金属圆管水下爆炸复合的研究

发布时间：2018-03-29 04:20

  本文选题：金属复合管　切入点：水下爆炸焊接　出处：《中国科学技术大学》2017年博士论文

【摘要】：金属复合管是由两种或两种以上不同金属管材构成,由于其综合了基、覆管金属的优点,具有单一金属管材不具备的综合性能。通过不同金属之间的组合可获得耐高温、耐磨损、高比强度、高导电性等性能优异的金属复合管,被广泛应用于城市建设、石油天然气行业、化工行业、能源环保、核设施以及航空航天等领域。制造金属复合管的工艺有很多种,包括拉拔法、胀接法、旋压法、热挤压法、爆炸复合法、离心铝热法、中频感应加热钎焊法以及堆焊成型法等。其中爆炸复合法因其可实现数百种金属组合的复合,成为金属复合工艺中最具发展潜力的一支。爆炸复合又称为爆炸焊接,是利用炸药爆炸产生的能量来驱动覆板(管)以某一合适的速度撞击基板(管),从而使两板(管)形成牢固结合的一种工艺。经过七十多年的研究和发展,爆炸复合工艺得到了快速的发展,特别是金属板的爆炸复合已经形成了一定的规模。与金属板的爆炸复合工艺相比,金属圆管的爆炸复合工艺更为复杂。除了板材复合时遇到的炸药用量大、能量利用率低、振动大、粉尘噪声污染严重等问题外,管材的内爆炸复合通常还面临着装药困难、装药不均匀、内管壁烧蚀严重、模具通用性差和模具损耗严重等问题。而关于金属圆管的外包爆炸复合,可查的文献十分有限,这方面的研究工作进展缓慢。本文围绕金属圆管爆炸复合存在的主要问题,以实现规模化工业生产为主要目标开展工作。目前用于金属爆炸复合的焊接炸药主要有乳化炸药、膨化硝铵炸药以及膨化铵油炸药,以这些炸药为基通过现场筛混的办法添加调节剂配制的爆炸焊接炸药存在贮存稳定性差、均匀性差以及爆轰不稳定等问题,严重影响爆炸焊接质量且不利于安全生产。将这类炸药用于金属圆管的内爆炸复合时,由于圆管结构的半封闭性和炸药的粘附性,会造成装药困难以及装药不均匀。而且上述炸药的稳定爆轰临界尺寸较大,这就要求装药必须保证足够的厚度,为克服超药量引起的管体破裂问题,通常会在基管外施加钢模约束。而这种约束的通用性差,对于不同直径的基管都需要与之配套的约束钢模,在爆炸载荷的作用下模具损耗严重、寿命较短。此外,炸药在圆管这一半密闭结构中爆炸会形成数千摄氏度的高温,造成复合管内壁出现严重的烧蚀现象,增加了复合管二次加工成本。本文从金属导爆索出发,通过工艺的创新和配方的改进得到金属爆炸索,将这一原本用于传扩、爆的爆破器材变成金属圆管的爆炸焊接炸药。金属爆炸索具有能量密度高、稳定爆轰临界直径小、爆速合理、安全可靠等优点,可长期贮存和远距离运输并能实现工业化生产。其作为一种柱状结构炸药,解决了金属圆管内爆炸复合时装药困难、装药不均匀的问题。基于在金属圆管爆炸焊接炸药上取得的新思路和新突破,为解决金属圆管内爆炸复合时出现的内管壁烧蚀损伤问题,本文开展了内管壁的防护研究。在防护材料的选择方面以廉价、来源广、使用方便、复合效果好作为标准进行筛选,通过综合分析最终选择液态水作为防护材料。在此基础上,设计了金属圆管的水下内爆炸复合系统,并以Q235钢管、1060铝管为基、覆管进行了水下内爆炸复合系统可行性试验,结果显示,铝-钢复合管内表面未出现任何的烧蚀损伤现象,压剪实验表明铝-钢复合管的结合强度达到3.27MPa,远高于CJ/T192-2004标准和SY/T6623标准规定的0.2MPa和0.5MPa。可行性试验说明水下内爆炸复合系统可有效解决内管壁的烧蚀损伤问题,复合管结合强度远高于城镇建设行业和石油天然气行业两大标准。此外,以Q235钢管、1060铝管为基、覆管探究了炸药量对复合管的影响,使用四种不同规格的爆炸索对未做深度表面清洁处理的基、覆管进行了水下内爆炸复合实验。结果表明,当使用外径为5mm、线密度约为14.7g/m的爆炸索时获得的铝-钢复合管结合质量优异,对其结合界面进行的微观形貌观察显示,铝-钢结合界面呈现波状特征,从波长和波幅判断,该波状结合界面为一种介于微波和小波之间的混合波状结合界面,与大波状或小波状结合界面相比,这种波状结合界面通常表示复合管具有更高的结合强度。通过对经典波状结合界面形成机理的探讨,本文给出了复合管不规则波状结合界面形成的主要原因。在金属圆管的内爆炸复合试验中,常出现复合管末端开裂现象。本文开创性的将PVDF压电薄膜传感器用于爆炸复合动态参数的测量,对于缺乏动态观测方法的金属圆管的爆炸复合研究来说意义重大。利用PVDF压电薄膜传感器测量了铝-钢水下内爆炸复合过程中铝层对钢层的撞击压力,结果表明金属圆管的内爆炸复合过程中覆管对基管的撞击压力沿炸药爆轰方向呈现递增趋势。在对复合管初始端、中段和末端结合界面的微观形貌观察显示:结合界面由初始端的带有钢碎片的裂隙界面转变为中段的平直界面,最后在爆轰结束端呈现为波状结合界面。上述结合界面微观形貌的变化过程直观的反应了金属圆管内爆炸复合过程撞击压力和能量的变化。对于这一现象本文从水下冲击波在复合管内壁的反射过程出发做出了解释。这一现象的研究有助于改变装药结构,节约炸药用量并提高复合质量。基于金属圆管的外爆炸复合研究现状,以热交换系统中广泛使用的换热管为应用背景,通过对金属爆炸索装药结构的改变,设计了一种非对称的金属圆管外爆炸复合系统,并利用该工艺将1070铝管外包复合于10100螺纹铜管,获得了铝-铜双金属复合管。对复合管样品的大角度三点弯实验展示了铝-铜复合管优良的宏观力学性能。对弯曲后的试样进行取样,利用扫描电子显微镜对其结合界面进行观察,结果显示铝层的一部分已经完全被压入铜管螺纹的凹陷处,形成了铝层与铜层的啮合,两种金属的大部分结合界面为直接结合,但在一些铜层凹陷处产生了金属的熔化块和熔化层。铝层与铜管螺纹顶部平台结合界面的高倍率背散射照片显示:即使在弯曲实验后,具有微波状特征的结合界面依然保持紧密的结合,未出现分离现象。而铝层与铜管螺纹凹陷处的结合界面存在大面积的熔化块和熔化层,在这些熔化区存在微裂纹和空洞,表明该区域为铝·铜复合管结合界面的薄弱区。利用能谱仪对这一区域进行元素定量分析,结果显示裂纹附近区域的Al、Cu原子百分比约为2:1,这与金属间化合物CuAl2一致,而CuAl2是一种脆性的金属间化合物,这也是裂纹在这些区域产生、发展的内在因素。
[Abstract]:Metal composite pipe is composed of two or more than two kinds of metal pipe, due to its complex medium, metal clad tube has the advantages of comprehensive performance, with a single metal pipe has not. Through the combination between the different metals can obtain high temperature resistance, abrasion resistance, high strength, high conductivity metal composite pipe properties excellent, is widely used in city construction, petroleum industry, chemical industry, energy and environmental protection, nuclear facilities and aerospace fields. The process for making metal composite pipe has many kinds, including drawing method, expansion method, spinning method, hot extrusion, explosive bonding, centrifugal thermit process, intermediate frequency the induction heating brazing and welding molding method. The composite method because it can achieve hundreds of composite metal combination, become a metal composite technology with the most potential for development. Also known as explosive composite explosive welding, is the use of explosives Fried the energy to drive plate (tube) at an appropriate speed impact substrate (tube), so that the two plate (tube) to form a solid combination process. After more than 70 years of research and development, technology of explosive composite has been rapid development, especially the explosive composite metal plate has been formed a certain scale. Compared with the composite technology of explosive metal plate, metal round tube explosion composite process is more complex. In addition to the plate when the composite explosive consumption, low utilization ratio of energy, vibration, dust and noise pollution problems, tube explosion in composite often confront drug difficulties. The charge is not uniform, the inner tube wall erosion, the serious problem of poor universality of mould and die loss. And on outsourcing compound explosion metal tube, the available literature is very limited, the progress of the research work in this field. This paper focuses on the metal round slowly The main problems existing of explosive composite pipe, in order to achieve large-scale industrial production as the main target to carry out the work. The explosive used for welding metal composlte mainly in emulsion explosive, expanded ammonium nitrate explosive and expanding ANFO explosive, explosive based on these through the sieve mixed way adding regulators explosion exists poor storage stability of explosive welding that poor uniformity and detonation instability problems, seriously affect the welding quality and is not conducive to safe production. This kind of composite explosives for explosive metal pipe, due to adhesion of semi closed and explosive tube structure, will cause the charge charge difficult and uneven. And the explosive detonation critical size is large, which requires charge must ensure sufficient thickness for pipe rupture caused by super dose to overcome, usually in the base tube is applied to steel mould The versatility of this constraint constraint. The difference for constrained steel mould of different diameter tube are matched with the need, in serious explosion load die loss, short service life. In addition, the explosive in pipe explosion in this half closed structure will form a high temperature thousands of degrees Celsius, resulting in a composite pipe the ablation phenomenon occurs serious, has increased two times. The machining cost of composite pipe from the metal detonating cord, by improving the technological innovation and the formulation of the metal cable explosion, this was originally used in the transmission and amplification of blasting equipment, blasting into metal tube explosive welding. Explosive explosive metal cable with high energy density steady detonation, small critical diameter, the detonation velocity is reasonable, safe and reliable, long-term storage and long-distance transportation and industrial production can be realized. As a columnar structure of explosives, solve the metal tube explosion composite fashion The medicine is difficult, the problem of uneven charge. New ideas and new breakthroughs in metal tube explosive based on the explosive welding, in order to solve the problem of tube wall ablation damage metal tube explosion in the composite, this thesis carried out the research of protective tube wall. In terms of the protection material selection to cheap wide source, easy to use, good compounding effect as the standard for screening, through a comprehensive analysis of the final choice of liquid water as protective materials. On this basis, the design of metal tube water composite system under explosion, and to Q235 steel, 1060 Aluminum base, covering tube composite system feasibility test, underwater explosion in the results show that the aluminum steel composite pipe inner surface does not appear to damage any ablation pressure shear experiments show that the combination of aluminum and steel composite pipe strength reached 3.27MPa, far higher than the CJ/T192-2004 standard and SY/T6623 standard 0.2MPa and 0.5M Pa. feasibility test showed that the damage can effectively solve the problem of inner pipe wall composite system of underwater explosion in the composite pipe bonding strength is much higher than that of urban construction industry and the oil and gas industry. In addition to the two standard, Q235 steel, 1060 Aluminum Clad Tube as the base, to explore the impact of the amount of explosives composite pipe, the use of four different specifications of cable explosion did not deal with clean surface depth, covering tube of explosive composite under water. Experimental results show that when using the outside diameter 5mm, line density is about 14.7g/m cable explosion when aluminum steel composite pipe with excellent quality, microstructure of interface observation shows that aluminum steel interface shows wave characteristics from the wavelength and amplitude of the wavy judgment, binding interface for mixed wavy between microwave and wavelet, compared with wavy or small wavy interface, this A wavy interface usually indicates that the composite pipe has higher bond strength. Based on the classic wavy interface with the formation of the discussion of the mechanism, this paper gives the main reasons of irregular wavy interface of composite tube formation. In metal pipe explosion composite test, often appear at the end of the tube composite cracking phenomenon. The article groundbreaking the PVDF piezoelectric film sensor for measuring the dynamic parameters of composite explosion, for lack of dynamic observation method of metal pipe explosion composite research is of great significance. The piezoelectric film sensor to measure the aluminum layer of steel composite layer of aluminum - Steel under explosive impact pressure by PVDF, the results show that the metal tube inside the explosion cladding tube on the impact pressure of the base pipe along the detonation direction showed an increasing trend during the compound process. In the end of the initial microstructure of composite pipe, the middle and end interface view 瀵熸樉绀，

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