Vacuum electron beam solders technology and its play body to process medium application in empty empty missile

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In the domain of sophisticated science and technology such as aviation, spaceflight, nuclear energy, solder the technology has all in all place from beginning to end. Solder technical progress and development make different material is like firm joint can come true between heterogeneous metal; Make the weldability of metal of active metal, difficult frit can be improved greatly; Make the complex welding line of accessibility extreme difference comes true to solder automatically; Solder consequently the technology was won " division of modern industry sew " beautiful praise. In numerous and advanced solder in the method, 50 time just develop the century on the vacuum electron beam that rise solders is the among them person that above average. With its he fuses solder method photograph is compared, solder has vacuum electron beam energy density is tall, penetrable ability quality of strong, welding line is good, hot influence stricture, solder be out of shape small dominant position, and soldering in the process, it won't produce any pollution, can solder commonly the place that the method is close to hard. Wide application received in the treatment that the advantage that these cannot replace makes its bomb put oneself in another's position in empty empty missile, if steel of extra high strength plays body, solid to wait for numerous sky to intake duct of engine titanium alloy,empty missile plays the decisive component in body use electron beam solder to the method solders and be become, they not only dimension precision is tall, and solder quality is stable. The complex part treatment with the new-style design conception that the application of electron beam solder still makes think that he cannot undertake machining before and treatment very great difficulty is able to come true, make the material that solders hard can realize reliable join easily, advanced to new generation empty empty missile plays the development of body to develop main stimulative effect. Vacuum electron beam solders principle vacuum electron beam solder is to use a space after the electron beam that directional high speed moves bumps workpiece surface, change partial kinetic energy into heat energy, make be fused by solder metal, condensation, crystal and form welding line, its principle signal sees a picture 1. Graph 1 electron beam solders when principle sketch map solders, the cathode electrify of electron gun heats to launch a large number of electrons to high temperature, the electron cloud with concentrated posse is formed in cathode surface, these are thermionic be gone to quickly below the action of strong electric field very high rate, the electronic course that high speed moves gets together bundle extremely, the electromagnetism field of zincous electrostatic field action and focusing coil action and the ray of a bundle of electron that gathers into high-energy quantity density, when its bombard point point in workpiece and electron of material crystal lattice, atomic photograph collides, be mixed to prevent by scattering, change of its kinetic energy is energy of crystal lattice vibration namely heat energy. Below low energy density, electron beam basically is in the surface of workpiece, solder process and likeness of general arc welding; But fall in high energy density, workpiece material fuses for an instant below the bombard of electron beam and evaporate, strong metallic evaporate air current blows metal of partial liquid state from area of electron beam action, make electron beam is on the solid state metal of bath bottom again focusing, make its are dissolved again, evaporate again, show new bath floor again, so layer upon layer come off, form the fine and deep cavity that is surrounded by liquid state metal thereby, namely " alveolus " effect. After the exterior pulling force that controls force and liquid state metal when metallic steam recoil and gravity achieve a balance, alveolus continues no longer thorough; When density of electron beam power enough big when, the alveolus that produces will be perforative whole board thick. Fused metal is advanced in electron beam by repulsion of direction rear, as the forward shift of electron beam, fused metal forms welding line with respect to cooling, caky, crystallization. Welder of vacuum electron beam art choice of 1 connect form and juncture preparation (1) contact form chooses. Because concentration of energy of electron beam solder, welding line is narrow, when soldering, cannot fill add welding wire, take the contact that receives a form join area is lesser, carrying capacity is not high, answer to avoid as far as possible usually; Add a soldering horn to receive formal welding line like need, soldering quality is not good also; The butt joint is the form of a kind of connect with electron beam the most applicable solder, solder to making those who be main technique index with intensity contact, more such. When electron beam solder, the main contact form of the butt joint has butt joint of edge of crop butt joint, biconvex, strengthen the butt joint end butt joint, lock, stop buccal butt joint, differ ply butt joint, solder Shi Kegen chooses according to be being asked to undertake by the structural characteristic of solder workpiece and technology, for example when circumferential butt welding, to raise precision, avoid amlposition, can use the butt joint end the lock or stop the type of buccal butt joint. (2) juncture preparation. The juncture end panel of contact should undertake be repairinged carefully closing, make its level off, smooth, without burr, hold acute edge. Be received to locking up a bottom to be opposite or stop the circumferential juncture of type of buccal butt joint, should make joint close together, buckle close firm. Clear before 2 solder electron beam solder solders below vacuum condition, won't produce air to be opposite commonly of bath area erode and pollute a problem, but the harmful gas such as the hydrogen that appears to interior of electron beam area, oxygen, nitrogen, electron beam solder is without the ability of dispel however. But if workpiece cleans ungodliness, the oxidation skin of remaining, grease and moisture can enter bath and electron beam area to go inside the country, they are decomposed quickly below high temperature for hydric with oxygen, this not only can burn the alloying element with good damage, and meeting occurrence stoma, slag inclusion and hydrogen are fragile, pollute atelier lumen. Accordingly, clear seriously before solder workpiece, those who take strict precautions against the harmful gas such as hydrogen, oxygen enter, crucial to the assurance of welding line quality; Clear before solder cent clears for chemistry and machinery clears two kinds, after clearing, arrive solder to be restricted to ask sometimes. Be polluted afresh to prevent the workpiece after clearing, have enough to meet need and when applying solder, handlers all should wear clean glove, to prevent to solder at the same time material surface adheres to more moisture, still should control welder to make the humidity between, wait for the material of easy occurrence stoma to titanium, aluminium, answer to avoid to solder in damp season as far as possible. Because 3 workpiece demagnetization is met to make electron beam produces deflection by the remanence of solder workpiece, cause incomplete fusion or solder to slant blemish, so the magnetic flux density of all fixture that be mixed by solder workpiece must not exceed 1 × 10-4T, must undertake demagnetization is handled otherwise. Nextpage4 tool design solders for control be out of shape, the requirement of relative position precision between the dimension precision that assures weldment and each spare parts, need design fixture when necessary. The design principle of clamping apparatus should be helpful for workpiece assemble fixed position, prevent to solder be out of shape, go to the lavatory to solder and improve labor efficiency. The outfit clip of 5 workpiece and assemble before soldering, all spare partses in workpiece should be mixed according to structural dimension the requirement of appearance position, combine by certain order on fixture, assemble a whole. When assembling, answer accurate reach the designated position, make sure the relative position precision between each spare parts, precision that makes sure juncture is in clearance and amlposition asks, usually, juncture clearance should be controlled in 0.

In 15 Mm, amlposition quantity should not exceed 0.

20 Mm. 6 corrective welder add up to an axis to debug, corrective welder adds up to an axis to make namely the coincide of central axle photograph of the central axle of electron beam and focusing lens. Otherwise, electron beam is mixed with respect to possible diverge deflection, before every approve product solder, answer commonly corrective. 7 welder art parameter reachs his to debug (1) solder craft parameter. The craft parameter of electron beam solder basically includes to quicken voltage (KV) , focusing electric current (MA) , electron beam flows (MA) , solder speed (Mm/s) spend with the vacuum of atelier etc. Their change, will right of electron beam solder solder the effect that the appearance of cross section geometry of deepness, in-house quality and welding line produces different rate. · quickens voltage (KV) : When other condition is changeless, quicken voltage taller, solder frit is jumped over greatly big, because quicken,this is when voltage is elevatory, the power of electron beam and power density also increase subsequently, penetrable ability increases. Carry out a proof, electron beam is penetrable metallic deepness is as tall as what quicken voltage second just become direct ratio, also become inverse ratio with metallic density at the same time. · electron beam flows (MA) : When other condition is certain, increase electron beam electric current, the frit deep He Rongkuan of welding line can greaten, because electron beam electric current increases,this is when, although the power of electron beam increases, but its focusing function becomes poor, the power density of electron beam increases relatively delay, deep He Rongkuan increases the frit that reason expression is welding line at the same time. · focusing electric current (MA) : The central issue that the size of focusing electric current decided electron beam is in the position that is gotten on by direction of solder workpiece ply. When the focus of electron beam is in workpiece surface upper part, call medicinal powder anxious solder; When the focus is in the surface on workpiece, call exterior focusing; The focus is in workpiece ply limits when the focusing in calling; The focus is in the surface below workpiece to reach the following when become next focusing. Carry out a proof, solder frit is deep with electron beam in focusing is the biggest. Usually, when 2mm of ≤ of weldment ply δ , use medicinal powder anxious solder; When 10mm of ≤ of δ of ＜ of weldment ply 2mm, use exterior focusing to solder; When 20mm of ≤ of δ of ＜ of weldment ply 10mm, the focusing in using solders; When 20mm of ＞ of weldment ply δ , need to use next focusing to solder. · solders speed (Mm/s) : Usually, solder rate increases, solder wiring energy is reduced, frit is on the geometrical figure that is reflected in welding line cross section wide with frit deep will reduce. The vacuum of · atelier spends: Spend when the vacuum of atelier when reducing, not only can make the contaminative rate of welding line increases, still can make electron beam produces scattering, the power of electron beam and power density are reduced, penetrable ability drops, make the frit of welding line deep reduce, deep wide than reducing. (2) solder of craft parameter debug. The in-house quality of electron beam welding line, solder deepness and appearance of cross section geometry, depend on not only craft parameter, and still mix with the power volume of electron beam welder, performance data, electron gun by the relative position between solder workpiece, be concerned by the technical characteristic of solder workpiece. Accordingly, when the craft parameter that debugs specific certain workpiece, the action that should understand adequately and is familiar with each parameter, mutual influence between them and match a relation, union is asked by the structural characteristic of solder workpiece, technology, the element such as precision of appearance of material sort and function, geometry, dimension, important rate, pass those who relapse for many times to solder experiment, final sieve singles out a group of first-rate to solder craft standard parameter. Ought to notice: What debug solder parameter examines in the exterior of test specimen welding line only, intensity of X- smooth flaw detection, connect accords with a design to ask entirely, passed 3 first solder after test and verify, ability is used at batch to produce. 8 workpiece solder (1) bundle stream in be opposite. The purpose is stain of electron beam of test and verify be located in from beginning to end when shift be gettinged on by solder workpiece on juncture line, its deviation should not exceed 0.

2 ～ 0.

3 Mm. (2) tack welding. It is with circumferential juncture exemple, usually, when 500mm of diametical φ ≤ , fixed position at 8 o'clock; When 500mm of diametical φ ＞ , fixed position at 16 o'clock; Length of each bits is: Remove arc 2.

5 ° , solder 2 ° , receive arc 2.

5 ° . Bundle drifting size can be mixed according to the ply of cylindrical shell assemble clearance to master neatly, it is commonly solder bundle of drifting 25% ～ 35% , use when gap is big medicinal powder anxious, clearance can use exterior focusing when small or very close to each other is unoccupied place. (3) soldering and sealing. Solder to assure quality, avoid to burn wear the generation that waits for blemish, must undertake soldering and sealing. The size that the electron beam when soldering and sealing sheds inspects the clearance of juncture and decide, it is with can sealing juncture accurate, it is commonly solder bundle flow 30% the left and right sides, whether to use according to the size decision of clearance medicinal powder anxious. (4) solder. The size that the electron beam when soldering sheds does not appear with welding line front cave, the reverse side makes sure solder is appeared, the exterior shapes good undertake for the basis. (5) got-up solder. Shape when welding line surface undesirable or appear bite an edge, cave when waiting for blemish, can undertake got-up solder, when got-up solder bundle flow to be used commonly medicinal powder anxious, when its size and soldering and sealing basic and identical. Vacuum electron beam solders the technology plays body to process medium application in empty empty missile the 1 base that play a wing and of the cylindrical shell outside bombing put oneself in another's position solder the spare parts that the base that play a wing is fixed ala face, should bear the weight of in missile flight process the weight that plays completely, and when missile tracks a target to make motor-driven fly, bear even tens of times overload that measures at playing weight, it is empty empty missile in important bear force. It and rely on to solder to be an organic whole repeatedly between the cylindrical shell outside bombing put oneself in another's position, two spare partses all are made by steel of effectiveness for a given period of time of martensite of 0018Ni high strenth. When using solder of manual argon arc to solder, not only solder be out of shape big, circularity achieves a requirement not easily, and still can appear the base playing a wing that the graph shows 2 times and outside the interface of cylindrical shell relies on circumjacent solder to be together only, and the phenomenon that intermediate area still is separate two system structure. The better settlement after Nextpage uses method of electron beam solder this problem, not only dimension precision is taller, and came true to play tentative idea of complete connective of alar base and interface of the cylindrical shell outside bombing put oneself in another's position, machine with whole basic and identical, rose to play alar base to be opposite greatly the carrying capacity of empty empty missile. Of envelope of 2 helm face and framework solder the helm face of modern empty empty missile uses relatively advanced envelope framework structure commonly, material is taller than intensity TC4 titanium alloy. Resistor is used to roll solder join between envelope and envelope among them, between envelope and framework use resistor spot welding more before, to satisfy light quantified requirement, the comparison that framework width makes commonly is narrow, often happen when spot welding splatter, cause solder the dot is loose wait for blemish too greatly with impress, if use electron beam solder, can overcome this kind of phenomenon. Moreover, because electron beam solder is,solder below vacuum condition, those who avoided air to affect an area to welding line and heat erode and pollute, having favorable protective effect to titanium alloy, we are working in the test that develops this field now, if pursue,3 are shown. The 3 cylinder that bomb put oneself in another's position solder with what carry ring empty empty missile gets shot body cylinder and through circumferential welding line join is a whole between upright annulus. Assemble to facilitate, assure dimension precision, used the configuration of the butt joint end the lock. Using automatic tungsten extremely when argon arc solder solders, fused metal severely deflection plays body cylinder one party, if the graph is shown 4 times, ministry of the root end the lock that carrying ring appears not solder shows defect. Increase electric current to eliminate this kind of flaw, but burn the cylinder that bomb put oneself in another's position even when wearing, ministry of the root end the lock that carries ring still carries in good condition solid state form, did not fuse at all, not solder appears blemish to exist continuously. In the meantime, increase electric current overly to still can be in the hot influence of a side of the cylinder that bomb put oneself in another's position is caused inside the area cave, pass an analysis, we think this is end annulus and the thermal capacitance of the cylinder that bomb put oneself in another's position are lopsided, both differ too great disparity causes. Wall of the canister that carry ring is large, thermal capacitance is big, and wall of canister of the cylinder that bomb put oneself in another's position is thin, thermal capacitance is small, give at identical quantity of heat, the temperature of the cylinder that bomb put oneself in another's position rises quickly fused, and upright annulus warms up however slow, temperature is low, the place end the lock did not reach fused temperature and cause not solder shows defect. Use vacuum electron beam solder won't appear this kind of phenomenon, vacuum electron beam has energy density the characteristic with rapid input of tall, quantity of heat, deep and narrow penetrable welding line can be formed when soldering, reason juncture the thermal capacitance of two side is lopsided solder to its with the structure end the lock quality won't make an impact, won't arise not solder shows defect, this had gotten the test and verify of the experiment. Last word electron beam solders the technology is had with its other solder the characteristic that the method cannot replace and huge advantage was shown in the treatment that bombs put oneself in another's position in empty empty missile. The way that sides with long-range, high speed, tall motor-driven, tall overload as empty empty missile develops, a few exceed spare parts of material of light metal, high strenth, tall precision solder will be carried in succession program, all sorts of contact forms that implement hard also will appear in succession, this solders for electron beam technical application and development offerred capacious prospect. Believe to play system to build as empty empty missile to soldering of technical demand pull move and drawing, electron beam solders the technology will get develop further and be perfectinged, satisfy new generation conversely advanced empty empty missile is developing the requirement that to soldering the technology raises increasingly in the process. CNC Milling