Integrated method for manufacturing high-temperature resistant thin-walled component by preforming by laying metal foil strip

An integrated method for manufacturing a high-temperature resistant thin-walled component by preforming by laying a metal foil strip, comprising steps of:

• defining a dimensional size and a shape for a thin-walled preform;
• forming a support die by using an inner wall of the preform as a characteristic surface;
• defining a thickness of a plurality of A single-layer foil strips and a plurality of B single-layer foil strips:
• calculating a total thickness ratio of the A single-layer foil strips composed of a metal A to the B single-layer foil strips composed of a metal B, and then calculating theft thickness of the A single-layer foil strips and the B single-layer foil strips, according to a ratio of the number of atoms A to the number of atoms B in an intermetallic compound (IMC) composed of the metal A and the metal B;
• defining a width of each foil strip:
• defining a width for each of the A single-layer foil strips and each of the B single-layer foil strips applicable in each characteristic zone to produce the plurality of the A single-layer foil strips and the B single-layer foil strips, and pretreating each of the A single-layer foil strips and each of the B single-layer foil strips;
• developing a laying process:
• determining a sequence and a path for laying each layer of foil, according to the thickness of the A single-layer foil strips and the B single-layer foil strips and the width of the A single-layer foil strips and the B single-layer foil strips in each characteristic zone;
• laying the A single-layer foil strips and the B single-layer foil strips:
• alternately laying the plurality of A single-layer foil strips and B single-layer foil strips on a surface of the support die according to the sequence and the path for laying each layer of foil;
• filling a first gap between the A single-layer foil strips vertically adjacent to each other with one of an A liquid or an A powder made of the metal A, and filling a second gap between the B single-layer foil strips vertically adjacent to each other with one of a B liquid or B powder made of the metal B to define an AB laminated preform on the support die;
• obtaining the AB laminated preform:
• separating the AB laminated preform from the support die to obtain the AB laminated preform;
• bulging the AB laminated preform:
• placing the AB laminated preform into a bulging die to bulge to fully fit with the bulging die to produce a bulged component with a desired shape;
• performing a reactive synthesis and a densification process of the bulged component:
• subjecting the bulged component to a diffusion synthesis and a densification process under a high temperature and a high pressure in the bulging die to produce a complex thin-walled alloy component;
• performing a subsequent treatment of the complex thin-walled alloy component:
• cutting or polishing an end and a surface of the complex thin-walled alloy component;
• wherein the support die is formed from a foam plastic by using an inner wall of the thin-walled shaped component as the characteristic surface by three-dimensional (3D) printing.