铝合金激光填丝点焊工艺研究
摘要
铝及其合金重量轻,成型性好,高的比强度,抗腐蚀性能优良,其在航空、汽车、造船等领域的应用越来越广泛。但是激光点焊铝合金时,却容易出现裂纹、下塌等缺陷,并且焊点的抗拉剪能力和激光点焊的间隙适应能力较低。本文采用了填充焊丝的方法来改善上述问题,获得了高质量的焊点。
本论文建立了一套送丝控制系统。利用计算机和NI数据采集卡,实现了对焊丝抽送运动、送丝速度和激光开闭的控制,可以方便的设置送丝延迟时间、送丝时间和激光点焊时间等参数,从而实现激光器与送丝机之间的协调控制。
论文研究了送丝角度、送丝高度、延迟时间、送丝量等送丝参数对焊点成形和缺陷的影响。结果显示:送丝角度和送丝高度是焊丝熔化后能否稳定进入熔池的关键因素,送丝角30°左右,送丝高度为0mm-1.5mm时,熔化焊丝进入熔池最为稳定;延迟时间过短,在熔池尺寸过小时就送进焊丝,易造成焊丝在试件上表面的堆积;而送丝量与焊点表面下塌的改善效果相关。
通过填充焊丝,焊点表面的下塌问题得到了解决;进而缓解了焊点下塌中心的应力集中,对裂纹的产生有了抑制作用;焊点的X射线图片显示,焊点中气孔的数量有所减少。本文还发现,焊点的抗拉剪载荷的大小不仅仅与熔合面的直径有关,还与下塌有关,下塌过大时,会引起焊点断裂路径的改变,显著的减小了抗拉剪能力。
最后对有间隙情况下的激光点焊进行了研究。实验时发现,不填丝时能连接的最大间隙为1.0mm,而通过填丝,则实现了2.5mm间隙情况下的连接;填丝之后,改善了焊点的成形,增加了间隙处金属连接层的厚度,增加了焊点的间隙搭桥能力,同时焊点的力学性能也得到了显著的提高,同样间隙条件下,抗拉剪载荷比未填丝的焊点要高出60%以上。结果显示,用于间隙搭桥的金属量决定了焊点间隙连接的能力和强度。
Asaluminumanditsalloysarelight,goodformabilityandhavehighstrength-to-weightratio,goodmechanicalpropertiesatlowtemperatureandexcellentcorrosionresistance,theyareusedmoreandmoreintheaerospace,automotive,shipbuildingandotherfields.Laserspotweldinghashighaccuracy,highflexibilityandotheradvantages.However,cracks,collapsedandotherdefectsareoftenobservedinaluminumalloyweldsbylaserspotweldingprocess.Besides,theabilitytoresisttotensile-shearandtobridgegapispoor.Weusefillerwiretosolvetheaboveproblemsandgethighqualitywelds.
UsingtheLabVIEWandNIdataacquisitioncard,sequentialpulseswereacquired,thentheopeningandclosingofthewirefeederandthelaserraster,wirefeedspeedscanbecontrolled.ByDAQAssistant,wecaneasilysetthedelaytime,wire-feedtimeandlaserspotweldingtime.Sincethelaserandthewirefeedercanbecontrolledcoordinately,thelaserspotweldingwithfillerwireiscarriedout.
Theangle,heightandvolumeofthefillerwire,thedelaytimeandotherparametershaveeffectontheforminganddefectsofthewelds.Theexperimentsresultsshowthat,theangleandtheheightofthefillerwirearethekeyfactorswhichinfluencethestabilityoftheprocessofthemeltwireintothepool,whenthewirewasfeedatanangleof30°orso,height0mm-1.5mm,thefeedprocesswasmoststable;thedelaytimeisoneofthemainfactorswhichdeterminethepoolsize,whenthedelaytimeistooshort,itcaneasilyresultwireaccumulationonthesurfaceofthespecimen;Thevolumeofthewirefeedintothepoolisdirectlyrelatedtothesizeofcollapse.
Theweldsthathavenocollapsewerereceived.Thusthestressconcentrationwerealleviated,thecrackproblemwaseffectivelyinhibited;X-raypicturesshowthatthenumberoftheporesintheweldsweresignificantlyreduced.Itwasalsofoundthatthetensileshearloadofweldsarenotonlywiththediameterofcriticalnugget,butalsowiththesizeofthecollapse,whenthecollapseislarge,itwillleadtochangeofthefracturepathandreducetensionshearcapacitysignificantly.
Finally,thelaserspotweldingwithgapbetweentheplateswasstudied.Thestudyshowsthatthelargestgapthatcanbebridgedbythebasemetalisonly1.0mm,whilethisnumbercanreach2.5mmbyusingthefillerwiretobridgethe gap;Bycontrasttotheweldswhichhavenofiller,theweldswhichhavefillerhavegoodformation;Thethicknessofthemetaltobridgethegapismorelarger,sotheabilitytobridgethegapisimprovedgreatly,Moreover,thetensile-shearstrengthis60%higherormore,whichisalsoimprovedgreatly.Itcanbeconcludedthattheamountofmetalusedforgapbridgingdeterminestheabilityofgapjoiningandthestrengthofthewelds.
本论文建立了一套送丝控制系统。利用计算机和NI数据采集卡,实现了对焊丝抽送运动、送丝速度和激光开闭的控制,可以方便的设置送丝延迟时间、送丝时间和激光点焊时间等参数,从而实现激光器与送丝机之间的协调控制。
论文研究了送丝角度、送丝高度、延迟时间、送丝量等送丝参数对焊点成形和缺陷的影响。结果显示:送丝角度和送丝高度是焊丝熔化后能否稳定进入熔池的关键因素,送丝角30°左右,送丝高度为0mm-1.5mm时,熔化焊丝进入熔池最为稳定;延迟时间过短,在熔池尺寸过小时就送进焊丝,易造成焊丝在试件上表面的堆积;而送丝量与焊点表面下塌的改善效果相关。
通过填充焊丝,焊点表面的下塌问题得到了解决;进而缓解了焊点下塌中心的应力集中,对裂纹的产生有了抑制作用;焊点的X射线图片显示,焊点中气孔的数量有所减少。本文还发现,焊点的抗拉剪载荷的大小不仅仅与熔合面的直径有关,还与下塌有关,下塌过大时,会引起焊点断裂路径的改变,显著的减小了抗拉剪能力。
最后对有间隙情况下的激光点焊进行了研究。实验时发现,不填丝时能连接的最大间隙为1.0mm,而通过填丝,则实现了2.5mm间隙情况下的连接;填丝之后,改善了焊点的成形,增加了间隙处金属连接层的厚度,增加了焊点的间隙搭桥能力,同时焊点的力学性能也得到了显著的提高,同样间隙条件下,抗拉剪载荷比未填丝的焊点要高出60%以上。结果显示,用于间隙搭桥的金属量决定了焊点间隙连接的能力和强度。
Asaluminumanditsalloysarelight,goodformabilityandhavehighstrength-to-weightratio,goodmechanicalpropertiesatlowtemperatureandexcellentcorrosionresistance,theyareusedmoreandmoreintheaerospace,automotive,shipbuildingandotherfields.Laserspotweldinghashighaccuracy,highflexibilityandotheradvantages.However,cracks,collapsedandotherdefectsareoftenobservedinaluminumalloyweldsbylaserspotweldingprocess.Besides,theabilitytoresisttotensile-shearandtobridgegapispoor.Weusefillerwiretosolvetheaboveproblemsandgethighqualitywelds.
UsingtheLabVIEWandNIdataacquisitioncard,sequentialpulseswereacquired,thentheopeningandclosingofthewirefeederandthelaserraster,wirefeedspeedscanbecontrolled.ByDAQAssistant,wecaneasilysetthedelaytime,wire-feedtimeandlaserspotweldingtime.Sincethelaserandthewirefeedercanbecontrolledcoordinately,thelaserspotweldingwithfillerwireiscarriedout.
Theangle,heightandvolumeofthefillerwire,thedelaytimeandotherparametershaveeffectontheforminganddefectsofthewelds.Theexperimentsresultsshowthat,theangleandtheheightofthefillerwirearethekeyfactorswhichinfluencethestabilityoftheprocessofthemeltwireintothepool,whenthewirewasfeedatanangleof30°orso,height0mm-1.5mm,thefeedprocesswasmoststable;thedelaytimeisoneofthemainfactorswhichdeterminethepoolsize,whenthedelaytimeistooshort,itcaneasilyresultwireaccumulationonthesurfaceofthespecimen;Thevolumeofthewirefeedintothepoolisdirectlyrelatedtothesizeofcollapse.
Theweldsthathavenocollapsewerereceived.Thusthestressconcentrationwerealleviated,thecrackproblemwaseffectivelyinhibited;X-raypicturesshowthatthenumberoftheporesintheweldsweresignificantlyreduced.Itwasalsofoundthatthetensileshearloadofweldsarenotonlywiththediameterofcriticalnugget,butalsowiththesizeofthecollapse,whenthecollapseislarge,itwillleadtochangeofthefracturepathandreducetensionshearcapacitysignificantly.
Finally,thelaserspotweldingwithgapbetweentheplateswasstudied.Thestudyshowsthatthelargestgapthatcanbebridgedbythebasemetalisonly1.0mm,whilethisnumbercanreach2.5mmbyusingthefillerwiretobridgethe gap;Bycontrasttotheweldswhichhavenofiller,theweldswhichhavefillerhavegoodformation;Thethicknessofthemetaltobridgethegapismorelarger,sotheabilitytobridgethegapisimprovedgreatly,Moreover,thetensile-shearstrengthis60%higherormore,whichisalsoimprovedgreatly.Itcanbeconcludedthattheamountofmetalusedforgapbridgingdeterminestheabilityofgapjoiningandthestrengthofthewelds.
引文
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2MasashiOIKAWA,KatsuhiroMINAMIDA.DEVELOPMENTOFTHELASERSPOTWELDEDSTAINLESSSTEELPANELFORVEHICLEBODY.CongressProceedings,ICALEO2006:330-336
3SeijiKATAYAMAA,kiraMATSUNAWA.EffectofPulseShapingonDefectReductioninPulsedLaserWelding.ICALEO.1992:547-556
4徐梅.点焊铝合金时点焊电极磨损研究.浙江大学工程硕士学位论文.2003:1-8
5宋东风,胡绳荪,马力.铝合金激光焊接技术的发展现状.电焊机.2004,09:34
6梁雪平,苏世怀.汽车拼板的激光焊接.钢铁钒钛.1999,04:17
7姚远.激光加工技术在国内外汽车工业中的应用概况.金属加工.2008.05:24-26,38
8杨春燕.激光焊接技术的应用与发展.西安航空技术高等专科学校学报.2008.26(5):18-20
9方志民,谢颂京,姚建华.激光加工在先进制造技术中的应用.机械工程师.2003,08:27-30
10J.M.Jouvard,K.Girard,O.Perret.KeyholeFormationandPowerDepositioninNd:YAGLaserSpotWelding.AppliedPhysics.2001,34:2894-2901
11T.W.JUHL,Olsen.AssessmentofHotCrackPropertiesofLaserWeldedStainlessSteelAlloys.ProceedingsofSPIE.2003,4831:128-134
12T.MYS,M.Geiger.UseofPulseinLaserSpotWeldingofmaterialswithhighopticalreflection.ProceedingsofSPIE.2003,5063:221-225
13A.MatsunaWa,M.Mizutani,S.Katayama.PorosityFormationMechanismandItsPreventioninLaserWelding.WeldingInternational.2002,17(6):431-437
14S.Katayama,S.Naoki,A.MatsunaWa.X-RayTransmissionIn-SituObservationofKeyholeduringLaserSpotWeldingandPulse-ShapingforPreventionofPorosity.ProceedingsofSPIE.2002,(3888):566-577
15赵守辉.铝合金激光点焊工艺优化.哈尔滨工业大学硕士学位论文.2006:20-27
16AlexanderF.H.KAPLAN,MasamiMIZUTANI,SeijiKATAYAMA,AkiraMATSUNAWA.KeyholeLaserSpotWelding.21thInternationalCongressonApplicationsofLasers&Electro-Optics(ICALEO2002).Scottsdale,Arizona,USA.2002:10
17AlexanderF.H.KAPLAN,MasamiMIZUTANI,SeijiKATAYAMA,AkiraMATSUNAWA.OntheMechanismofporeformationduringkeyholelaserspotwelding.ProceedingsofSPIE.2003,(4831):186-191
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19AlexanderF.H.KAPLAN,MasamiMIZUTANI,SeijiKATAYAMA,AkiraMATSUNAWA.AnalysisofDifferentMethodsforthePreventionofPoreFormationInKeyholeLaserSpotWelding.ProceedingsofSPIE.2003,5063:39-50
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