向沿竖直方向。沿高度方向实现墩粗，压下坯料总高度的30-55％。对坯料实施高温扩散连接。将墩粗后的坯料送回加热炉加热，加热温度不低于1200℃，均温后的保温时间不低于12小时。随后对坯料进行滚圆处理，见图3(e)。
第八步，对坯料进行锻造前加热，最高加热温度不低于1200℃。对坯料进行模锻，形成II级锥台形状单元，见图3(f)。
第九步，对II级锥台形状单元进行真空电子束焊接。在真空室内，对叠加好的II级锥台形状单元坯料进行真空电子束封焊，焊接深度20-50mm，形成II级沙漏形模块，见图3(g)。
第十步，对焊接好的形成II级沙漏形模块进行锻造前加热，最高加热温度不低于1200℃。将加热后的坯料放在压机操作台上，使坯料高度方向沿竖直方向。沿高度方向实现墩粗，压下坯料总高度的30-55％。对坯料实施高温扩散连接。将墩粗后的坯料送回加热炉加热，加热温度不低于1200℃，均温后的保温时间不低于12小时。随后对坯料进行滚圆处理制成毛坯，见图3(h)。
第十一步，将毛坯进行镦粗保压、滚圆及扩孔形成最终尺寸的管坯，见图3(i)。
该实施例中第八步至第十步可以重复进行，将中间坯料制成多级沙漏形模块，然后再制成毛坯。
另外，上述实施例的最终产品不只局限于大型环形锻件或管坯，还可以加工成其它零件或部件，如立方体形状板坯等。
显然，本领域的技术人员可以对本发明进行各种改动和变型而不脱离本发明的精神和范围。这样，倘若对本发明的这些修改和变型属于本发明权利要求及其同等技术的范围之内，则本发明也意图包含这些改动和变型在内。

Claims (10)

  1. 一种模块式金属构筑成形方法，包括如下步骤：
    (S1)制备2N个预制坯，N≥2；
    (S2)将预制坯在真空室内进行两两焊合，制成2N-1个Ⅰ级模块；
    (S3)通过对Ⅰ级模块加热后实施沿高度方向的镦粗变形和锻间保温，制成中间坯料；
    (S4)将中间坯料在真空室内进行两两焊合，制成2N-2个Ⅱ级模块，并对Ⅱ级模块加热后实施沿高度方向的镦粗变形和锻间保温；
    (S5)如果2N-2＞1，则将步骤(S4)制成的中间坯料在真空室内进行两两焊合，进一步制成多级模块，并对所述多级模块加热后实施沿高度方向的镦粗变形和锻间保温，通过一次或多次重复该步骤，直至制成1个毛坯；
    (S6)将毛坯加工成部件或零件。
  2. 如权利要求1所述的模块式金属构筑成形方法，其特征在于：所述的Ⅰ级模块、Ⅱ级模块和多级模块均为沙漏形模块。
  3. 如权利要求1或2所述的模块式金属构筑成形方法，其特征在于：步骤(S1)中所述的预制坯由铸坯、锻坯或轧坯基元构筑并封焊、锻造而成；或者由锻坯通过机械加工方式直接制成。
  4. 如权利要求2所述的模块式金属构筑成形方法，其特征在于：步骤(S2)中，将所述预制坯制成锥台形状单元，然后将两个锥台形状单元的小面叠放在一起，进行真空电子束焊接，制成Ⅰ级沙漏形模块；步骤(S4)或(S5)中，将所述中间坯料制成锥台形状单元，然后将两个锥台形状单元的小面叠放在一起，进行真空电子束焊接，制成Ⅱ级沙漏形模块或多级沙漏形 模块。
  5. 如权利要求4所述的模块式金属构筑成形方法，其特征在于：所述锥台形状单元可以为圆锥台形状或四棱锥台形状，两个锥台形状单元的中间界面处平滑过渡。
  6. 如权利要求4所述的模块式金属构筑成形方法，其特征在于：所述真空电子束焊接的焊接深度为20-50mm。
  7. 如权利要求2所述的模块式金属构筑成形方法，其特征在于：所述沙漏形模块的高径比在1-3之间。
  8. 如权利要求2或7所述的模块式金属构筑成形方法，其特征在于：步骤(S3)、(S4)和(S5)中对沙漏形模块实施镦粗变形的压下量为坯料总高度的30％-55％。
  9. 如权利要求1或2所述的模块式金属构筑成形方法，其特征在于：步骤(S3)、(S4)和(S5)中将镦粗后的坯料实施高温扩散连接，加热温度不低于1200℃，均温后的保温时间不低于12小时。
  10. 如权利要求1或2所述的模块式金属构筑成形方法，其特征在于：步骤(S6)中对毛坯进行墩粗、冲孔、扩孔、平整形成环形锻件；或者对毛坯进行镦粗保压、滚圆及扩孔形成管坯；或者对毛坯进行镦粗保压、滚圆及镦粗压方形成立方体形状板坯。
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