航空航天大型锻件质量与生产能耗检测方法

Detection Method for Production Quality and Energy Consumption of Large Forgings in Aerospace

锻造工艺作为航空航天领域生产制造企业至关重要的精密成形方法,被广泛应用于大飞机和火箭上多品种锻件的批量生产,但是对锻件质量要求很高,且锻造工艺能耗巨大,直接影响企业的经济效益,间接造成众多环境污染问题。为争取早日实现我国“双碳”目标以及持续推进制造业转型和能源结构调整的目标,亟需在保证锻件质量要求的基础上采取节能降耗措施。针对航空航天领域以铝合金材料为代表的大型锻件常见缺陷与核心质量要求,将锻造生产流程分解为原材料、备料、加热、锻压和锻后热处理5个主要环节,归纳总结了锻件缺陷及其产生原因和影响机制;系统阐明外观质量、力学性能、晶粒度/平均晶粒尺寸、断裂韧性、残余应力和抗腐蚀能力等质量要求的检测方法的研究现状,为铝合金等金属大型锻件的重要质量检测研究提供指导;同时,针对大型金属锻件锻造工艺能耗管控粗放的特点,从工厂层、装备层、产品层3个层面梳理能耗检测方法并提供提高能效的相关研究思路,为实现航空航天大型锻件节能降耗生产提供指导。在锻造行业高质低耗生产转型发展过程中,该理论方法在以铝合金为代表的大型金属锻件关键质量检测和生产能耗检测方面,具有一定的指导意义。

As a crucial precision forming method in the aerospace manufacturing industry,forging process is widely used in mass production of structural parts for large aircraft and rockets.The production quality of the forgings is often highly de-manded,and the huge energy consumption of forging process directly affects the economic benefits of enterprises and indirectly causes many environmental pollution problems.To strive for the early realization of China’s“carbon peaking and carbon neu-trality”and continuously advance the transformation of the manufacturing industry and the adjustment of the energy structure,it is urgent to take energy-saving measures on the basis of ensuring the quality of forgings.Focusing on the defects and core qual-ity requirements of large forgings in aerospace,especially for aluminum alloy and other metals,the forging production process was divided into five main stages:raw materials,preparation,heating,forging,post-forging heat treatment,and the potential forging defects,their causes,and the resulting impacts were summarized step by step.In addition,the current research status of detection methods for quality requirements such as appearance quality,mechanical performance,crystallite size/average grain size,fracture toughness,residual stress,and corrosion resistance was systematically clarified to provide guidance for the crucial quality detection research of large forgings made of metals like aluminum alloy.Simultaneously,considering the extensive en-ergy consumption characteristics of the forging process for large metal components,energy consumption detection methods were explored at three levels:factory,equipment,and product.The methods provide a theoretical research thought on improving energy efficiency,and offer guidance for achieving energy-saving goals in the aerospace sector’s large forgings.The theoretical approach plays a crucial guiding role in key quality and energy consumption detection of large metal forgings represented by aluminum alloy in the transformation and development of high-quality,low-consumption manufacturing in the forging industry.