3A21铝合金-20#钢管件磁脉冲焊接数值模拟与工艺试验
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摘要
异种材料管件磁脉冲焊接（MPW）是利用磁脉冲成形原理，在室温条件下实现的高速、固相连接，合适工艺条件下，能获得高强度的焊接接头。将MPW应用于铝合金-钢等异种材料的管-管焊接有利于实现零件轻量化结构设计。本文从磁脉冲焊接原理和特点出发，利用3A21铝合金高应变速率下的本构关系，采用数值模拟和工艺试验相结合的方式对Al-Fe异种管件磁脉冲焊接工艺进行了系统研究。通过SEM试验及TEM试验对磁脉冲焊接接头的形貌及成分进行分析，得出了磁脉冲焊接工艺中接头波的形成机理以及磁脉冲焊接机理。
采用松散耦合法对磁脉冲焊接过程进行电磁场分析以及变形场分析。利用ANSYS/Multiphysics模块建立电压激励的三维电磁场耦合模型，对磁脉冲焊接过程中的磁场力进行分析，研究了放电电压、设备电容、系统电阻以及管件材料等工艺参数对磁场力的影响。通过霍普金森压杆试验建立了3A21铝合金在高应变速率下的J-C模型。以电磁场分析中的磁场力为边界条件，在ANSYS/LS-DYNA模块中，利用高应变速率下材料的本构关系建立管件变形分析模型，并对外管变形过程进行分析。研究了放电电压、内外管间隙及搭接角度等工艺参数对碰撞速度的影响，确定了磁脉冲焊接过程的最佳工艺参数，有限元分析结果对工艺试验的进行有重要指导意义。
利用高速摄像机对不同放电电压条件下铝管运动规律进行拍摄，通过对拍摄结果进行分析，得到了外管运动过程的位移-时间以及速度-时间曲线。通过工艺试验研究放电电压、搭接角度以及内、外管间隙等参数对磁脉冲焊接速度的影响，得到了不同工艺参数条件下的内、外管碰撞速度以及使内、外管实现冶金结合的临界碰撞速度。利用SEM对不同碰撞速度条件下得到的磁脉冲焊接接头进行分析，研究了各工艺参数对焊接接头形貌的影响。对磁脉冲焊接接头的宏观缺陷及微观组织缺陷进行分析，并给出了避免缺陷形成的有效方法。
对内管刚度条件进行了理论分析、数值模拟及工艺试验，得到了不同电压条件下满足内管刚度条件的壁厚最小值。将内管等效为无端部封头厚壁筒形件在外压作用下受力变形模型，利用平衡方程与协调方程求解内管在磁场力作用下的位移分量，根据屈雷斯加屈服准则求解内管塑形极限的压力方程，得到了不同碰撞速度的临界壁厚表达式。利用ANSYS/LS-DYNA模块建立管件磁脉冲焊接过程变形场模型，研究了不同工艺条件下内管刚度条件，并与理论计算结果进行了对比。针对不同放电电压进行工艺试验，以对理论计算及模拟结果进行试验验证，结果表明三者之间吻合度较好。
采用单向拉伸试验及扭转试验对磁脉冲焊接接头力学性能进行测试，结果表明在适当的工艺条件下，接头抗拉强度大于母材抗拉强度。采用纳米硬度仪对焊接接头及接头两侧金属进行硬度测试，研究了沿接头两侧金属硬度分布规律以及接头处硬度提高的成因。通过金相显微镜及SEM对过渡区形貌进行观察，对磁脉冲焊接接头处形成的开尔文波形的形成机理进行研究，并得到了过渡区宽度的近似表达式。采用SEM、TEM对磁脉冲焊接接头的微观组织及成分进行分析，通过与压力焊形成条件以及爆炸焊接的接头形貌进行对比，得到了磁脉冲焊接过程的焊接机理。
Magnetic pulse welding (MPW) of pipe fittings made of dissimilar materials refersto high-speed solid-phase connection at room temperature using magnetic-pulse formingprinciple and under appropriate technical conditions, high-strength welding joints canbe obtained. The application of MPW to the welding of pipes made of such dissimilarmaterials as aluminum alloy-steel will help realize lightweight structural design of parts.Starting from the principle and characteristics of MPW, using the constitutive relation of3A21aluminum alloy at high strain rate, a method of combining numerical simulationand process tests is used to make a systematic study of the MPW procedure for Al-Fedissimilar pipe fittings. Through SEM tests and TEM tests, an analysis is made of theappearance and composition of MPW joints, with the formation mechanism of weldingwave involved in the MPW procedure and mechanism of MPW obtained.
A loose coupling method is adopted to make an electromagnetic field analysis and adeformation field analysis of pipe fittings in the MPW process. A voltage drive-basedthree dimensional electromagnetic field coupling model is established using ANSYS-Multiphysics module to analyze the magnetic force in the MPW process and study theefect of such process parameters as discharge voltage, equipment capacitance, system re-sistance and pipe materials on the magnetic force. Through Hopkinson pressure bar test,a J-C model of3A21aluminum alloy at high strain rate is established. With the magneticforce involved the magnetic field analysis as boundary conditions, in the ANSYS/LS-DYNA module, the constitutive relation of materials at high strain rate is utilized to es-tablish a pipe deformation analysis model to make analysis of the deformation processof external pipes. The efect of such process parameters as discharge voltage, clearancebetween internal and external pipes and overlapping angle on collision velocity, with theoptimum process parameters in the MPW process determined to guide process tests.
The movement process of aluminum pipes under diferent discharge voltage con-ditions is shot using a high-speed camera and through the analysis of shooting results,the displacement-time curve and velocity-time curve involved in the movement processof external pipes are obtained. Through process tests, the efect of such parameters asdischarge voltage, overlapping angle and clearance between pipes on the collision veloc-ity of MPW is studied, with the collision velocity of internal and external pipes under diferent process parameter conditions and the critical collision velocity for realizing themetallurgical bond of internal and external pipes. SEM is used to analyze the joints ofMPW obtained under diferent collision velocity conditions and study the efect of themovement speed of the collision point on the appearance of welding joints. The analysisof the macro-defects and microstructure defects of MPW joints is made, with methods foravoiding the formation of defects presented.
Theoretical analysis, numeral simulation and process tests of internal pipe stifnessare conducted to obtain the minimum wall thickness value for meeting the internal pipestifness conditions under diferent voltage conditions. With internal pipes consideredequivalent to the force-deformation model of thick-walled cylinder parts without end clo-sure, equilibrium equations and coordination equations are used to obtain the displace-ment component of internal pipes under the action of magnetic force, with the pressureequation of plastic limit of internal pipes obtained based on Tresca yield criterion and thecritical wall thickness expression under diferent collision velocity conditions derived. Adeformation field model of pipes in the MPW process is established using the LS-DYNAmodule, the stifness conditions of internal pipes under diferent process parameter condi-tions are studied and the comparison with the result of theoretical analysis is conducted.Process tests are conducted under diferent conditions to verify theoretical calculation andsimulation results, with results showing these three have excellent goodness of fit.
The mechanical properties of MPW joints are tested using uniaxial tension tests andtorsion tests. Through tension tests, the tensile strength of MPW joints and the base metalstrength are compared. A nano-hardness tester is adopted to test the hardness of weldedjoints and the metal on both sides of the joints. The hardness distribution law of themetal on both sides of MPW interface and the cause of increased hardness of the metalnear the interface are studied. The appearance in the transition area is observed througha metallurgical microscope and SEM, and the formation mechanism of Kelvin wavesformed around MPW joints is studied, with the expression of the width of the transitionarea obtained. The welding mechanism of the MPW process is obtained, using SEM andTEM to analyze the microstructure and composition of MPW joints, through comparisonwith the formation conditions of pressure welding and explosive welding.
采用松散耦合法对磁脉冲焊接过程进行电磁场分析以及变形场分析。利用ANSYS/Multiphysics模块建立电压激励的三维电磁场耦合模型，对磁脉冲焊接过程中的磁场力进行分析，研究了放电电压、设备电容、系统电阻以及管件材料等工艺参数对磁场力的影响。通过霍普金森压杆试验建立了3A21铝合金在高应变速率下的J-C模型。以电磁场分析中的磁场力为边界条件，在ANSYS/LS-DYNA模块中，利用高应变速率下材料的本构关系建立管件变形分析模型，并对外管变形过程进行分析。研究了放电电压、内外管间隙及搭接角度等工艺参数对碰撞速度的影响，确定了磁脉冲焊接过程的最佳工艺参数，有限元分析结果对工艺试验的进行有重要指导意义。
利用高速摄像机对不同放电电压条件下铝管运动规律进行拍摄，通过对拍摄结果进行分析，得到了外管运动过程的位移-时间以及速度-时间曲线。通过工艺试验研究放电电压、搭接角度以及内、外管间隙等参数对磁脉冲焊接速度的影响，得到了不同工艺参数条件下的内、外管碰撞速度以及使内、外管实现冶金结合的临界碰撞速度。利用SEM对不同碰撞速度条件下得到的磁脉冲焊接接头进行分析，研究了各工艺参数对焊接接头形貌的影响。对磁脉冲焊接接头的宏观缺陷及微观组织缺陷进行分析，并给出了避免缺陷形成的有效方法。
对内管刚度条件进行了理论分析、数值模拟及工艺试验，得到了不同电压条件下满足内管刚度条件的壁厚最小值。将内管等效为无端部封头厚壁筒形件在外压作用下受力变形模型，利用平衡方程与协调方程求解内管在磁场力作用下的位移分量，根据屈雷斯加屈服准则求解内管塑形极限的压力方程，得到了不同碰撞速度的临界壁厚表达式。利用ANSYS/LS-DYNA模块建立管件磁脉冲焊接过程变形场模型，研究了不同工艺条件下内管刚度条件，并与理论计算结果进行了对比。针对不同放电电压进行工艺试验，以对理论计算及模拟结果进行试验验证，结果表明三者之间吻合度较好。
采用单向拉伸试验及扭转试验对磁脉冲焊接接头力学性能进行测试，结果表明在适当的工艺条件下，接头抗拉强度大于母材抗拉强度。采用纳米硬度仪对焊接接头及接头两侧金属进行硬度测试，研究了沿接头两侧金属硬度分布规律以及接头处硬度提高的成因。通过金相显微镜及SEM对过渡区形貌进行观察，对磁脉冲焊接接头处形成的开尔文波形的形成机理进行研究，并得到了过渡区宽度的近似表达式。采用SEM、TEM对磁脉冲焊接接头的微观组织及成分进行分析，通过与压力焊形成条件以及爆炸焊接的接头形貌进行对比，得到了磁脉冲焊接过程的焊接机理。
Magnetic pulse welding (MPW) of pipe fittings made of dissimilar materials refersto high-speed solid-phase connection at room temperature using magnetic-pulse formingprinciple and under appropriate technical conditions, high-strength welding joints canbe obtained. The application of MPW to the welding of pipes made of such dissimilarmaterials as aluminum alloy-steel will help realize lightweight structural design of parts.Starting from the principle and characteristics of MPW, using the constitutive relation of3A21aluminum alloy at high strain rate, a method of combining numerical simulationand process tests is used to make a systematic study of the MPW procedure for Al-Fedissimilar pipe fittings. Through SEM tests and TEM tests, an analysis is made of theappearance and composition of MPW joints, with the formation mechanism of weldingwave involved in the MPW procedure and mechanism of MPW obtained.
A loose coupling method is adopted to make an electromagnetic field analysis and adeformation field analysis of pipe fittings in the MPW process. A voltage drive-basedthree dimensional electromagnetic field coupling model is established using ANSYS-Multiphysics module to analyze the magnetic force in the MPW process and study theefect of such process parameters as discharge voltage, equipment capacitance, system re-sistance and pipe materials on the magnetic force. Through Hopkinson pressure bar test,a J-C model of3A21aluminum alloy at high strain rate is established. With the magneticforce involved the magnetic field analysis as boundary conditions, in the ANSYS/LS-DYNA module, the constitutive relation of materials at high strain rate is utilized to es-tablish a pipe deformation analysis model to make analysis of the deformation processof external pipes. The efect of such process parameters as discharge voltage, clearancebetween internal and external pipes and overlapping angle on collision velocity, with theoptimum process parameters in the MPW process determined to guide process tests.
The movement process of aluminum pipes under diferent discharge voltage con-ditions is shot using a high-speed camera and through the analysis of shooting results,the displacement-time curve and velocity-time curve involved in the movement processof external pipes are obtained. Through process tests, the efect of such parameters asdischarge voltage, overlapping angle and clearance between pipes on the collision veloc-ity of MPW is studied, with the collision velocity of internal and external pipes under diferent process parameter conditions and the critical collision velocity for realizing themetallurgical bond of internal and external pipes. SEM is used to analyze the joints ofMPW obtained under diferent collision velocity conditions and study the efect of themovement speed of the collision point on the appearance of welding joints. The analysisof the macro-defects and microstructure defects of MPW joints is made, with methods foravoiding the formation of defects presented.
Theoretical analysis, numeral simulation and process tests of internal pipe stifnessare conducted to obtain the minimum wall thickness value for meeting the internal pipestifness conditions under diferent voltage conditions. With internal pipes consideredequivalent to the force-deformation model of thick-walled cylinder parts without end clo-sure, equilibrium equations and coordination equations are used to obtain the displace-ment component of internal pipes under the action of magnetic force, with the pressureequation of plastic limit of internal pipes obtained based on Tresca yield criterion and thecritical wall thickness expression under diferent collision velocity conditions derived. Adeformation field model of pipes in the MPW process is established using the LS-DYNAmodule, the stifness conditions of internal pipes under diferent process parameter condi-tions are studied and the comparison with the result of theoretical analysis is conducted.Process tests are conducted under diferent conditions to verify theoretical calculation andsimulation results, with results showing these three have excellent goodness of fit.
The mechanical properties of MPW joints are tested using uniaxial tension tests andtorsion tests. Through tension tests, the tensile strength of MPW joints and the base metalstrength are compared. A nano-hardness tester is adopted to test the hardness of weldedjoints and the metal on both sides of the joints. The hardness distribution law of themetal on both sides of MPW interface and the cause of increased hardness of the metalnear the interface are studied. The appearance in the transition area is observed througha metallurgical microscope and SEM, and the formation mechanism of Kelvin wavesformed around MPW joints is studied, with the expression of the width of the transitionarea obtained. The welding mechanism of the MPW process is obtained, using SEM andTEM to analyze the microstructure and composition of MPW joints, through comparisonwith the formation conditions of pressure welding and explosive welding.
引文
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