超高强度钢整体模锻全过程微观组织演化及数字化表征
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摘要
随着现代航空制造技术水平的不断发展,越来越多地采用大型复杂整体模锻件制造飞机的关键承力件,以满足飞机不断提高的服役性能指标要求。高合金超高强度钢已成为当今世界用于制造飞机起落架构件的新型材料,其强度性能指标达到1930MPa,晶粒度达到8级(22.5μm),以满足飞机在复杂、重载等极端服役条件下的使用需要。然而,超高强度钢整体模锻件的热加工经历了材料热塑性成形、热处理等多个物理过程,材料微观组织演化机制十分复杂,尤其对于能满足极端服役要求的大型复杂整体起落架模锻件,其晶粒度指标与性能均匀性要求给锻造生产提出了新的挑战。我国在生产大型整体超高强度钢模锻件方面的技术储备与基础研究不足,晶粒度不达标、工艺稳定性差已成为制约我国高性能航空锻件制造的主要瓶颈。本文针对目前我国起落架锻件生产存在的问题,以新一代高合金超高强度钢23Co13Ni11Cr3Mo为对象,系统研究了该材料在加热、热塑性成形、冷却以及热处理等热加工全过程微观组织结构与力学性能演化规律及其数字化表征方法,进一步研究了超高强度钢起落架整体模锻成形过程微观组织演化规律,提出了在800MN巨型液压机上起落架成形新工艺以及获得锻件高性能指标的锻造工艺参数,完成的主要工作与研究成果如下：
1)开展了超高强度钢23Co13Ni11Cr3Mo等温压缩热模拟实验,研究了热变形过程超高强度钢的高温塑性流变特性与组织演化规律,建立了23Co13Ni11Cr3Mo钢动态再结晶动力学模型与晶粒尺寸模型,提出了采用逐次逼近法建立超高强度钢变形抗力模型的新思路,确定了23Co13Ni11Cr3Mo钢动态再结晶临界应变条件与变形激活能。基于热模拟流变应力实验数据与塑性失稳准则建立了23Co13Ni11Cr3Mo钢材料热加工图,获得了材料稳定高效变形的热加工可行域。研究结果表明,在热加工可行域内增大应变可提高再结晶体积分数,获得均匀细小的晶粒组织。
2)根据大型整体模锻件热塑性成形过程复杂的组织演化机制、时变的宏观物理场等特征,建立了基于位错驱动力的介观组织演化元胞自动机(CA)模型,提出了组织演化的参数辨识方法；建立了加工硬化指数、二相粒子钉扎效应与宏观变形参数的函数关系,实现了锻件的热塑性成形过程宏观-介观晶粒组织模拟；根据实际热加工特性提出了一系列介观组织CA改进算法,基于DEFORM-3D、QFORM等宏观有限元仿真平台,开发了具有自主知识产权的微观组织可视化模拟机软件。实验结果表明,本文提出的CA模型与分析软件可预测晶粒组织形貌、分布规律以及多轮次动态再结晶的晶粒组织动态演化。
3)针对大型整体模锻件在转移、等待、冷却及热处理等静置过程易出现晶粒粗化的现象,开展了23Co13Ni11Cr3Mo钢高温静置过程组织演化规律的实验研究,建立了晶粒长大模型、亚动态再结晶及静态再结晶动力学和晶粒尺寸模型,实现了23Co13Ni11Cr3Mo钢热加工全过程微观组织演化数字化表征。研究结果表明,晶粒细化取决于终锻变形及其冷却过程晶粒组织演变；静态再结晶晶粒组织与亚动态再结晶、动态再结晶组织相比更为粗大,是造成23Co13Ni11Cr3Mo钢起落架锻件晶粒度不达标的主要原因。
4)开展了工业条件下的23Co13Ni11Cr3Mo钢锻造工艺实验,研究了热变形工艺参数对晶粒组织演化、力学性能的影响,获得了满足最终组织性能要求的锻造工艺条件,可实现锻件在热加工全过程中的晶粒组织调控。研究结果表明,锻造晶粒尺寸与热处理晶粒尺寸呈正比关系,锻造晶粒组织需超过8级才能获得8级最终晶粒组织；锻造工艺参数对锻件的力学性能影响较小,在变形温度为980～1140℃、变形程度为12～30%的范围内,强度指标差异为3.5%,断裂韧性KIC差异为8.7%。
5)对现有整体模锻工艺条件下23Co13Ni11Cr3Mo钢起落架模锻件进行了解剖分析,锻件不同位置的微观组织分析和力学性能参数测试表明,采用整体模锻工艺可将锻件断裂韧性提高20.5%,但晶粒度仅为5～6.5级。23Co13Ni11Cr3Mo冈起落架锻件热加工全过程组织演化模拟与实验研究发现,锻件变形不充分、不连续变形引发的静态再结晶、晶粒长大是造成晶粒粗大及工艺稳定性差的主要原因,低温、高速率、大变形条件有利于获得细小晶粒组织锻件,提出了起落架锻件在800MN巨型液压机上起落架成形新工艺,终锻变形量提高至33.7%可抑制静态再结晶发生,晶粒组织演化机制转变为亚动态再结晶,晶粒显著细化。图105幅,表19个,参考文献190篇。
With the continuous development of modern aviation manufacturing technology, more and more overall die forgings with large size and complex shape are applied for load-bearing structures of aircraft to meeting the extreme mechanical properties. For this goal, high-alloy ultra-high strength steel, which has strength of1930Mpa and grain size of22.5μm (level8), has been developed to manufacture aircraft landing gear. However, the high requirements of grain size and its homogeneity bring big challenge to the overall die forging process, especially for large-sized landing gear. Because, material goes through heating, deformation and heat treatment during the whole forming process, and its microstructure evolution mechanism is very complicated. Meanwhile, China is lack of basic research and technical reserve in the field of overall die forging. Now, grain dissatisfaction and instability of deformation have become the main problem for obtaining high quality aircraft forgings. In this paper, a series of research work were done on newly developed ultra-high strength steel23Co13Ni11Cr3Mo for solving the problem listed above. The evolution of microstructure and mechanical properties during the whole hot forming process, including heating, deformation, cooling and heat treatment, were studied. And, the corresponding models were developed. Then, microstructure evolution of landing gear during the overall die forging process was investigated. Based on these research works, a new forging process on800MN hydraulic press with high stability and efficiency was proposed, and deformation parameters for high quality forgings were acquired. The main conclusions are listed as following:
(1) Isothermal compression tests of23Co13Ni11Cr3Mo steel were carried out. Deformation behaviors during high temperature and microstructure evolution rules were studied. Dynamic recrystallization models, including recrystallized fraction and grain size, were developed. A new approach for establishing the model of flow stress was developed, wihch is successive approximation method. Consequently, the deformation active energy and critical strain conditions of dynamic recystallization were obtained. Then, hot processing map for 23Co13Ni11Cr3Mo steel was developed on the basis of experimental flow stress and deformation instability rules. Hot deformation zone with high stability and efficiency was recognized through processing map. The results show that in this zone the degree of dynamic recrystallization is increased by increasing deformation degree, and small even grain is achieved.
(2) The overall die forging process of large-size products was characterized for complex microstructure evolution mechanism and varied physical fields. For this reason, cellular automaton(CA) model based on dislocation density was developed to describe grain evolution. During this process, the identification method on the basis of optimization theory was proposed for acquiring parameters of microstructure evolution. The relationships between macroscopic deformation parameters and hardening exponent, two-phase particle pinning effect were developed. Through these measures, the microstructure evolution through macroscopic and mesoscopic was realized. According to the actual forging processing characteristics, a series of CA improving algorithm were developed. Moreover, a software for visualized microstructure simulation was developed coupled with FEM platform, such as DEFORM and QFORM. The experimental results show the proposed CA model and developed software can predict grain shape, distribution and its evolution rule during multiple dynamic recrystallization very well.
(3) For large-sized forgings, its grain is easily to becoming coarse during static process of transferring, waiting, cooling and heat treatment. Therefore, microstructure evolution of ultra-high strength steel with high temperature during static processes was studied by experimental methods. Models of static behaviors, such as grain growth, meta-dymamic and static recrystallization were established, by which microstructure evolution during the whole deformation process can be expressed quantitatively. The results show that grain refinement is determined by the final forging process and its following cooling process. Grain size of static recrystallization is larger than that of meta-dynamic and dynamic recrystallization, which is the main reason for grain dissatisfaction of landing gear forging.
(4) Experimental forging of ultra-high strength steel was carried out on the industrial conditions. Influences of deformation parameters on grain evolution and mechanical properties were investigated. Consequently, deformation conditions which could fulfill the demands of grain and mechanical properties were reached, and grain evolution during the whole forming process could be controlled. The results show that a proportional relationship exists between forging grain size and heat treatment grain size, forging grain size should reach level8for the final grain size of level8. Deformation paramaters has little effects on mechanical properties. Under a deformation temperature of980-1140℃, strain of12-30%, the variation of strength is3.5%, and the variation of KIC is8.7%.
(5) Landing gear under the existing overall die forging process was dissectted and analyzed. The results of microstructure and mechnical properties show KIC can be improved about20.5%by applying overall die forging process. However, grain size can only reach level5-6.5. Microstructure simulation and experimental research during the whole hot forming process of landing gear show that the static recrystallization and grain growth caused by insufficient and discontinous deformation are the main reason for coarse grain and instable deforamtion. Lower temperature, higher strain rate and larger defromation degree lead to smaller grain size. So, a new forging process on800MN hydraulic press with high stability and efficiency was proposed. With the deformation degree of the final forging process increasing to33.7%, static recrystallization can be restrained, and grain evolution mechanism changes to meta-dynamic recrystallization, grain is refined greatly.
1)开展了超高强度钢23Co13Ni11Cr3Mo等温压缩热模拟实验,研究了热变形过程超高强度钢的高温塑性流变特性与组织演化规律,建立了23Co13Ni11Cr3Mo钢动态再结晶动力学模型与晶粒尺寸模型,提出了采用逐次逼近法建立超高强度钢变形抗力模型的新思路,确定了23Co13Ni11Cr3Mo钢动态再结晶临界应变条件与变形激活能。基于热模拟流变应力实验数据与塑性失稳准则建立了23Co13Ni11Cr3Mo钢材料热加工图,获得了材料稳定高效变形的热加工可行域。研究结果表明,在热加工可行域内增大应变可提高再结晶体积分数,获得均匀细小的晶粒组织。
2)根据大型整体模锻件热塑性成形过程复杂的组织演化机制、时变的宏观物理场等特征,建立了基于位错驱动力的介观组织演化元胞自动机(CA)模型,提出了组织演化的参数辨识方法；建立了加工硬化指数、二相粒子钉扎效应与宏观变形参数的函数关系,实现了锻件的热塑性成形过程宏观-介观晶粒组织模拟；根据实际热加工特性提出了一系列介观组织CA改进算法,基于DEFORM-3D、QFORM等宏观有限元仿真平台,开发了具有自主知识产权的微观组织可视化模拟机软件。实验结果表明,本文提出的CA模型与分析软件可预测晶粒组织形貌、分布规律以及多轮次动态再结晶的晶粒组织动态演化。
3)针对大型整体模锻件在转移、等待、冷却及热处理等静置过程易出现晶粒粗化的现象,开展了23Co13Ni11Cr3Mo钢高温静置过程组织演化规律的实验研究,建立了晶粒长大模型、亚动态再结晶及静态再结晶动力学和晶粒尺寸模型,实现了23Co13Ni11Cr3Mo钢热加工全过程微观组织演化数字化表征。研究结果表明,晶粒细化取决于终锻变形及其冷却过程晶粒组织演变；静态再结晶晶粒组织与亚动态再结晶、动态再结晶组织相比更为粗大,是造成23Co13Ni11Cr3Mo钢起落架锻件晶粒度不达标的主要原因。
4)开展了工业条件下的23Co13Ni11Cr3Mo钢锻造工艺实验,研究了热变形工艺参数对晶粒组织演化、力学性能的影响,获得了满足最终组织性能要求的锻造工艺条件,可实现锻件在热加工全过程中的晶粒组织调控。研究结果表明,锻造晶粒尺寸与热处理晶粒尺寸呈正比关系,锻造晶粒组织需超过8级才能获得8级最终晶粒组织；锻造工艺参数对锻件的力学性能影响较小,在变形温度为980～1140℃、变形程度为12～30%的范围内,强度指标差异为3.5%,断裂韧性KIC差异为8.7%。
5)对现有整体模锻工艺条件下23Co13Ni11Cr3Mo钢起落架模锻件进行了解剖分析,锻件不同位置的微观组织分析和力学性能参数测试表明,采用整体模锻工艺可将锻件断裂韧性提高20.5%,但晶粒度仅为5～6.5级。23Co13Ni11Cr3Mo冈起落架锻件热加工全过程组织演化模拟与实验研究发现,锻件变形不充分、不连续变形引发的静态再结晶、晶粒长大是造成晶粒粗大及工艺稳定性差的主要原因,低温、高速率、大变形条件有利于获得细小晶粒组织锻件,提出了起落架锻件在800MN巨型液压机上起落架成形新工艺,终锻变形量提高至33.7%可抑制静态再结晶发生,晶粒组织演化机制转变为亚动态再结晶,晶粒显著细化。图105幅,表19个,参考文献190篇。
With the continuous development of modern aviation manufacturing technology, more and more overall die forgings with large size and complex shape are applied for load-bearing structures of aircraft to meeting the extreme mechanical properties. For this goal, high-alloy ultra-high strength steel, which has strength of1930Mpa and grain size of22.5μm (level8), has been developed to manufacture aircraft landing gear. However, the high requirements of grain size and its homogeneity bring big challenge to the overall die forging process, especially for large-sized landing gear. Because, material goes through heating, deformation and heat treatment during the whole forming process, and its microstructure evolution mechanism is very complicated. Meanwhile, China is lack of basic research and technical reserve in the field of overall die forging. Now, grain dissatisfaction and instability of deformation have become the main problem for obtaining high quality aircraft forgings. In this paper, a series of research work were done on newly developed ultra-high strength steel23Co13Ni11Cr3Mo for solving the problem listed above. The evolution of microstructure and mechanical properties during the whole hot forming process, including heating, deformation, cooling and heat treatment, were studied. And, the corresponding models were developed. Then, microstructure evolution of landing gear during the overall die forging process was investigated. Based on these research works, a new forging process on800MN hydraulic press with high stability and efficiency was proposed, and deformation parameters for high quality forgings were acquired. The main conclusions are listed as following:
(1) Isothermal compression tests of23Co13Ni11Cr3Mo steel were carried out. Deformation behaviors during high temperature and microstructure evolution rules were studied. Dynamic recrystallization models, including recrystallized fraction and grain size, were developed. A new approach for establishing the model of flow stress was developed, wihch is successive approximation method. Consequently, the deformation active energy and critical strain conditions of dynamic recystallization were obtained. Then, hot processing map for 23Co13Ni11Cr3Mo steel was developed on the basis of experimental flow stress and deformation instability rules. Hot deformation zone with high stability and efficiency was recognized through processing map. The results show that in this zone the degree of dynamic recrystallization is increased by increasing deformation degree, and small even grain is achieved.
(2) The overall die forging process of large-size products was characterized for complex microstructure evolution mechanism and varied physical fields. For this reason, cellular automaton(CA) model based on dislocation density was developed to describe grain evolution. During this process, the identification method on the basis of optimization theory was proposed for acquiring parameters of microstructure evolution. The relationships between macroscopic deformation parameters and hardening exponent, two-phase particle pinning effect were developed. Through these measures, the microstructure evolution through macroscopic and mesoscopic was realized. According to the actual forging processing characteristics, a series of CA improving algorithm were developed. Moreover, a software for visualized microstructure simulation was developed coupled with FEM platform, such as DEFORM and QFORM. The experimental results show the proposed CA model and developed software can predict grain shape, distribution and its evolution rule during multiple dynamic recrystallization very well.
(3) For large-sized forgings, its grain is easily to becoming coarse during static process of transferring, waiting, cooling and heat treatment. Therefore, microstructure evolution of ultra-high strength steel with high temperature during static processes was studied by experimental methods. Models of static behaviors, such as grain growth, meta-dymamic and static recrystallization were established, by which microstructure evolution during the whole deformation process can be expressed quantitatively. The results show that grain refinement is determined by the final forging process and its following cooling process. Grain size of static recrystallization is larger than that of meta-dynamic and dynamic recrystallization, which is the main reason for grain dissatisfaction of landing gear forging.
(4) Experimental forging of ultra-high strength steel was carried out on the industrial conditions. Influences of deformation parameters on grain evolution and mechanical properties were investigated. Consequently, deformation conditions which could fulfill the demands of grain and mechanical properties were reached, and grain evolution during the whole forming process could be controlled. The results show that a proportional relationship exists between forging grain size and heat treatment grain size, forging grain size should reach level8for the final grain size of level8. Deformation paramaters has little effects on mechanical properties. Under a deformation temperature of980-1140℃, strain of12-30%, the variation of strength is3.5%, and the variation of KIC is8.7%.
(5) Landing gear under the existing overall die forging process was dissectted and analyzed. The results of microstructure and mechnical properties show KIC can be improved about20.5%by applying overall die forging process. However, grain size can only reach level5-6.5. Microstructure simulation and experimental research during the whole hot forming process of landing gear show that the static recrystallization and grain growth caused by insufficient and discontinous deformation are the main reason for coarse grain and instable deforamtion. Lower temperature, higher strain rate and larger defromation degree lead to smaller grain size. So, a new forging process on800MN hydraulic press with high stability and efficiency was proposed. With the deformation degree of the final forging process increasing to33.7%, static recrystallization can be restrained, and grain evolution mechanism changes to meta-dynamic recrystallization, grain is refined greatly.
引文
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