Method for manufacturing curved thin-walled intermetallic compound component by winding mandrel with metal foil strips

A method for manufacturing a curved intermetallic compound component by winding a mandrel with metal foil strips, comprising the following steps:

• step 1, designing prefabricated blank:
• carrying out characteristic analysis on a curved component to determine shape of a prefabricated blank required;
• step 2, preparing an internal support mandrel:
• determining material of an internal support mandrel required, and preparing the internal support mandrel according to the shape of the prefabricated blank determined in step 1;
• step 3, determining thicknesses and layer numbers of foil strips:
• determining total thickness ratio of A foil strips to B foil strips according to atom number ratio of A atoms to B atoms in an intermetallic compound AxBy, wherein A is Ni or Ti, and B is Al;
• determining total thicknesses of the A foil strips and the B foil strips according to wall thickness of the curved component to be finally formed and thickness of the internal support mandrel;
• determining laying sequence of the foil strips based on the internal support mandrel;
• A is the material of the internal support mandrel for increasing the bonding degree of the internal support mandrel and a laminated foil prefabricated blank, B is the material of the foil strips which is adjacent to the surface layer of the internal support mandrel, and forming the A foil strips and the B foil strips in a manner of B, A, B . . . A as the laying sequence, starting from the surface layer of the internal support mandrel;
• when the layer number of the A foil strips is n, the layer number of the B foil strips is also n, and the value of n depends on the ratio of respective total thickness to respective single layer thickness of the A foil strips and the B foil strips;
• step 4, determining widths of the foil strips:
• carrying out three-dimensional scanning on the curved component to obtain the shape of surface contour thereof, then performing curvature analysis on each characteristic region of the surface contour thereof to determine the applicable widths of a single layer of A foil strips and a single layer of B foil strips in each characteristic region;
• step 5, establishing a laying process:
• establishing a laying sequence according to the laying sequence and layer numbers of the A foil strips and the B foil strips determined in step 3, and establishing a laying path of each layer of foil strips according to the thicknesses of a single layer of A foil strips and a single layer of B foil strips determined in step 3 and step 4 as well as the widths of a single layer of A foil strips and a single layer of B foil strips in each characteristic region;
• step 6, pretreating surfaces of the foil strips:
• pretreating the surfaces of the foil strips before laying of the foil strips;
• first, scrubbing the surfaces of the A foil strips and the B foil strips with organic solvent, then washing the A foil strips with acid, and washing the B foil strips with alkaline;
• step 7, laying A foil strips and B foil strips:
• alternately laying the foil strips on the surface layer of the internal support mandrel in sequence according to the laying process established in step 5, so that a laminated foil prefabricated blank with an internal support mandrel is obtained;
• step 8, carrying out bulge forming on the laminated foil prefabricated blank:
• placing the laminated foil prefabricated blank with an internal support mandrel in a gas bulging forming mould and carrying out bulge forming, so as to make the laminated foil prefabricated blank fully fayed with the gas bulging forming mould to obtain a required bulged component shape;
• step 9, carrying out reaction synthesis and densification treatment on a bulged component:
• carrying out diffusion synthesis reaction and densification treatment on a bulged component with an internal support mandrel at high temperature and high pressure;
• diffusion synthesis reaction:
• synthesis of the first reaction, heating the gas bulging forming mould to 610° C.-650° C., increasing gas pressure to 10-20 MPa, and keeping the temperature and the pressure for 2-5 hours;
• next, carrying out synthesis of the second reaction, heating the gas bulging forming mould to 1000° C.-1300° C., increasing gas pressure to 10-50 MPa, and keeping the temperature and the pressure for 2-4 hours;
• densification treatment:
• heating the gas bulging forming mould to 1000° C.-1300° C., increasing gas pressure to 50-100 MPa, and keeping the temperature and the pressure for 1-5 hours, thereby obtaining a complex curved surface component, wherein the material thereof is Ni—NiAl or Ti—TiAl.