铝合金薄板超声搅拌焊接装备与工艺研究
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摘要
薄板结构是轻质铝合金构件的主要特征,搅拌摩擦焊在这类技术方面具有很强的经济优势,在铝合金构件焊接成型中有着巨大的应用前景。然而由于搅拌摩擦焊在铝合金薄板焊接时,焊接区热容和热惯性小,焊接过程中温度的稳定性易受焊台接触界面、冷却介质和焊件的自身热传导性等不确定因素影响,因而易产生虚焊疏松等缺陷,同时由于焊件本身很薄以及残余应力等的作用容易产生变形翘曲,成为薄板搅拌摩擦焊接的两大技术瓶颈。本文在超声搅拌焊接课题前期研究的基础上,研制了超声搅拌薄板焊接系统,针对铝合金薄板焊接改进搅拌头,设计了随动压紧滚轮和水雾冷却装置,并与搅拌摩擦焊机集成,以期解决上述薄板焊接问题。
本文运用所研制的超声搅拌薄板焊接系统进行了航空铝合金薄板焊接。实验采用1.8mm2524铝合金和2.5mm2219铝合金进行了超声搅拌焊接研究,通过大量的实验摸索出高强度航空铝合金薄板的较佳焊接工艺参数和冷却条件,同时和搅拌摩擦焊做了相应的对比实验,通过焊缝外观、力学性能、金相组织、显微硬度和断口扫描的比较分析,发现超声搅拌焊焊缝性能要优于搅拌摩擦焊,成型稳定。实验结果显示在焊接参数为1600r/min,120mm/min时2524和2219均可得最佳焊接效果。2524铝合金超声搅拌焊试样平均焊后抗拉强度为399.5MPa,达到母材的89.9%,2219铝合金平均抗拉强度为394.5 MPa,达到母材强度的89.5%,焊后平均抗拉强度和搅拌摩擦焊相当,但超声搅拌试样强度性能稳定,2524铝合金抗拉强度最高值和最低值相差为10MPa,2219铝合金高低差值仅为3MPa；搅拌摩擦焊焊接试样缺陷率接近30%左右,而超声搅拌焊缝基本上没有缺陷,稳定性相当高,对薄板焊接接头的变形翘曲量可以控制在0.5mm以下。实验证明超声搅拌焊能够提高焊缝强度性能,增加焊缝质量稳定性,有效控制接头变形。
从实验结果对比发现超声引入后焊缝质量有着明显的提高,分析认为超声作为一种辅助能量,能够对焊接工艺及焊缝质量起到一定的积极影响。一方面超声的各向传导性和介质对超声能量的吸收性,使得超声能在焊缝前进侧与搅拌焊头弱作用处(缺陷多发处)积聚,从而抑制缺陷的形成；另一方面,超声振动能够带动搅拌头周围金属颗粒频繁振动,且具有极大的加速度,能够减小流变阻力,增强搅拌头周围金属流动性,在一定程度上可以抑制焊接变形。
Sheet structure is the main features of lightweight aluminum components, friction stir welding has great economic advantage in such technology and has a great prospect in the forming of welded aluminum components. However, in the process of aluminum alloy sheet friction stir welding, the heat capacity and thermal inertia in the welding zone is small, the stability of temperature in the welding process can be easily affected by the soldering station contact interface, cooling medium and thermal conductivity of the welding pieces, and so easy to produce weld defects such as osteoporosis, at the same time the deformation of welds can be easily produced because the weldment itself is very thin and the effect of residual stress, so the two problems become the technology bottlenecks of sheet friction stir welding. Based on the previous research of ultrasonic stir welding, the ultrasonic stirring plate welding system was developed in this paper, mixing head was improved according to aluminum alloy sheet welding, the dynamic compaction rollers and water spray cooling devices was designed, and integrated with the friction stir welding, expected to solve the problem of thin plate welding.
Aviation aluminum alloy sheet has been successfully welded by ultrasonic stir welding in this paper.1.8mm thick 2524 and 2.5mm thick 2219 aluminum alloy was adoped in the experiment and appropriate welding parameters and cooling conditions of high-strength aluminum alloy sheets were explored through a large number of ultrasonic stir welding experiments, some comparative experimints were done between ultrasonic stir welding and friction stir welding, through the comparison and analysis of the weld appearance, mechanical properties,microstructure,microhardness and fracture scanning found that the weld properties of ultrasonic stir welding was superior to friction stir welding.The experiments reselts showed that the best weld was available when welding parameters was 1600r/min,120mm/min.The average tensile strength of 2524 aluminum alloy welded by ultrasonic stir welding was 399.5MPa,which reach to 89.9% of the base metal, and the average tensile strength of 2219 aluminum alloy was 393.5 MPa which reach to 89.4% of the base metal, the ultrasonic stir welding samples average tensile strength was similar with friction stir welding but had a great stable strength properties, the higest and lowest of 2524 tensile strength only lOMPa different, and the higest and lowest of 2219 only 3MPa different.The defect rate of FSW samples reached to 40% while ultrasonic stir welding almost no defects, the deformation of welds by ultrasonic stir welding can be controlled below 0.5mm. Experiments showed that the ultrasonic stir welding can improve the weld strength,increase the stability of the weld quality and control the joint deformation dffectivly.
Weld quality was significantly improved after the introduction of ultrasound from the results contrasted, ultrasound as a supplementary energy could play a certain positive effects to the welding process and weld quality. On one hand, the conductivity of the ultrasonic and dielectric absorption of ultrasonic energy, which made the ultrasound can be builded in the weld forward side and the weak role place of mixing head (defect-prone office), so to inhibiting the formation of defects. On the other hand, ultrasonic vibration can bring the metal particles around the mixing head vibrated frequenly, and the acceleration was great, the flow resistance can be reduced, and the flow of the metal around the mixing head was enhanced, which can inhibit the welding deformation in a certain extent.
本文运用所研制的超声搅拌薄板焊接系统进行了航空铝合金薄板焊接。实验采用1.8mm2524铝合金和2.5mm2219铝合金进行了超声搅拌焊接研究,通过大量的实验摸索出高强度航空铝合金薄板的较佳焊接工艺参数和冷却条件,同时和搅拌摩擦焊做了相应的对比实验,通过焊缝外观、力学性能、金相组织、显微硬度和断口扫描的比较分析,发现超声搅拌焊焊缝性能要优于搅拌摩擦焊,成型稳定。实验结果显示在焊接参数为1600r/min,120mm/min时2524和2219均可得最佳焊接效果。2524铝合金超声搅拌焊试样平均焊后抗拉强度为399.5MPa,达到母材的89.9%,2219铝合金平均抗拉强度为394.5 MPa,达到母材强度的89.5%,焊后平均抗拉强度和搅拌摩擦焊相当,但超声搅拌试样强度性能稳定,2524铝合金抗拉强度最高值和最低值相差为10MPa,2219铝合金高低差值仅为3MPa；搅拌摩擦焊焊接试样缺陷率接近30%左右,而超声搅拌焊缝基本上没有缺陷,稳定性相当高,对薄板焊接接头的变形翘曲量可以控制在0.5mm以下。实验证明超声搅拌焊能够提高焊缝强度性能,增加焊缝质量稳定性,有效控制接头变形。
从实验结果对比发现超声引入后焊缝质量有着明显的提高,分析认为超声作为一种辅助能量,能够对焊接工艺及焊缝质量起到一定的积极影响。一方面超声的各向传导性和介质对超声能量的吸收性,使得超声能在焊缝前进侧与搅拌焊头弱作用处(缺陷多发处)积聚,从而抑制缺陷的形成；另一方面,超声振动能够带动搅拌头周围金属颗粒频繁振动,且具有极大的加速度,能够减小流变阻力,增强搅拌头周围金属流动性,在一定程度上可以抑制焊接变形。
Sheet structure is the main features of lightweight aluminum components, friction stir welding has great economic advantage in such technology and has a great prospect in the forming of welded aluminum components. However, in the process of aluminum alloy sheet friction stir welding, the heat capacity and thermal inertia in the welding zone is small, the stability of temperature in the welding process can be easily affected by the soldering station contact interface, cooling medium and thermal conductivity of the welding pieces, and so easy to produce weld defects such as osteoporosis, at the same time the deformation of welds can be easily produced because the weldment itself is very thin and the effect of residual stress, so the two problems become the technology bottlenecks of sheet friction stir welding. Based on the previous research of ultrasonic stir welding, the ultrasonic stirring plate welding system was developed in this paper, mixing head was improved according to aluminum alloy sheet welding, the dynamic compaction rollers and water spray cooling devices was designed, and integrated with the friction stir welding, expected to solve the problem of thin plate welding.
Aviation aluminum alloy sheet has been successfully welded by ultrasonic stir welding in this paper.1.8mm thick 2524 and 2.5mm thick 2219 aluminum alloy was adoped in the experiment and appropriate welding parameters and cooling conditions of high-strength aluminum alloy sheets were explored through a large number of ultrasonic stir welding experiments, some comparative experimints were done between ultrasonic stir welding and friction stir welding, through the comparison and analysis of the weld appearance, mechanical properties,microstructure,microhardness and fracture scanning found that the weld properties of ultrasonic stir welding was superior to friction stir welding.The experiments reselts showed that the best weld was available when welding parameters was 1600r/min,120mm/min.The average tensile strength of 2524 aluminum alloy welded by ultrasonic stir welding was 399.5MPa,which reach to 89.9% of the base metal, and the average tensile strength of 2219 aluminum alloy was 393.5 MPa which reach to 89.4% of the base metal, the ultrasonic stir welding samples average tensile strength was similar with friction stir welding but had a great stable strength properties, the higest and lowest of 2524 tensile strength only lOMPa different, and the higest and lowest of 2219 only 3MPa different.The defect rate of FSW samples reached to 40% while ultrasonic stir welding almost no defects, the deformation of welds by ultrasonic stir welding can be controlled below 0.5mm. Experiments showed that the ultrasonic stir welding can improve the weld strength,increase the stability of the weld quality and control the joint deformation dffectivly.
Weld quality was significantly improved after the introduction of ultrasound from the results contrasted, ultrasound as a supplementary energy could play a certain positive effects to the welding process and weld quality. On one hand, the conductivity of the ultrasonic and dielectric absorption of ultrasonic energy, which made the ultrasound can be builded in the weld forward side and the weak role place of mixing head (defect-prone office), so to inhibiting the formation of defects. On the other hand, ultrasonic vibration can bring the metal particles around the mixing head vibrated frequenly, and the acceleration was great, the flow resistance can be reduced, and the flow of the metal around the mixing head was enhanced, which can inhibit the welding deformation in a certain extent.
引文
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