High-energy beam processing technology is the frontier field of today's manufacturing technology development, and is an indispensable special processing technology in the development of weapons and equipment. High-energy beam processing technology uses high energy density beam currents with photons, electrons, and plasma as energy carriers to process materials and components. It is a typical cross-disciplinary field with rich research content in optics, electricity, thermodynamics, metallurgy, metal physics, fluid mechanics, materials science, vacuum science, mechanical design and automation, and computer technology. Its main technical fields include laser beam processing technology, electron beam processing technology, ion beam and plasma processing technology, and high-energy beam combined processing technology.
First, the development of foreign high-energy beam processing technology Developed countries in the United States, Japan, and Western Europe have included high-energy beam processing technology as an important component of advanced manufacturing technology in the corresponding industrial development plans in the 1970s and 1980s, and established corresponding development and research institutions. There are high-energy beam processing research centers such as the Osaka University, the Welding Institute of Achen University in Germany, the British Welding Research Institute, the French Welding Research Institute, and the Barton Welding Research Institute in Ukraine. Through the investigation and data research of the above research center, we can see the future development trend of high-energy beam processing technology.
(a) Electron beam processing technology
The main application of electron beam processing technology is electron beam welding (EBW). After more than 30 years of development, it has become a mature technology and is in a stage of steady development and expansion. The current research work focuses on real-time tracking of weld seams, computer simulation of electron beam heating temperature field, research of high-power two-pole guns (intercalary cathode, high voltage discharge protection), electron beam energy density testing, electron beam welding expert systems, etc. In terms of applied research, it mainly focuses on the study of electron beam welding equipment and processes under atmospheric conditions and the study of large-thickness electron beam welding. In addition, in the development of electron beam processing equipment, the use of smaller, high-voltage power supplies, and the use of advanced computer-controlled and industrial television monitoring technologies have enabled the commercialized EBW devices to be more aesthetically pleasing and easier to operate. Electron beam physical vapor deposition (EB-PVD) technology is gaining increasing attention in the aero-engine manufacturing industry. Russia, Ukraine and other countries have successively applied this technology to thermal barrier coatings for aero engine blades as well as the manufacture of blades and the preparation of metallic materials. It is worth mentioning that the (EB-PVD) equipment of the Barton Welding Institute in Ukraine has formed a series of products for laboratory, pilot production and batch production; the Kuznetsov Design Bureau of Russia has been starting since 1978. The technology was applied to the production of HK series engine blades and three units were installed in its batch production plant. Nowadays, this technology has increasingly attracted the attention of the West. For example, the joint venture between U.S. P&W and U.S. Barton Welding established the technology to promote the technology in the United States as soon as possible.
(b) Laser processing technology
10 years ago, the main application of laser in the industry is cutting (more than 70% of the laser processing machine for cutting) and making holes. In recent years, laser welding has become a hot spot. Thin-piece welding is mainly used in aerospace and automotive industries, and laser-welded large-thickness parts will be mainly used in the nuclear industry, shipbuilding, petroleum, military vehicles, and off-road vehicles. The British Welding Research Institute and the French Welding Research Institute are conducting a joint research on large thickness laser welding parts, namely 45KW CO[_2] laser welding. The expected value of welded steel thickness is 50mm. At present, in the aspects of plasma + laser hybrid welding, argon arc welding + laser hybrid welding, and laser quality inspection technology basis (such as temperature field, plasma monitoring, etc.), the research work on the mechanism of laser processing technology is carried out. In terms of application, laser welding of galvanized sheet, aluminum sheet, heat pipe of nuclear power plant, high-pressure gas bottle, and oil pipeline are mainly used. The application area and material range of laser cutting are also becoming wider and wider. The most widely used laser processing equipment in the industry is the 4-6 kW CO[2] processing machine, which is developing in the direction of high power of several tens of kilowatts. The diffusion-cooled CO[2] slat laser developed in recent years has the advantages of low cost, high efficiency, and good quality, and has a wide range of application prospects. The pulsed maximum power of the YAG laser is 1KW, and the maximum continuous power is 4KW. The double-tube YAG laser currently under development is expected to reach 5KW by 1998. In addition, semiconductor lasers have low cost and long life, and will soon be used in industrial production lines such as automobiles. In the laser shock hardening, a quenched and tempered YAG laser is used, and the copper vapor laser is originally used for isolating the isotope elements, and it is very suitable for a laser shock hardening process and the like.
(III) Plasma Processing Technology
The development of high-tech in modern times, especially the demand for high-tech development in aviation and aerospace, has injected vitality into plasma processing technology. Plasma cutting, plasma welding, plasma spraying, and plasma source ion implantation and ion etching have all developed rapidly. Foreign countries have paid great attention to the research and application of plasma processing technology. The research on plasma jets at the Science Campus of Novosibirsk, Russia, has deepened the development of plasma moments and developed plasma equipment software. The Barton Welding Research Institute of Ukraine has carried out a great deal of research and application in supersonic flame spraying, microplasma spraying, and explosion spraying. After the 1990s, the plasma beam processing technology was developed from the vacuum coating of special function coatings for aerospace and aerospace power plants to the preparation of special integral machine components, namely plasma spray forming technology. It is expected that plasma processing technology will have new development after entering the 21st century.
Second, the status quo of China's high-energy beam processing technology, the gap with foreign countries and the countermeasures to be taken In the 1960s, in order to strengthen the research on high-energy beam processing technology, the "Key Laboratory of High-energy Beam Processing Technology for National Defense Science and Technology" was established at the 625th Research Institute of China National Aviation Industry Corporation with the approval of the National Commission of Science, Technology and Industry for National Defense, and the domestic high-energy beam was started. Flow machining technology research. The laboratory integrates laser processing technology, electron beam processing technology and plasma processing technology. It is the only research unit in China that has three processing technologies at the same time. Its establishment has created a good research environment for us and will play a significant role in promoting the development of high energy beam current processing technology in China. The three specialties (laser, electron beam, and plasma) of the "High-energy Beam Processing Technology Key Laboratory" have carried out a great deal of work in both mechanism research and applied research in the past thirty years. High-energy beam processing technology has made great contributions. The results have been applied in the development and production of new aerodynamic devices in China. Such as electron beam welding used in aerospace industry, laser cutting, laser heat treatment, laser surface modification for automotive and metallurgical industries, plasma spraying, ion etching, etc. are also applied in many sectors. Another example is laser drilling technology, which solves the problem of thousands of film cooling holes on high-performance engine blades. The temperature before the turbine is increased by 300-350°C, and the engine thrust is increased by 20%-30%. Welding solves the key welding technology of the new aeroengine compressor compressor, combustion chamber, heavy-duty titanium alloy casing, saves a lot of mechanical connections, reduces the structural weight by 10% to 20%; Plasma spraying technology is used in the engine Thermal barrier coatings and seal coatings improve engine performance. Compared with the world advanced level, China's high-energy beam processing technology still has a big gap. The performances are as follows: 1 The basic research is not thorough enough, the quality of personnel is low, and the research level is not high; 2 The quality control technology is less researched and the methods are lacking; 3 Scientific research equipment is always in a backward state; 4 The transformation of engineering application is slow. The above factors will affect the development of high-energy beam processing technology in China. We must take practical measures to actively overcome difficulties and strive to track the advanced world level and narrow the gap. The specific measures are as follows:
(1) Combine research work and carry out international cooperation to improve the scientific research starting point of high-energy beam processing technology. The foreign developed countries have many successful experiences and advanced methods in the research of high-energy beam processing technology. Therefore, in conjunction with our research direction and cooperation with them, we can grasp new trends in world development and improve the starting point for scientific research in the short term.
(2) According to the principle of "demand traction, promote scientific and technological progress, make some achievements, and do something wrong," we will carry out basic and applied research on key directions. The research field and application direction of high-energy beam processing technology is very wide, but the national conditions (funding, time, etc.) do not allow us to have a comprehensive research work. We must formulate corresponding application technology research directions based on the needs of the industrial sector, especially the defense industry. Some necessary basic research as a technical reserve.
(3) Implement the "open, flow, and unite" operating mechanism. The "High-energy Beam Processing Technology Key Laboratory" is a base for carrying out research on high-energy beam processing technology. Only an open, mobile, and joint operating mechanism can truly play its role, and attracts people with lofty aspirations from other research institutes and schools. Carry out research to achieve complementary advantages, so that the overall level of high-energy beam processing technology in China has been improved.
Third, the research direction of China's high-energy beam processing technology and "High-energy beam processing technology key laboratory" during the "Ninth Five-Year Plan" research work (I) Research direction The research directions of high-energy beam processing technology in China mainly focus on the following three aspects: (1) Research on high energy beam processability and process optimization technology for new materials and difficult-to-machine materials; (2) New structure of weaponry and equipment The new laser beam, electron beam, plasma beam and new processing methods and key technology and equipment; (3) to improve the performance of high-energy beam beam source and process control and quality monitoring technology research.
(2) "Key Laboratory of High-energy Beam Processing Technology for National Defense Science and Technology" during the "Ninth Five-Year Plan" Period The main research work of the "High Energy Beam Processing Technology Key Laboratory" during the "Ninth Five-Year Plan" period is: (1) High quality Research on Laser Hole Making and Quality Assurance Technology; (2) Research on Precision Laser Welding Technology; (3) Laser Shock Hardening Technology; (4) Laser Holography Technology Used for Weld Seam Quality Inspection; (5) Laser Rapid Prototyping Technology (6) Multi-functional electron beam processing technology and integrated process research; (7) Research on large thick piece electron beam welding technology; (8) Electron beam physical vapor deposition technology research; (9) Plasma spraying high performance coating technology research; (10) Research on supersonic plasma spraying technology; (11) Research on pulsed plasma arc welding technology; (12) Research on comprehensive plasma source ion implantation technology.
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