基于材料基因组理念的钎焊材料开发与智能钎焊技术创新系统工程
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摘要
近年来,依赖于科学直觉与试错的传统材料研究方法日渐成为制造业发展与技术进步的瓶颈。革新材料研发方法已成为国际新材料研发的趋势。材料基因组技术是材料科学技术的一次飞跃,是新材料研发的"加速器"。钎焊过程的复杂性和随机性使得钎焊材料的设计开发相比普通材料更加复杂、研发周期更长,"材料基因组计划"作为先进材料开发的崭新模式也应及时应用到钎焊材料性能优化及开发中,这对促进钎焊技术尤其是智能钎焊的长足发展具有重要意义。材料基因组技术包括高通量材料计算、高通量材料实验和材料数据库三个要素。大规模的高通量计算可提供大量而系统的数据,高通量实验方法可对这些数据进行快速验证,材料数据库的建立则可实现计算数据与实验数据的有效集成,使其相互补充的同时相互验证。三要素协同工作,可以使得材料研发过程中的理论与实验结合更加紧密,加快材料从研发、制造到应用的过程,降低新材料的开发成本。开发新型钎焊材料除考虑材料本身的性能外,还需要考虑钎焊材料与母材物理化学性能的匹配性以及连接过程中钎焊材料与母材之间的相互作用(扩散和新相形成)。钎焊材料与母材之间的相互作用非常复杂,除了受到连接工艺(连接温度、保温时间、压力、气氛等)的影响之外,还与钎料和母材的成分有直接关系。因此,相比于普通材料,钎焊材料的设计开发过程更加复杂,需要考虑的因素更多,新材料的研发周期更长,有必要尽快启动钎焊材料基因工程。开发高通量计算软件、高通量实验方法(高通量制备及表征)及数据集成系统是实施钎焊材料基因工程需解决的三个基础问题。目前焊接智能化的发展多集中在熔化焊领域,如弧焊、激光焊等,也取得了比较显著的成果。但是,钎焊全过程智能控制的发展相对缓慢,现有研究多集中在钎焊设备及钎焊过程控制方面。钎焊材料制备是智能钎焊的重要组成部分,钎焊材料基因工程的实施将促进钎焊技术的智能化进程。智能焊接尤其是智能钎焊的技术进步可大大简化和缩短新型钎料的试验验证过程,同时能够在过程中搜集到更多实时数据,丰富数据库,因而反过来又会对钎焊材料基因工程的发展起到显著的推动作用。本文论述了材料基因组技术的三要素及其国内外研究现状,分析了材料基因组技术应用于钎焊材料开发时需考虑的影响因素及需解决的关键共性基础问题,并且阐述了钎料材料基因工程与智能钎焊相互促进的发展关系。
In recent years,the conventional material research methodologies depending on scientific intuition and trial and error have been increasingly regarded as the bottleneck for development and technological advance of manufacturing industry. Then,the innovation on material research methodology has become the international new trend of materials research and development. Materials genome technology is considered as a giant leap of materials S&T and the accelerator of new material development. The complexity and randomicity of brazing process make the design and development of brazing materials more complicated and time-consuming than ordinary materials. Materials genome initiative,as a brand new concept for advanced materials development,should also be adopted to the performance optimization and development of new brazing materials.This is of great significance to promote the rapid development of welding technology,especially intelligent welding.The three main facets of materials genome technology are high-throughput material computation,high-throughput material experimentation and material basic data. Large-scale high-throughput computation can provide abundant and systematic data. High-throughput material experimentation can quickly verify these data. Moreover,the establishment of the material database can realize( i) the effective integration of calculated data with experimental data,and( ii) their mutual complementation and mutual verification. These three elements work together and then contribute to a more close relationship between theoretical and experimental research in the process of material development. This can shorten the period of research,manufacturing and application,and reduces the development cost of new materials.In addition to the performance of material itself,developing new brazing materials also need to consider( i) physical and chemical compatibility of brazing materials and base materials,( ii) interaction( diffusion and formation of new phase) between brazing materials and base materials during brazing process. The interaction between brazing materials and base materials is very complex,as it not only depends on the brazing process( temperature,holding time,pressure,atmosphere,etc.),but is directly related to the composition of brazes and base materials. Therefore,compared with ordinary materials,the design and development of brazing materials require a more complicated methodology and a more time-consuming course. And the initiation of brazing materials genome project is of great urgency. This relies to a considerable degree on the satisfactory achievement towards three essential engineering issues,i.e. development of high-throughput computing software,high-throughput experimental methodologies and data integration system.The development of intelligent welding at present has focused mostly on fusion welding,e.g. arc welding,laser welding,etc.,and has also acquired notable achievements. However,the full-intelligent control technology for brazing still lies at a fairly primitive level,and the current researches concentrate mainly on brazing equipment and brazing process control. The brazing materials play an important role in intelligent brazing. So the brazing materials genome project can facilitate the intelligentization of brazing technology. In return,the advancement of intelligent brazing will also advance the course of brazing materials genome project,as it will greatly simplify and accelerate the performance examination upon new designed brazes,and in addition,it will help to collect more real-time data for the numerous artificially created brazes.This paper discusses the three basic elements of materials genome technology and the corresponding global research status. It also analyzesthe influence factors and key common problems for the adoption of materials genome technology to brazing materials development,and states dialectically the mutually reinforcing relationship between brazes genome project and intelligent brazing technology.
In recent years,the conventional material research methodologies depending on scientific intuition and trial and error have been increasingly regarded as the bottleneck for development and technological advance of manufacturing industry. Then,the innovation on material research methodology has become the international new trend of materials research and development. Materials genome technology is considered as a giant leap of materials S&T and the accelerator of new material development. The complexity and randomicity of brazing process make the design and development of brazing materials more complicated and time-consuming than ordinary materials. Materials genome initiative,as a brand new concept for advanced materials development,should also be adopted to the performance optimization and development of new brazing materials.This is of great significance to promote the rapid development of welding technology,especially intelligent welding.The three main facets of materials genome technology are high-throughput material computation,high-throughput material experimentation and material basic data. Large-scale high-throughput computation can provide abundant and systematic data. High-throughput material experimentation can quickly verify these data. Moreover,the establishment of the material database can realize( i) the effective integration of calculated data with experimental data,and( ii) their mutual complementation and mutual verification. These three elements work together and then contribute to a more close relationship between theoretical and experimental research in the process of material development. This can shorten the period of research,manufacturing and application,and reduces the development cost of new materials.In addition to the performance of material itself,developing new brazing materials also need to consider( i) physical and chemical compatibility of brazing materials and base materials,( ii) interaction( diffusion and formation of new phase) between brazing materials and base materials during brazing process. The interaction between brazing materials and base materials is very complex,as it not only depends on the brazing process( temperature,holding time,pressure,atmosphere,etc.),but is directly related to the composition of brazes and base materials. Therefore,compared with ordinary materials,the design and development of brazing materials require a more complicated methodology and a more time-consuming course. And the initiation of brazing materials genome project is of great urgency. This relies to a considerable degree on the satisfactory achievement towards three essential engineering issues,i.e. development of high-throughput computing software,high-throughput experimental methodologies and data integration system.The development of intelligent welding at present has focused mostly on fusion welding,e.g. arc welding,laser welding,etc.,and has also acquired notable achievements. However,the full-intelligent control technology for brazing still lies at a fairly primitive level,and the current researches concentrate mainly on brazing equipment and brazing process control. The brazing materials play an important role in intelligent brazing. So the brazing materials genome project can facilitate the intelligentization of brazing technology. In return,the advancement of intelligent brazing will also advance the course of brazing materials genome project,as it will greatly simplify and accelerate the performance examination upon new designed brazes,and in addition,it will help to collect more real-time data for the numerous artificially created brazes.This paper discusses the three basic elements of materials genome technology and the corresponding global research status. It also analyzesthe influence factors and key common problems for the adoption of materials genome technology to brazing materials development,and states dialectically the mutually reinforcing relationship between brazes genome project and intelligent brazing technology.
引文
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3 Fan X L.Materials China,2015,34(9),689(in Chinese).范晓丽.中国材料进展,2015,34(9),689.
4 Shen Z C,Dai W,Ma Z L.Spaceraft Environment Engineering,2017,34(3),324(in Chinese).沈自才,代巍,马子良.航天器环境工程,2017,34(3),324.
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12 Lin P P,Lin T S,He P,et al.Ceramics International,2017,43,13530.
13 He Y M,Zhang J,Wang X,et al.Journal of Materials Science,2010,46(8),2796.
14 Yang M,Lin T,He P.Ceramics International,2012,38(1),289.
15 Yang W Q,Lin T S,He P,et al.Journal of the American Ceramic Society,2013,96(12),3712.
16 Zhang G J,Li Y Z.Aeronautical Manufacturing Technology,2016(11),28(in Chinese).张广军,李永哲.航空制造技术,2016(11),28.
17 Chen S B,Lyu N.Electric Welding Machine,2013,43(5),28(in Chinese).陈善本,吕娜.电焊机,2013,43(5),28.
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