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基于有限元分析的异种高温合金电子束焊液化裂纹抑制方法

Suppression method of liquefaction crack in electron beam welding of dissimilar superalloy based on finite element analysis

  • 摘要: 为了解决Mar-M247/GH4169异种高温合金电子束焊接头易产生液化裂纹的技术难题,开展了针对性的有限元分析与试验验证. 采用有限元模拟与试验验证相结合的方法,通过分析当前主流裂纹形成机制,提出敏感温度区间等效应力增量(SSTRESI)的概念评价异种高温合金电子束焊接头液化裂纹敏感性,与实际裂纹情况对比验证了SSTRESI的准确性,并借助有限元模型阐明了液化裂纹的有效抑制策略,即束流偏移和预热这两种方法可有效降低高温合金热影响区裂化裂纹敏感性. 结果表明,SSTRESI极值出现在Mar-M247侧热影响区中心区域,其值约为428 MPa,实际的液化裂纹也出现在该位置;而通过束流偏移和预热也有效降低SSTRESI极值降低液化裂纹敏感性. 当偏移量为0.5 mm时,SSTRESI极值降低至400 MPa;当偏移量为1 mm时降低至355 MPa;当偏移量为1.5 mm时SSTRESI极值区域消失. 当预热温度增加至200 ℃时,SSTRESI极值降低至352 MPa;当预热温度增加至600 ℃后SSTRESI极值范围消失;当束流向GH4169侧偏移1.5 mm与预热600 ℃时,可以有效避免Mar-M247侧热影响区中心区域产生液化裂纹. 束流偏移是通过降低两侧热影响区的热变形量差异,平衡了焊接接头两侧的应力状态,从而降低了Mar-M247侧SSTRESI极值,避免了液化裂纹的产生.

     

    Abstract: To address the technical challenge of liquefaction cracking in the electronic beam welded joint of the Mar-M247/GH4169 superalloy, targeted finite element analysis and experimental validation were conducted. This study employed a combined approach of finite element simulation and experimental validation. Specifically, by analyzing prevailing crack formation mechanisms, the concept of sensitivity temperature range equivalent stress increment (SSTRESI) was proposed to evaluate the liquefaction crack sensitivity of electronic beam welded joints in dissimilar high-temperature alloys. The accuracy of SSTRESI was validated through comparative analysis with actual crack conditions. A finite element model was utilized to elucidate effective suppression strategies for liquefaction cracks, demonstrating that beam offset and preheating methods can significantly reduce cracking sensitivity in the heat-affected zone of high-temperature alloys. Research findings indicate that the SSTRESI peak occurs at approximately 428 MPa in the central region of the side heat-affected zone of Mar-M247, which also corresponds to the location of observed liquefaction cracks. Both beam offset and preheating effectively mitigate the SSTRESI peak to reduce liquefaction crack sensitivity. When the offset is 0.5 mm, the SSTRESI peak decreases to 400 MPa; at 1 mm, it drops to 355 MPa; and at 1.5 mm, the SSTRESI peak region disappears. Increasing the preheating temperature to 200 ℃ reduces the SSTRESI peak to 352 MPa, while exceeding 600 ℃ completely eliminates the SSTRESI peak range. When the beam is offset by 1.5 mm from the GH4169 side and preheated to 600 ℃, it effectively prevents liquefaction cracks from forming in the central region of the side heat-affected zone of Mar-M247. The beam offset reduces the thermal deformation difference between the two sides of the heat-affected zone, balancing the stress states on both sides of the welded joint. This lowers the SSTRESI (side stress) extremum of Mar-M247 and thus avoids the occurrence of liquefaction cracks.

     

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