大型复杂高精度波导钎焊设备的研制：简介ZHS—132型真空钎焊炉

应军事电子装备，特别是军用雷达预研和生产的急需，电子工业部第二研究所近期研制的成功大型、复杂、高精度波导钎焊设备ＺＨＳ－１３２型真空钎焊炉。文中主要介绍了该设备的开发背景和对波导钎焊工艺的影响，该设备的设计构思、结构和技术特征，使用功能和效果，以及推广应用前景。     

Silicon doped carbon/Cu joints based on amorphous alloy brazing for first wall application

Amorphous ribbon-type filler-metals represent a promising selection for joining heterogeneous materials together. In this work, rapidly solidified ribbon-type Ti based amorphous filler with a melting temperature of 850 °C and a thickness up to 20 μm is used to join silicon doped carbon to pure copper. SEM examinations demonstrate that a high quality brazed joints could be acquired. The brazed seam has a uniform structure and pore free along its entire length. TiC and ZrC are formed near the interface of carbon and filler-metal when the brazing holds enough time. Using very thin Mo and Cu foil (0.2 mm in thickness) as multiple interlayer are very effective to mitigate the thermal stress occurred in the interface between carbon and copper. The shear strength of this carbon-multiple interlayer-copper joint is more than 20 MPa, and the rupture is mainly occurred on the carbon side.     

电机转子线圈焊接工艺及设备研究

本文就电机转子线圈采用电阻钎焊的可行性进行了论述,并就几种焊接方法的接头性能进行了分析对比,同时还阐述了电机转子线圈电阻钎焊机的结构原理。     

Brazing temperature-dependent interfacial reaction layer features between CBN and Cu-Sn-Ti active filler metal

CBN/Cu-Sn-Ti (CBN: cubic boron nitride) composites are prepared by active brazing sintering at 1123 K, 1173 K, 1223 K and 1273 K, respectively. The effects of brazing temperature on the wettability, interfacial characteristics, and elemental distribution variations are fully investigated. When the brazing temperature is below 1223 K, completely uncoated and/or partially coated CBN particles with sharp edges can still be observed, and the reaction layer, mainly composed of TiN and TiB2, appears to be thin and uneven. When the brazing temperature is 1223 K, all CBN particles are completely coated, suggesting that adequate wetting has taken place. Besides, as Ti diffuses thoroughly and enriches the interface, the reaction layer, filled primarily by TiN, TiB₂ and TiB, becomes thicker (about 1.30 μm), more uniform, stable and continuous. Further increasing the temperature to 1273 K is unnecessary or even harmful as the reaction layer thickness undergoes negligible change yet some tiny micro-cracks appear on the interface, which may likely deteriorate the grinding capability of the final brazing products.     

Ni-Cr合金真空钎焊金刚石界面微结构分析

钎焊单层超硬磨料砂轮极高的结合强度和接近理想的锋利形貌 ,使它在生产应用中显示出传统砂轮无法比拟的优异性能。这种新型超硬磨料砂轮以其卓越的磨削性能必将逐步取代传统单层电镀砂轮。本文在真空炉中用钎焊的方法 ,用Ni Cr合金钎料 ,适当控制钎焊温度、保温时间和冷却速度 ,实现了金刚石与钢基体的高强度连接。并用深腐蚀的方法处理钎焊后的试样 ,用扫描电镜、X 射线能谱仪 ,结合X 射线衍射结构分析 ,对金刚石与钎料界面微区结构进行了分析。结果表明 :在钎焊过程中 ,钎料会在金刚石界面形成富铬层并与金刚石表面的C元素反应生成Cr7C3 和Cr3 C2 ,其中Cr7C3 呈笋状生长 ,Cr3 C2 呈片状生长。Ni Cr合金与金刚石的冶金结合 ,是实现金刚石和钢基体有高结合强度的主要因素。最后通过磨削对比实验确证了金刚石与钎料有较高的结合强度     

Effects of boron and silicon on microstructure and isothermal solidification during TLP bonding of a duplex stainless steel using two Ni–Si–B insert alloys

Abstract

The influence of B and Si on microstructure and isothermal solidification during transient liquid phase (TLP) bonding of a duplex stainless steel using MBF-30 (Ni–4·5Si–3·2B, wt-%) and MBF-35 (Ni–7·3Si–2·2B, wt-%), was investigated. Based on experimental studies, the formation of Ni₃B within the joint centreline is dependent on B content; the morphology of Ni₃Si is dominated by Si concentration. There was a deviation between the times for complete isothermal solidification obtained by the experiment and the conventional TLP bonding model. Isothermal solidification of the liquid dependent on different solidification regimes is suggested to be a controlling factor contributing to the change in the rate of isothermal solidification observed using the two filler metals.     

Fluxless arc weld-brazing of aluminium alloy to steel

In this work, joining of aluminium alloy AA6061-T6 to Interstitial Free steel using pulsed gas metal arc welding process has been attempted. The effect of different surface conditions of steel (viz, galvanized, galvanealed and uncoated) and gap between the sheets on braze joint formation have been investigated. Galvanized steel surface showed good bead width, joint formation and lap shear strength compared to the other two combinations. Interface gap has not affected the wetting behaviour significantly but presence of a gap of 300 μm or so helped in escape of zinc vapour during the process there by avoiding formation of any crevice or macroporosity in the joint. Features and properties of the joint are characterized by metallography, fractography, energy dispersive spectroscopy (EDS) and lap shear tests. Load carrying capacity of Al-Galvanized steel was highest (222 N/mm of seam length) compared to other combinations, aided by better wetting due to presence of Zn on the surface and minimum porosity due to interfacial gap provided during brazing.     

大间隙钎焊在燃气轮机热端部件修复领域的应用和发展

综述了钎焊修复技术在燃气轮机高温部件修复领域的研究进展,介绍了国内外一些先进的大间隙钎焊技术(WGB)修复方法,深入分析了不同修复方法的特点。探讨了WGB修复技术存在的一些问题并对未来的发展进行展望。     

基于带可变遗忘因子的GA和RLS的气体保护钎焊炉温度优化

在钎焊生产中,钎焊炉第三阶段加热温度具有大时滞和强时变特点,钎焊温度控制困难.为了优化钎焊温度,必须建立钎焊温度模型并对其进行优化.基于带可变遗忘因子的递推最小二乘法(RLS)研究了一阶时滞温度模型的在线参数辨识,得到了该模型的参数和延迟时间.基于遗传算法(GA),研究了温度目标函数的PID参数优化.结果表明:应用优化的目标函数可使得超调量、静态误差和上升时间等得到很好的控制.     

Microstructural evolution during the brazing of Al2O3 ceramic to kovar alloy by sputtering Ti/Mo films on the ceramic surface

Alumina (Al₂O₃) ceramics were metallized by magnetron sputtering Ti/Mo bilayer films on the surface with a subsequent high temperature sintering and were brazed to Kovar alloy (Fe-Ni-Co) using Ag-Cu eutectic alloy. The Ti/Mo metallization film and the brazing seam microstructures were investigated and the correlation between the Al₂O₃/Kovar joining strength and the microstructures of the brazing seam was discussed. The results show that the joining strength is related to the thickness of the Ti/Mo adhension layer which depends on the holding time during brazing. The mutual diffusion of the elements at the interface firstly increases the thickness of the adhension layer as the holding time increases and the Mo film acts as a barrier layer to block the diffusion of Ti atoms into the seam. The optimal brazing joining strength of 72.6±5.0 MPa could be achieved at a brazing temperature of 810 °C for 14 min However, if the holding time is further prolonged, Mo atoms will diffuse into the (Ni, Cu) solid solution, resulting in the diffusion of Ti atoms and the adhension layer becoming indistinguishable. Therefore, the intermetallic Ni₃Ti forms in the seam and the titanium oxide changes from TiO to Ti₂O₃ or Ti₃O₅, which leads to the joint strength decreasing.