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大尺寸铝合金火箭贮箱拉拔式摩擦塞补焊工艺及接头质量评价

Friction pull plug welding process and joint quality evaluation for large-scale aluminum alloy rocket tanks

  • 摘要: 为满足火箭贮箱制造与服役过程中的高质量补焊需求,提出了一种面向火箭贮箱的拉拔式摩擦塞补焊(friction pull plug welding, FPPW)实施方案,主要涵盖缺陷定位、机头姿态调整、缺陷去除和原位补焊等环节. 通过无损检测、气密性检测、组织观察和力学性能测试,验证了补焊接头质量.结果表明,该方案可实现高质量塞孔加工和稳定补焊成形,接头宏观形貌良好,无裂纹、未焊合和孔洞等缺陷,气密性检测结果满足贮箱检漏要求.接头内部形成不同微观组织区域,动态再结晶消除了塞棒与贮箱材料之间的原始界面,并实现冶金结合.拉伸结果显示,接头抗拉强度达到322.2 MPa,相对于2219-T6塞棒材料的接头系数为0.80,断后伸长率为8.2%. 断口形貌呈韧窝特征,断裂模式以韧性断裂为主. 该研究可为FPPW技术在火箭贮箱补焊中的工程应用提供参考.

     

    Abstract: To meet the demand for high-quality repair welding during the manufacturing and service of rocket tanks, an implementation scheme for friction pull plug welding (FPPW) of rocket tanks was proposed. This scheme mainly covered defect localization, welding head attitude adjustment, defect removal, and in-situ repair welding. The quality of the repaired joint was verified by nondestructive testing, leak-tightness testing, microstructural observation, and mechanical property testing. The results show that the scheme can achieve high-quality plug hole machining and stable repair welding formation. The joint exhibits sound macroscopic morphology without defects such as cracks, lack of fusion, and pores, and its leak-tightness testing results meet the leak detection requirements of tanks. Different microstructural regions are formed within the joint, and dynamic recrystallization eliminates the original interface between the plug and the tank materials, realizing metallurgical bonding. The tensile results show that the joint achieves an ultimate tensile strength of 322.2 MPa, a joint efficiency of 0.80 relative to the 2219-T6 plug material, and an elongation after fracture of 8.2%. The fracture surface shows dimple features, and the fracture mode is mainly ductile fracture. This study can provide a reference for the engineering application of the FPPW technology in the repair welding of rocket tanks.

     

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