铝合金薄板搅拌摩擦焊残余应力及失稳变形的预测研究
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摘要
搅拌摩擦焊作为一种新型固态连接技术,目前在航空航天、造船及交通运输等铝合金结构制造领域获得广泛推广应用。尽管在搅拌摩擦焊过程中不会发生熔化现象,但由于铝合金导热系数和线膨胀系数大,仍会产生较大的残余应力和变形,对工程应用尤其是对薄板焊接构件的失稳变形带来很大的影响。目前国内外许多学者通过试验手段及数值模拟方法对搅拌摩擦焊接热过程及焊接残余应力进行了许多研究,但针对铝合金薄板失稳变形的研究较少,因此通过试验与数值模拟相结合的方法来研究铝合金薄板搅拌摩擦焊接头的残余应力和失稳变形规律,对在大型铝合金薄板结构制造中推广和应用搅拌摩擦焊技术具有重要工程应用意义。
本文以厚度为5mm的5A06-H112和6061-T6铝合金薄板构件为研究对象,对搅拌摩擦焊接过程中产生的焊接失稳变形和残余应力分布规律进行了详细探讨。首先通过试验方法对搅拌摩擦焊铝合金薄板构件的焊接失稳变形和残余应力进行测试。失稳变形试验结果表明,铝合金薄板呈马鞍形,变形挠度约为13mm。残余应力试验结果表明,纵向残余应力是应力场中的主要应力形式,5A06和6061的残余应力分别为71.2MPa和83.7MPa,为各自屈服强度的37.5%和30.3%,明显低于熔焊接头的残余应力水平。
其次建立了三维有限元模型并分析搅拌摩擦焊过程中温度场的分布。在温度场模型中施加边界条件,确定搅拌摩擦焊热源模型,得到整个焊接过程中的热循环曲线,最高温度值均在各自的高塑性温度区间。
最后采用间接热耦合法把在温度场中得到的热载荷施加到构件模型中,获得了薄板焊后的残余应力及焊接热弹塑性失稳变形分布特征。残余应力计算分析表明,5A06和6061接头的残余应力数值较大,接近材料的屈服强度,与试验测量值有较大差异。但基于残余应力计算的等效热载荷法和间接热耦合法得到的失稳变形结果,与数显百分表的试验测量结果趋势相同,同时相对变形量吻合较好,误差控制在30%以内,说明预测失稳变形的两种模拟方法是可行的。失稳变形分析结果表明铝合金薄板搅拌摩擦焊后存在较大的残余应力,明显高于测量值,但残余应力的数值分析结果与试验测量值具有相似的应力分布趋势,说明间接热耦合模型预测铝合金薄板搅拌摩擦焊接残余应力是基本可行的。
As a new type of solid connection, Friction stir welding(FSW) is used widely in manufacturing the aluminum structural parts in the airspace、shipbuilding and transportation industry. Although there is no melting phoneme in the FSW process, the residual stress and distortion is still obvious because of the high thermal conduc-tivity and linear expansion coefficient. This has a great influence on the application in engineering,especially in the buckling deformation of the thin sheet。Most scholars at home and abroad researched thermal process and the residual stress of the FSW by means of experiment and numerical simulation。But only a little research was about aluminum alloy sheets buckling deformation. So it is necessary to inte-grate the numerical simulation and experiment to analysis the residual stress and buckling deformation in the aluminum sheet FSW joints. then analyze the feasibility of the prediction model。
In this thesis,5A06-H112 and 6061-T6 aluminum alloy sheets with 5mm thickness are chose as the study objects. The welding buckling and resistant stress caused in the FSW process was investigated in detail. First the resistant stress and buckling deformation of friction stir welded aluminum sheets was tested through experiments. The buckling testing results showed that the sheets had a saddle shape after welded. The deformation flexibility is about 13mm. The resistant stress results showed that the main stress direction was along vertical. The resistant stress of 5A06 and 6061 is respectively 71.2MPa and 83.7MPa, which is respectively 37.5% and 30.3% of its yield strength. This result was obviously lower than the average resis-tant stress of fusion weld joints.
On the other hand, a three-dimensional finite element model was established and the temperature distribution in the FSW process was analyzed. Through impos-ing the boundary conditions in the temperature model, the heat source model of FSW was defined and the thermal cycle curve of the whole welding process was obtained. The results showed that the maximum temperature values were all in their high plas-tic temperature range。
At last, the heat load obtained in the temperature distribution was applied to the component model through indirect thermal coupled method. The resistant stress and the thermal elastic-plastic buckling deformation of welded sheets were obtained. The results of calculating resistant stress showed that the resistant stress of 5A06 and 6061 joints were nearly equal to the material yield strength. The difference between calculating and experiment was large. But after calculating by equivalent heat load method and indirect heat coupled method which were based on the resistant stress, the result trend was as same as the experiment. At the same time, the relative defor-mation is anatomized well and errors were all limited below 30%. This improved that this two kinds of methods to predict the buckling deformation were feasible. The results of buckling deformation showed that there was high resistant stress in the aluminum sheets after FSW, which was obviously higher than the experimental re-sults. The numerical analysis results of resistant stress and the experimental results showed the similar stress distributing trend. This proved that it was feasible to pre-dict the resistant stress in FSW aluminum sheets through indirect heat coupled model.
本文以厚度为5mm的5A06-H112和6061-T6铝合金薄板构件为研究对象,对搅拌摩擦焊接过程中产生的焊接失稳变形和残余应力分布规律进行了详细探讨。首先通过试验方法对搅拌摩擦焊铝合金薄板构件的焊接失稳变形和残余应力进行测试。失稳变形试验结果表明,铝合金薄板呈马鞍形,变形挠度约为13mm。残余应力试验结果表明,纵向残余应力是应力场中的主要应力形式,5A06和6061的残余应力分别为71.2MPa和83.7MPa,为各自屈服强度的37.5%和30.3%,明显低于熔焊接头的残余应力水平。
其次建立了三维有限元模型并分析搅拌摩擦焊过程中温度场的分布。在温度场模型中施加边界条件,确定搅拌摩擦焊热源模型,得到整个焊接过程中的热循环曲线,最高温度值均在各自的高塑性温度区间。
最后采用间接热耦合法把在温度场中得到的热载荷施加到构件模型中,获得了薄板焊后的残余应力及焊接热弹塑性失稳变形分布特征。残余应力计算分析表明,5A06和6061接头的残余应力数值较大,接近材料的屈服强度,与试验测量值有较大差异。但基于残余应力计算的等效热载荷法和间接热耦合法得到的失稳变形结果,与数显百分表的试验测量结果趋势相同,同时相对变形量吻合较好,误差控制在30%以内,说明预测失稳变形的两种模拟方法是可行的。失稳变形分析结果表明铝合金薄板搅拌摩擦焊后存在较大的残余应力,明显高于测量值,但残余应力的数值分析结果与试验测量值具有相似的应力分布趋势,说明间接热耦合模型预测铝合金薄板搅拌摩擦焊接残余应力是基本可行的。
As a new type of solid connection, Friction stir welding(FSW) is used widely in manufacturing the aluminum structural parts in the airspace、shipbuilding and transportation industry. Although there is no melting phoneme in the FSW process, the residual stress and distortion is still obvious because of the high thermal conduc-tivity and linear expansion coefficient. This has a great influence on the application in engineering,especially in the buckling deformation of the thin sheet。Most scholars at home and abroad researched thermal process and the residual stress of the FSW by means of experiment and numerical simulation。But only a little research was about aluminum alloy sheets buckling deformation. So it is necessary to inte-grate the numerical simulation and experiment to analysis the residual stress and buckling deformation in the aluminum sheet FSW joints. then analyze the feasibility of the prediction model。
In this thesis,5A06-H112 and 6061-T6 aluminum alloy sheets with 5mm thickness are chose as the study objects. The welding buckling and resistant stress caused in the FSW process was investigated in detail. First the resistant stress and buckling deformation of friction stir welded aluminum sheets was tested through experiments. The buckling testing results showed that the sheets had a saddle shape after welded. The deformation flexibility is about 13mm. The resistant stress results showed that the main stress direction was along vertical. The resistant stress of 5A06 and 6061 is respectively 71.2MPa and 83.7MPa, which is respectively 37.5% and 30.3% of its yield strength. This result was obviously lower than the average resis-tant stress of fusion weld joints.
On the other hand, a three-dimensional finite element model was established and the temperature distribution in the FSW process was analyzed. Through impos-ing the boundary conditions in the temperature model, the heat source model of FSW was defined and the thermal cycle curve of the whole welding process was obtained. The results showed that the maximum temperature values were all in their high plas-tic temperature range。
At last, the heat load obtained in the temperature distribution was applied to the component model through indirect thermal coupled method. The resistant stress and the thermal elastic-plastic buckling deformation of welded sheets were obtained. The results of calculating resistant stress showed that the resistant stress of 5A06 and 6061 joints were nearly equal to the material yield strength. The difference between calculating and experiment was large. But after calculating by equivalent heat load method and indirect heat coupled method which were based on the resistant stress, the result trend was as same as the experiment. At the same time, the relative defor-mation is anatomized well and errors were all limited below 30%. This improved that this two kinds of methods to predict the buckling deformation were feasible. The results of buckling deformation showed that there was high resistant stress in the aluminum sheets after FSW, which was obviously higher than the experimental re-sults. The numerical analysis results of resistant stress and the experimental results showed the similar stress distributing trend. This proved that it was feasible to pre-dict the resistant stress in FSW aluminum sheets through indirect heat coupled model.
引文
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[2] David S A,Debroy T.Current issues and problems in welding science[J]. Science,1992,257(5069):497~502.
[3] David S A,FengZhili.Friction stir welding of advanced materials:challenges[C]//.IIW Materials Conference.Craz,Austria,2004.
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[5]陈先民,廖江海,弓云昭.新型制造技术—搅拌摩擦焊的研究现状、应用及趋势[J].结构强度研究,2009(4):9~13.
[6]秦红珊,杨新岐.搅拌摩擦点焊技术及在汽车工业应用前景[J].汽车技术,2006(1):1~5.
[7]盛建辉,彭家仁,李光,等.搅拌摩擦焊工艺及其在地铁铝合金车体上的应用[J].电力机车与城轨车辆,2009,32(3):28~31.
[8] P J Webster,Oosterkamp L,Browne P A.Synchrotron X-ray residual strain scanning of a friction stir weld[J].The Journal of Strain Aanlysis for Engi-neering Design,2001,1(36):61~70.
[9] Omar Hatamle.h,Iris V Rivero,Shayla E Swain.An investigation of the residual stress characterization and relaxion in peened friction stir welded aluminum-lithium alloy joints[J].Materials and Design,2009,3367~3373.
[10] Omar Hatamleh,Iris V Rivero,Arif Maredia.Residual stress in Friction-Stir -Welded 2195 and 7075 Aluminum alloys[J].The Minerals,Metals&Materials Society and ASM International,2008(39):2867~2874.
[11] Peel M,Steuwer A,Preuss M,et al.Microstructure,mechanical properties and residual stresses as a function of welding speed in aluminium AA5083 friction stir welds[J].Acta Materialia.2003,51(16):4791~4801.
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