863 TIG welding in aero-engine manufacturing

(5/5 for @liwers_loor League)

"It's a good thing that there are more crazy scientists. There are still too few of these crazy scientists in our country. "Liu Yijiu doesn't think there's anything wrong with these people who are engaged in scientific research being crazy.

On the contrary, he felt that only the emergence of crazy scientists would allow a country to advance by leaps and bounds.

It was because of the many crazy scientists that the Soviet Union had the emergence of the Caspian Sea monster, the nuclear energy aircraft, the huge attack nuclear submarine, the condensation nuclear reaction battery and a series of black technologies.

These things allowed Lao Maozi to be able to deter US imperialism for decades after the collapse of the Soviet Union.

"Crazy, can you afford it? The engine of your fighter plane has a problem again...... "Many of Liu Yijiu's projects are because of madness, but until now, it is obviously just an imitation, and it has to be changed beyond recognition."

So far, no finished product has come out.

Hearing Long Yaohua's words, Liu Yijiu immediately frowned, "Didn't our engine say that it had been tested on the air platform?" ”

"I flew for more than 20 hours, and something went wrong." Long Yaohua sighed a little.

When Liu Yijiu heard this, the corners of his mouth twitched.

"Chief, why don't you help me communicate with the Ministry of Aerospace Industry about the engine project first? The originally scattered technical research is obviously not possible. It has to come together, and this can be done together, on their side, on our side. However, I think that even on their side, it is better to be in Rongcheng. Liu Yijiu's heart is now eager.

Turbofan VI succeeded. But the engine with a larger thrust-to-weight ratio, the turbofan eight, has been studied for many years.

This must have happened for a while, otherwise Long Yaohua would not have told him at this time.

There is no way to solve even an aero engine, so how can we solve the plug engine that the Americans did not solve in the first two decades of the twenty-first century?

"You're in a hurry to go back?"

"Can I not go? The Panda prototype has an American engine, but we can't just fly a prototype. "Liu Yijiu is also a big head.

Domestic fighters, in fact, are poor engines.

Only two F14 Panda fighters were obtained from Iran. There are only four engines in total, one is training pilots, and the other has been dismantled for research. The engine was used for the first flight of the prototype, as well as for test flights.

Once something goes wrong, there's no follow-up.

It is now impossible for the USSR to export AL-31 engines to China.

Again, it is even more unlikely that the Americans will export engines to China.

For the single-engine J-8 II fighter with not advanced performance, the Americans ended up dragging it.

Liu Yijiu soon returned to Rongcheng. Directly from the airport to the 132 factory. On the way, I listened to the work report of Qi Hai, the chief designer of the engine.

The turbofan 8 used in the F-14 Panda fighter, which has been disassembled and assembled many times, was very effective in the ground test platform experiment, but problems arose after it went into the sky. The main manifestation is that the welded connection of important parts of the engine cannot maintain stability when the fighter is maneuvering at high speed, and the weld cracks occur.

"Did you find the reason?" Liu Yijiu asked with a frown.

There is a big difference between a ground test platform and an air test platform.

Moreover, for the sake of ease of detection, the engine and fuselage were not completely covered with skin when the aerial test platform was tested. This also makes it easier to spot problems with the engine.

"Found it. It's the welding process we adopt that doesn't work......" Qi Hai looked at Liu Yijiu with some embarrassment. "During the welding process, the titanium alloy oxidizes during the high-temperature welding process. Morph ......"

"When you produce, isn't argon arc welding used?" Liu Yijiu has never paid attention to this issue.

This is because the engine research project team never asked this question.

Usually they are very busy, and there is not much time to understand the specific production process.

The domestic technical foundation is too poor, and any project basically starts with the most basic supporting materials, manufacturing processes, and even equipment and a series of problems.

If Liu Yijiu has to do everything himself, and a hundred more Liu Yijiu will not be enough.

"TIG welding? We are using this welding process, using argon to protect, and then welding, but there is still a phenomenon of oxidation, and the air platform of the test flight has a slightly larger range of action, and there will be problems. "Domestic titanium alloy is not a high-cost material in the Ninth Academy.

Moreover, with the emergence of titanium alloy, the processing problem of titanium alloy is placed in front of many technicians in the third area.

Whether it is cold working for cutting or hot working for welding, various technologies are being studied.

Liu Yijiu once mentioned that under the protection of argon, welding titanium alloy will not oxidize, and then their titanium alloy has been used for such a long time, and there has been no quality problem.

Now that such a thing appears makes Liu Yijiu a little big.

Along the way, he didn't ask anything, and when he arrived at the engine assembly workshop of Factory 132, Liu Yijiu saw the engine with cracked welds.

It is not only the welds between the titanium alloys that have problems, but also the welds of the superalloys.

When Qi Hai was observing Liu Yijiu, he introduced the working time of each engine and the various parameters of the fighter when there was a problem.

After the observation, Liu Yijiu did not say anything, but directly determined the process production route through the process documents.

After the inquiry of the assembled technical workers, the entire production process was investigated, and it was found that the argon arc welding process used in the production process is conventional argon arc welding, that is, directly during welding, through the argon gas installed in the compressed gas tank to protect the melted welding material, so as to weld.

When I think of UMPO, a subordinate unit of the Russian United Engine Group, when manufacturing the AL-31 engine, in order to ensure the integrity and accuracy of the welding of the engine parts, the welding of the key welding points of all the components is carried out by workers in the "atmosphere-24" pressurized cabin that can reach two atmospheres.

The "Atmosphere-24" pressurized chamber is the largest pressurized chamber in Russia, and in 1981, UMPO manufactured this pressurized chamber at the Prometheus Institute in Leningrad, mainly for the production of the engine AL-31 for the Su-27.

However, China does not have such a pressurized cabin.

The turbofan 8 is not AL-31, but the production process is basically based on this.

After all, the engine used at the beginning of the domestic J-10 was the AL-31 imported from Russia, and the domestic engine was not used until the turbofan 10 was fully developed.

"Designing and building a pressurized chamber capable of reaching two atmospheres can solve this problem? If this problem can really be solved, will Simonloff not bring it up? He is the chief designer of the Su-27, so it is impossible not to understand this situation......" Qi Hai did not believe too much in the statement put forward by Liu Yijiu.

TIG welding technology has been used for such a long time, and there has never been such a problem.

"Did you let Simon Love meddle in this? Moreover, all he wants is an engine, he is an aircraft designer, not an engine designer! Liu Yijiu didn't pursue these things too much.

Simonlov has now devoted most of his time and energy to the design of the new Giant Panda J-10 fighter.

And the test flight is being carried out by the imitation F-14.

"The AL-31 engine is indeed produced in this way, especially the welding process, almost all the key components are welded, all in the pressurized cabin, and other welding methods cannot compare the quality at all......" When he heard Liu Yijiu ask about the welding process used by the Su-27, Simonlov did not hesitate to tell everything he knew.

If it weren't for Liu Yijiu being with him from the moment he got off the plane, Qi Hai would even suspect that the two were colluding.

“…… The pressurized chamber is divided into a working area and an airlock, and the welders put on protective clothing that connects to the ventilation pipes outside and enter the airlock through the first door, then close the hatch and inject argon into the airlock, and wait until the airlock is filled with argon to reach the pressure balance, and then the welders will weld ......" Although Simonlov does not know the details of "Atmosphere-24", Liu Yijiu knows it clearly.

The AL-31 engine is very familiar to anyone in the Republic who has studied aviation equipment.

You can receive a lot of information online.

Liu Yijiu: They are very familiar with these technologies and even the entire engine production process.

So, under his personal responsibility, the 611 Institute began the design of the pressurized cabin.

This kind of work is the first time for 611, but with Liu Yijiu's participation, the design work was carried out quickly, and the plan was come up with in just over ten days and put into manufacturing.

In the process of waiting for the production of the pressurized cabin, Liu Yijiu asked the special clothing design unit of the Eighth District of the Ninth Academy to design and produce the protective clothing connected to the ventilation pipe, he provided a preliminary plan, and then began to sort out the production process of AL-31 that he knew.

In particular, the production of each key link and the matters that need attention.

It took more than 20 days in a row, and it was only after the pressurized cabin was produced that the process was completely straightened out.

He did not put the production process into production at the first time, and the problem with the turbofan-8 engine was not because of this, as long as the experiment was carried out, the results would be obtained quickly.

If there is no problem, there is nothing wrong with putting it back into production.

(To be continued.) )