高强铝合金薄壁高筋大型壁板精确成形制造技术基础

Panel is the main component of rocket cabin，which providing support and protection for the cabin. The present project focused on the difficulties, that aroused in engineering manufacturing process of panel, of low efficiency, high cost, low performance, which is hard to support the high performance, low cost and high efficiency manufacturing of large cabin with light weight and high strength. A new method of symmetrical extrusion of ribbed cylindrical parts, with temperature controlled, and dissected after precise close-form thinning to manufacture thin wall panel with high ribs is proposed, with which the requirement of industrial equipments for wide-width thin-wall panel with high ribs is reduced, and the forming stability is improved, also, this method is high efficiency, low cost and high performance. Accordingly, the formability of the alloy was improved by microstructure and composition design, and new casting technology develop, and high performance and high precision wide thin-wall panel with high ribs is integrally manufactured by cylindrical symmetrical extrusion and precision forming, together with microstructure control by heat treatment. Based on the detected mechanisms of microstructure and composition design, high-quality ingot manufacture, large thin-wall panels with high ribs quick and integral formed, and heat treatment, synergistic control prototype of alloy composition, casting, plastic processing, heat treatment and other processes are established. Meanwhile, the basic theory and method system for high-performance, high-precision forming and high-stability precision manufacturing of thin-wall integral panels with high ribs is formed, which supporting the efficiency manufacture of lightweight and high-strength thin-wall large-sized cabins with high performance and low cost.

壁板是火箭舱段的主体部件，为舱段提供支撑与防护。本项目针对壁板在工程制造过程中存在效率低、成本高、性能偏低等不足而难以支撑轻质高强大型舱段高性能、低成本、高效制造的困境，提出一种带筋筒形件对称控温挤压开坯、精近成形减薄后剖展的方法制造宽幅薄壁高筋壁板，在降低宽幅薄壁高筋壁板对工装高要求的同时提高成形稳定性，并兼具高效、低成本、高性能等特点；通过合金微观组织与成分设计和新型熔铸技术开发提高材料的成形性能，采用筒形对称控温挤压与精近成形技术结合热处理微结构调控实现宽幅薄壁高筋壁板的高性能高精度整体制造；在探明微观组织与成分设计、高品质铸锭制造、薄壁高筋大型壁板快速整体成形、热处理成性的微观机制的基础上，建立成分、熔铸、塑性加工、热处理等工艺过程的协同调控技术原型，形成薄壁高筋整体壁板高性能、高精度成形及高稳定性精确制造的基础理论与方法体系，支撑轻质高强薄壁大型舱段的高性能、低成本、高效制造。

本项目针对壁板在工程制造过程中存在效率低、成本高、性能偏低等不足而难以支撑轻质高强大型舱段高性能、低成本、高效制造的困境，通过采用带筋筒形件对称控温挤压开坯、精近成形减薄后剖展的方法制造了宽幅薄壁高筋壁板样件，在降低宽幅薄壁高筋壁板对工装高要求的同时提高成形稳定性，并兼具高效、低成本、高性能等特点；通过合金微观组织与成分设计和新型熔铸技术开发提高材料的成形性能，采用筒形对称控温挤压与精近成形技术结合热处理微结构调控实现宽幅薄壁高筋壁板的高性能高精度整体制造；在探明微观组织与成分设计、高品质铸锭制造、薄壁高筋大型壁板快速整体成形、热处理成性的微观机制的基础上，建立成分、熔铸、塑性加工、热处理等工艺过程的协同调控技术原型，形成薄壁高筋整体壁板高性能、高精度成形及高稳定性精确制造的基础理论与方法体系。基于建立的薄壁高筋构件材料成形性能与服役性能协同的成分与微结构匹配设计理论，开发了满足舱段结构壁板选材需求的新型高强高成形可焊铝合金材料，并注册了合金牌号7A43；实现了宽幅薄壁高筋壁板的高性能高精度整体制造，所研制的壁板样件各项性能满足指标要求。