钛合金激光焊接及其熔池流动场数值模拟
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摘要
钛合金由于密度小,比强度高,耐蚀性好等特点,广泛用于航空航天领域。激光焊接由于具有能量集中,焊缝成形好,操作简单等优势,正在成为钛合金焊接的重要手段。常规熔焊方法形成的焊接接头晶粒粗大,机械性能较差,焊接组织还需进行焊后热处理,降低了焊接效率。研究钛合金激光焊接技术,有利于提高导弹壳体材料焊接接头综合性能,在急需提高国防实力的今天,意义特别重大。
钛合金在高温下强烈吸收氮、氢、氧等气体,吸收这些气体严重影响焊接接头质量;其次钛合金焊接过程中会产生强烈的光致等离子体,如果等离子体不能很好地控制,就会对激光造成屏蔽,影响激光焊接的稳定性,对比钛合金与低碳钢焊接时的等离子体光信号强度,可以发现钛合金激光焊接等离子体光信号强度明显高于低碳钢激光焊接等离子体光信号强度。为了解决这些问题,设计专用同轴喷嘴用于钛合金激光焊接。
同轴喷嘴设计的关键问题在于如何获得稳定均匀的同轴气流,使气流在控制等离子体的同时,又能为钛合金高温熔池提供保护。系统地分析了侧吹气流控制等离子体的缺点,提出了在钛合金激光焊接过程中采用同轴气流控制等离子体的方案。为了获得稳定的流场,首次对激光焊接同轴喷嘴内部流场进行了有限元分析,分别比较了不同内腔直径、圆柱状与“漏斗”状内腔、有无收敛喷管、不同出口直径以及不同进气流量对气体出口流速影响。结果表明,当进气流量和出口直径相同时,带收敛喷管的“漏斗”状结构可获得最大的轴向流速和最小的湍流脉动,从而可以有效地减小保护气的无谓消耗。喷嘴气流试验表明:设计的同轴喷嘴能成功地抑制等离子体;拖罩流量为1.0m3/h,同轴气流量范围为0.25～1.25m3/h时,可以获得银白色的焊缝;最佳同轴进气流量为0.5m3/h;当同轴气流量超过1.5 m3/h时,焊缝金属轻微氧化,超过1.75 m3/h时,焊缝金属明显氧化,对应的湍流脉动动能明显增加,表明喷嘴气流紊乱是导致焊缝金属氧化的重要原因。
采用设计的同轴喷嘴进行激光焊接试验,研究了焦点位置变化对焊接过程的影响。BT20及TC1合金激光焊接接头焊缝组织均为马氏体组织,晶内为片状α'相;接头拉伸强度和显微硬度超过母材,塑性稍低于母材。同氩弧焊相比,激光焊接有
明显的优势,深宽比为氩弧焊的6～7倍,焊接速度可以达到氩弧焊的5～10倍。试验过程中还确定了激光焊接头拼缝间隙的宽容度,完成了卷制钛合金圆筒的焊接。
气孔是钛合金焊接的常见问题,尤其是宏观气孔的存在,不仅削弱焊缝的有效工件断面,同时也会带来应力集中,有必要搞清楚气孔形成的机理。锁底对接接头焊接以及自熔焊接试验表明,钛合金未穿透激光焊接过程中会形成宏观气孔,酸洗与否对宏观气孔的形成没有明显的影响。根据气孔的分布位置和尺寸大小,提出将钛合金激光焊接气孔分类为Ⅰ型气孔和Ⅱ型气孔。基于试验研究和熔池流动模拟计算结果,建立了两类气孔各自的形成模型。与局部高温造成金属蒸气定向喷射的模型不同,认为未穿透焊接过程中Ⅰ型气孔形成的机理是由于保护气体进入小孔,破坏了小孔后壁的压力平衡,形成小孔后壁液体金属波动凹坑,随着工件的运动,凹坑朝向小孔的开口失稳闭合形成“空腔”;小孔底部随着熔深的波动突变也很容易闭合形成“空腔”;由于受熔池金属中双对流环的影响,当“空腔”在熔池上部形成时,“空腔”会沿熔池中心迅速流动到焊缝的上表面逸出,而在熔池下部形成的“空腔”,只能够在熔池下部流动,且熔池未穿透,“空腔”不可能向下逸出,随着熔池金属的凝固而形成气孔。Ⅱ型气孔的形成机理是氢在凝固过程中由于溶解度突然下降,氢析出后来不及逸出而残留在焊缝内部形成气孔。
首次建立了复合热源作用下的激光穿透焊接熔池流动三维准稳态计算模型,热源由作用在激光表面的高斯热源以及沿激光入射方向的柱状热源组成,分别考虑了等离子体和小孔吸收机制。计算过程中,将带松弛因子的动量插值算法引入SIMPLE算法,从而成功地采用非交错网格对模型离散求解,解决了计算过程中压力和速度波动问题,保证计算结果与松弛因子无关;通过添加源项的办法解决了过渡区相变问题,从而将固态区和液态区组合一起求解,简化了固液边界条件的处理难度。通过TC1钛合金激光焊接试验验证了模型的正确性,计算所得的熔池截面与试验结果吻合良好,结果表明,Marangoni对流是形成激光穿透焊“沙漏”状熔池形貌的主要原因。
With the advantages of low density, high strength-to-weight ratio and superior corrosion resistance, titanium alloys have been applied more and more widely in the fields of aviation and aerospace industries. As the laser welding has some characteristics such as high speed, good appearance and narrow HAZ, it becomes a main method for titanium alloys welding. The weld microstructures produced by traditional welding methods are abnormally coarse and the comprehensive properties of the weld are poor due to the large heat input. And the weld needs post-weld heat treatment, which will decrease the welding efficiency. The investigation of the technology of titanium alloys laser welding benefits improvement of the weld quality used for missile shells. It is very important to increase the national defense power.
Titanium alloys absorb a large amount of N2, H2 and O2 gas at high temperature, which will badly destroy the weld performances; on the other hand, the intensive plasma appears during the titanium alloy laser welding, which influences the welding stability if the plasma is not controlled efficiently. The differences of the intensity of plasma light signal between titanium alloy and steel are studied, and the results indicate the light signal intensity produced during the laser welding for titanium alloy was greater than that for low-carbon steel. A special coaxial nozzle was designed to resolve the difficulties of the titanium alloys laser welding.
The key point of designing coaxial nozzle is how to acquire the steady airstream, which can be used to control the plasma and protect the molten pool at high temperature at the same time. Based on the analysis of the disadvantage of control plasma by side flow gas, a scheme was proposed that a coaxial nozzle was chose to control plasma for titanium alloy laser welding. In order to acquire the steady airflow, an analysis of flow with in the nozzles was executed for the first time. The flow in different diameters of nozzle, cylinder cavum and “filter” cavum structure, with and without convergence pipe, different outlet diameters and different input gas flux was compared. The calculated results indicate that the maximum axial flow speed and the minimum turbulent kinetic energy can be attained in the “filter” cavum structure with convergence pipe when the inlet flux and outlet diameters are equal, by which the consumption of the shielding gas can be efficiently reduced. A welding experiment was executed to study the flow of gas in nozzle. The
results indicate that the designed nozzle can be successfully used for suppressing the plasma; the silvery weld can be attained when the flux of gas from the coaxial nozzle is in the range of 0.25~1.25m3/h and that from the rear-cover is 1.0m3/h; the optimum flux of gas from the coaxial is 0.5m3/h. When the gas from coaxial nozzle over 1.5 m3/h, the weld was slightly polluted by oxygen; when over 1.75 m3/h,the weld was evidently polluted by oxygen. At that time, the kinetic energy of turbulent gas increases notably, which indicates the turbulence of gas is the reason why the weld was polluted by oxygen.
The titanium alloy weld was produced with the coaxial nozzle to investigate the influence of the focus positions to the weld quality. The tensile strength and micro-hardness of the weld of BT20and TC1 are higher than of the base metal, but the elongation relatively low. The microstructure of weld is martensite with acicular α' phase. The tolerance of weld gap was determined and annular weld was produced during experiments. In comparison with TIG welding, laser welding for Titanium alloy has some advantages, such as the depth to width ratio is 6~7 times and the welding speed is 5~10 times as those of the TIG welding.
The porosity is a common defect in laser welding for titanium alloy. Especially, the macro porosity weakens the strength of the cross-area, but also cause the stress concentrated. It is necessary to make clear the mechanism of the porosity formation. The results of the weld with a pad and the autogenous weld
钛合金在高温下强烈吸收氮、氢、氧等气体,吸收这些气体严重影响焊接接头质量;其次钛合金焊接过程中会产生强烈的光致等离子体,如果等离子体不能很好地控制,就会对激光造成屏蔽,影响激光焊接的稳定性,对比钛合金与低碳钢焊接时的等离子体光信号强度,可以发现钛合金激光焊接等离子体光信号强度明显高于低碳钢激光焊接等离子体光信号强度。为了解决这些问题,设计专用同轴喷嘴用于钛合金激光焊接。
同轴喷嘴设计的关键问题在于如何获得稳定均匀的同轴气流,使气流在控制等离子体的同时,又能为钛合金高温熔池提供保护。系统地分析了侧吹气流控制等离子体的缺点,提出了在钛合金激光焊接过程中采用同轴气流控制等离子体的方案。为了获得稳定的流场,首次对激光焊接同轴喷嘴内部流场进行了有限元分析,分别比较了不同内腔直径、圆柱状与“漏斗”状内腔、有无收敛喷管、不同出口直径以及不同进气流量对气体出口流速影响。结果表明,当进气流量和出口直径相同时,带收敛喷管的“漏斗”状结构可获得最大的轴向流速和最小的湍流脉动,从而可以有效地减小保护气的无谓消耗。喷嘴气流试验表明:设计的同轴喷嘴能成功地抑制等离子体;拖罩流量为1.0m3/h,同轴气流量范围为0.25～1.25m3/h时,可以获得银白色的焊缝;最佳同轴进气流量为0.5m3/h;当同轴气流量超过1.5 m3/h时,焊缝金属轻微氧化,超过1.75 m3/h时,焊缝金属明显氧化,对应的湍流脉动动能明显增加,表明喷嘴气流紊乱是导致焊缝金属氧化的重要原因。
采用设计的同轴喷嘴进行激光焊接试验,研究了焦点位置变化对焊接过程的影响。BT20及TC1合金激光焊接接头焊缝组织均为马氏体组织,晶内为片状α'相;接头拉伸强度和显微硬度超过母材,塑性稍低于母材。同氩弧焊相比,激光焊接有
明显的优势,深宽比为氩弧焊的6～7倍,焊接速度可以达到氩弧焊的5～10倍。试验过程中还确定了激光焊接头拼缝间隙的宽容度,完成了卷制钛合金圆筒的焊接。
气孔是钛合金焊接的常见问题,尤其是宏观气孔的存在,不仅削弱焊缝的有效工件断面,同时也会带来应力集中,有必要搞清楚气孔形成的机理。锁底对接接头焊接以及自熔焊接试验表明,钛合金未穿透激光焊接过程中会形成宏观气孔,酸洗与否对宏观气孔的形成没有明显的影响。根据气孔的分布位置和尺寸大小,提出将钛合金激光焊接气孔分类为Ⅰ型气孔和Ⅱ型气孔。基于试验研究和熔池流动模拟计算结果,建立了两类气孔各自的形成模型。与局部高温造成金属蒸气定向喷射的模型不同,认为未穿透焊接过程中Ⅰ型气孔形成的机理是由于保护气体进入小孔,破坏了小孔后壁的压力平衡,形成小孔后壁液体金属波动凹坑,随着工件的运动,凹坑朝向小孔的开口失稳闭合形成“空腔”;小孔底部随着熔深的波动突变也很容易闭合形成“空腔”;由于受熔池金属中双对流环的影响,当“空腔”在熔池上部形成时,“空腔”会沿熔池中心迅速流动到焊缝的上表面逸出,而在熔池下部形成的“空腔”,只能够在熔池下部流动,且熔池未穿透,“空腔”不可能向下逸出,随着熔池金属的凝固而形成气孔。Ⅱ型气孔的形成机理是氢在凝固过程中由于溶解度突然下降,氢析出后来不及逸出而残留在焊缝内部形成气孔。
首次建立了复合热源作用下的激光穿透焊接熔池流动三维准稳态计算模型,热源由作用在激光表面的高斯热源以及沿激光入射方向的柱状热源组成,分别考虑了等离子体和小孔吸收机制。计算过程中,将带松弛因子的动量插值算法引入SIMPLE算法,从而成功地采用非交错网格对模型离散求解,解决了计算过程中压力和速度波动问题,保证计算结果与松弛因子无关;通过添加源项的办法解决了过渡区相变问题,从而将固态区和液态区组合一起求解,简化了固液边界条件的处理难度。通过TC1钛合金激光焊接试验验证了模型的正确性,计算所得的熔池截面与试验结果吻合良好,结果表明,Marangoni对流是形成激光穿透焊“沙漏”状熔池形貌的主要原因。
With the advantages of low density, high strength-to-weight ratio and superior corrosion resistance, titanium alloys have been applied more and more widely in the fields of aviation and aerospace industries. As the laser welding has some characteristics such as high speed, good appearance and narrow HAZ, it becomes a main method for titanium alloys welding. The weld microstructures produced by traditional welding methods are abnormally coarse and the comprehensive properties of the weld are poor due to the large heat input. And the weld needs post-weld heat treatment, which will decrease the welding efficiency. The investigation of the technology of titanium alloys laser welding benefits improvement of the weld quality used for missile shells. It is very important to increase the national defense power.
Titanium alloys absorb a large amount of N2, H2 and O2 gas at high temperature, which will badly destroy the weld performances; on the other hand, the intensive plasma appears during the titanium alloy laser welding, which influences the welding stability if the plasma is not controlled efficiently. The differences of the intensity of plasma light signal between titanium alloy and steel are studied, and the results indicate the light signal intensity produced during the laser welding for titanium alloy was greater than that for low-carbon steel. A special coaxial nozzle was designed to resolve the difficulties of the titanium alloys laser welding.
The key point of designing coaxial nozzle is how to acquire the steady airstream, which can be used to control the plasma and protect the molten pool at high temperature at the same time. Based on the analysis of the disadvantage of control plasma by side flow gas, a scheme was proposed that a coaxial nozzle was chose to control plasma for titanium alloy laser welding. In order to acquire the steady airflow, an analysis of flow with in the nozzles was executed for the first time. The flow in different diameters of nozzle, cylinder cavum and “filter” cavum structure, with and without convergence pipe, different outlet diameters and different input gas flux was compared. The calculated results indicate that the maximum axial flow speed and the minimum turbulent kinetic energy can be attained in the “filter” cavum structure with convergence pipe when the inlet flux and outlet diameters are equal, by which the consumption of the shielding gas can be efficiently reduced. A welding experiment was executed to study the flow of gas in nozzle. The
results indicate that the designed nozzle can be successfully used for suppressing the plasma; the silvery weld can be attained when the flux of gas from the coaxial nozzle is in the range of 0.25~1.25m3/h and that from the rear-cover is 1.0m3/h; the optimum flux of gas from the coaxial is 0.5m3/h. When the gas from coaxial nozzle over 1.5 m3/h, the weld was slightly polluted by oxygen; when over 1.75 m3/h,the weld was evidently polluted by oxygen. At that time, the kinetic energy of turbulent gas increases notably, which indicates the turbulence of gas is the reason why the weld was polluted by oxygen.
The titanium alloy weld was produced with the coaxial nozzle to investigate the influence of the focus positions to the weld quality. The tensile strength and micro-hardness of the weld of BT20and TC1 are higher than of the base metal, but the elongation relatively low. The microstructure of weld is martensite with acicular α' phase. The tolerance of weld gap was determined and annular weld was produced during experiments. In comparison with TIG welding, laser welding for Titanium alloy has some advantages, such as the depth to width ratio is 6~7 times and the welding speed is 5~10 times as those of the TIG welding.
The porosity is a common defect in laser welding for titanium alloy. Especially, the macro porosity weakens the strength of the cross-area, but also cause the stress concentrated. It is necessary to make clear the mechanism of the porosity formation. The results of the weld with a pad and the autogenous weld
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