铝/钢电弧辅助激光熔钎焊接残余应力及焊接变形（英文）
|
摘要
采用热-弹-塑性有限元法对铝/钢异种金属钨极惰性气体保护(TIG)焊辅助激光对接熔钎焊接(A-LWB)过程进行数值模拟,考虑材料非线性、几何非线性和加工硬化的影响,与单激光焊接(SLWB)过程中温度场、残余应力和焊后变形进行对比。结果表明:数值计算得到的热循环、残余应力和焊接变形与测量结果吻合较好,验证有限元计算方法的有效性。与SLWB相比,A-LWB使得焊缝横向上的高温分布范围变宽,降低焊缝处产生的横向拉应力,缩小焊缝处纵向拉应力的分布范围,在一定程度上减小焊后变形。
The thermo-elastic-plastic finite element method(FEM) is used to simulate the thermo-mechanical behavior of Al/steel tungsten inert gas(TIG) arc-assisted laser welding-brazing(A-LWB) butt joint. The influence of material nonlinearity, geometrical nonlinearity and work hardening on the welding process is studied, and the differences in the welding temperature field, residual stress and welding distortion by A-LWB and by single laser welding-brazing(SLWB) are analyzed. The results show that the thermal cycle, residual stress distribution and welding distortion by the numerical simulation are in good agreement with the measured data by experiments, which verifies the effectiveness of FEM. Compared with the SLWB, A-LWB can make the high-temperature distribution zone of weld in width direction wider, decrease the transverse tensile stress in the weld and reduce the distribution range of longitudinal tensile stress. And the welding deformation also decreases to some extent.
The thermo-elastic-plastic finite element method(FEM) is used to simulate the thermo-mechanical behavior of Al/steel tungsten inert gas(TIG) arc-assisted laser welding-brazing(A-LWB) butt joint. The influence of material nonlinearity, geometrical nonlinearity and work hardening on the welding process is studied, and the differences in the welding temperature field, residual stress and welding distortion by A-LWB and by single laser welding-brazing(SLWB) are analyzed. The results show that the thermal cycle, residual stress distribution and welding distortion by the numerical simulation are in good agreement with the measured data by experiments, which verifies the effectiveness of FEM. Compared with the SLWB, A-LWB can make the high-temperature distribution zone of weld in width direction wider, decrease the transverse tensile stress in the weld and reduce the distribution range of longitudinal tensile stress. And the welding deformation also decreases to some extent.
引文
[1]WANG Peng-fei,CHEN Xi-zhang,PAN Qiu-hong,MADIGAN B,LONG Jiang-qi.Laser welding dissimilar materials of aluminum to steel:An overview[J].International Journal of Advanced Manufacturing Technology,2016,87:3081-3090.
[2]SIERRA G,PEYRE P,DESCHAUX-BEAUME F,STUART D,FRAS G.Steel to aluminium key-hole laser welding[J].Materials Science and Engineering A,2007,447:197-208.
[3]YANG Jin,LI Yu-long,ZHANG Hua.Microstructure and mechanical properties of pulsed laser welded Al/steel dissimilar joint[J].Transactions of Nonferrous Metals Society of China,2016,26:994-1002.
[4]TRAN V X,PAN J.Fatigue behavior of dissimilar spot friction welds in lap-shear and cross-tension specimens of aluminum and steel sheets[J].International Journal of Fatigue,2010,32:1167-1179.
[5]RATTANA B,TAISEI Y,YUKIO M,YOSHIHARU M.Suppression of intermetallic reaction layer formation by controlling heat flow in dissimilar joining of steel and aluminum alloy[J].Materials Science and Engineering A,2007,467:108-113.
[6]ZENG Zhi,LI Xun-bo,MIAO Yu-gang,WU Gang,ZHAO Zi-jin.Numerical and experiment analysis of residual stress on magnesium alloy and steel butt joint by hybrid laser-TIG welding[J].Computational Materials Science,2011,50:1763-1769.
[7]AHMADZADEH M,FARSHI B,SALIMI H R,HOSEINI FARD A.Residual stresses due to gas arc welding of aluminum alloy joints by numerical simulations[J].International Journal of Material Forming,2013,6:233-247.
[8]HE Ya-zhang,WANG Dong-po,WANG Ying,ZHANG Hai.Correction of buckling distortion by ultrasonic shot peening treatment for 5A06 aluminum alloy welded structure[J].Transactions of Nonferrous Metals Society of China,2016,26:1531-1537.
[9]MENG Xiang-meng,QIN Guo-liang,SU Yu-hu,FU Bang-long,JIYang.Numerical simulation of large spot laser+MIG arc brazingfusion welding of Al alloy to galvanized steel[J].Journal of Materials Processing Technology,2015,222:307-314.
[10]PARK J S,NA S J.Heat transfer in a stud-to-plate laser braze considering filler metal movement:A thermal computation model with the aid of a high-speed motion analyzer helps the development of a stainless steel to aluminum laser brazing process[J].Welding Journal,1998,77:155s-163s.
[11]PARK J S,NA S J.A Study on the numerical analysis of thermomechanical behaviour in a stud-to-plate laser braze joint[J].Proceedings of the Institution of Mechanical Engineers.Part C:Journal of Mechanical Engineering Science,1999,213:763-774.
[12]AGUDO L,WEBER S,PINTO H,ARENHOLZ E,WAGNER J,HACKL H,BRUCKNER J,PYZALLA A.Study of microstructure and residual stresses in dissimilar Al/Steels welds produced by cold metal transfer[J].Materials Science Forum,2008,571-572:347-353.
[13]HUANG Jian-kang,YANG Mao-hong,LIU Jian,FAN Ding,YUShu-rong.Residual stress field analysis of Al/steel butt joint using laser welding-brazing[J].Materials Science and Technology,2017,33:2053-2063.
[14]FAN Ding,WANG Bin,LI Chun-ling,HUANG Jian-kang,YUShu-rong.Method of fusion-brazed butt joint between aluminum alloy and galvanized steel by arc-assisted laser[J].Transactions of the China Welding Institution,2015,36:15-18,58.
[15]FENG Xiao-song,CHEN Yan-bin,LI Li-qun.Temperature filed simulation of laser brazing for galvanized steel sheets[J].Acta Metallurgica Sinica,2006,42:882-886.
[16]WU Su,ZHAO Hai-yan,WANG Yu,ZHANG Xiao-hong.A new heat source model in numerical simulation of high energy beam welding[J].Transactions of the China Welding Institution,2004,25:91-94.
[17]LIANG Wei,MURAKAWA H,DENG De-an.Investigation of welding residual stress distribution in a thick-plate joint with an emphasis on the features near weld end-start[J].Materials and Design,2015,67:303-312.
[18]ZHU X K,CHAO Y J.Effects of temperature-dependent material properties on welding[J].Computers and Structures,2002,80:967-976.
[19]SHI Jun-wei,HU Min-ying.Finite element numerical simulation of temperature field in deep penetration laser welding for aluminum alloys[J].Hot Working Technology,2009,38:120-122.
[20]DENG De-an,MURAKAWA H.Prediction of welding distortion and residual stress in a thin plate butt-welded joint[J].Computational Materials Science,2008,43:353-365.
[21]LIU C,ZHANG J X.Investigation of external restraining force effects on welding residual stresses using three-dimensional thermal elastic-plastic multi-body coupling finite element model[J].Proceedings of the Institution of Mechanical Engineers.Part B:Engineering Manufacture,2009,223:1591-1600.
[22]ZHANG Jian-qiang,ZHAO Hai-yan,LU An-li,LUO Chuan-hong,GUO Jia-lin,ZHANG Guo-dong.Effects of clamps on welding distortion in thin aluminum alloy plate[J].Rare Metal Materials and Engineering,2009,38:165-169.
[23]WANG Xue-dong,HE En-guang,CHEN Li.Influence of constraint on welding deformation of T joint welded by dual-beam laser[J].Transactions of the China Welding Institution,2016,37:101-105.
[24]ZHANG Zeng-lei,SHI Qing-yu,YAN Dong-yang,CAI Zhi-peng.Establishment and application of fixture constraint models in finite element analysis of welding process[J].Acta Metallurgica Sinica,2010,46:189-194.
[25]GUO Yu-quan,WU Dong-jiang,MA Guang-yi YANG Yi-bin,TONGYu,GUO Dong-ming.Influence of fixture restraint distance on pulsed laser welding distortion of Hastelloy C-276 thin sheet[J].Optics and Precision Engineering,2012,20:2465-2471.
[26]DENG De-an,LIU Xiao-zhan,HE Jing,LIANG Wei.Investigating the influence of external restraint on welding distortion in thin-plate bead-on joint by means of numerical simulation and experiment[J].The International Journal of Advanced Manufacturing Technology,2016,82:1049-1062.
[27]BANG H S,BANG H S,KIM Y C,OH I H,SUNG B S.Mechanical and microstructural characteristics of the dissimilar materials butt joints by hybrid CO2 laser-gas metal arc welding[J].Journal of Laser Applications,2011,23:012002-012008.
[28]DENGDA,KIYOSHIMA S.Numerical simulation of residual stresses induced by laser beam welding in a SUS316 stainless steel pipe with considering initial residual stress influences[J].Nuclear Engineering Design,2010,240:688-696.
[29]MANURUNG Y H P,SULAIMAN M S,ABAS S K,THAM G,HARUMAN E.Investigation on welding distortion of combined butt and T-joints with 9-mm thickness using FEM and experiment[J].The International Journal of Advanced Manufacturing Technology,2015,77:775-782.
[30]WANG Jiang-chao,YIN Xian-qing,MURAKAWA H.Experimental and computational analysis of residual buckling distortion of bead-on-plate welded joint[J].Journal of Materials Processing Technology,2013,213:1447-1458.
[2]SIERRA G,PEYRE P,DESCHAUX-BEAUME F,STUART D,FRAS G.Steel to aluminium key-hole laser welding[J].Materials Science and Engineering A,2007,447:197-208.
[3]YANG Jin,LI Yu-long,ZHANG Hua.Microstructure and mechanical properties of pulsed laser welded Al/steel dissimilar joint[J].Transactions of Nonferrous Metals Society of China,2016,26:994-1002.
[4]TRAN V X,PAN J.Fatigue behavior of dissimilar spot friction welds in lap-shear and cross-tension specimens of aluminum and steel sheets[J].International Journal of Fatigue,2010,32:1167-1179.
[5]RATTANA B,TAISEI Y,YUKIO M,YOSHIHARU M.Suppression of intermetallic reaction layer formation by controlling heat flow in dissimilar joining of steel and aluminum alloy[J].Materials Science and Engineering A,2007,467:108-113.
[6]ZENG Zhi,LI Xun-bo,MIAO Yu-gang,WU Gang,ZHAO Zi-jin.Numerical and experiment analysis of residual stress on magnesium alloy and steel butt joint by hybrid laser-TIG welding[J].Computational Materials Science,2011,50:1763-1769.
[7]AHMADZADEH M,FARSHI B,SALIMI H R,HOSEINI FARD A.Residual stresses due to gas arc welding of aluminum alloy joints by numerical simulations[J].International Journal of Material Forming,2013,6:233-247.
[8]HE Ya-zhang,WANG Dong-po,WANG Ying,ZHANG Hai.Correction of buckling distortion by ultrasonic shot peening treatment for 5A06 aluminum alloy welded structure[J].Transactions of Nonferrous Metals Society of China,2016,26:1531-1537.
[9]MENG Xiang-meng,QIN Guo-liang,SU Yu-hu,FU Bang-long,JIYang.Numerical simulation of large spot laser+MIG arc brazingfusion welding of Al alloy to galvanized steel[J].Journal of Materials Processing Technology,2015,222:307-314.
[10]PARK J S,NA S J.Heat transfer in a stud-to-plate laser braze considering filler metal movement:A thermal computation model with the aid of a high-speed motion analyzer helps the development of a stainless steel to aluminum laser brazing process[J].Welding Journal,1998,77:155s-163s.
[11]PARK J S,NA S J.A Study on the numerical analysis of thermomechanical behaviour in a stud-to-plate laser braze joint[J].Proceedings of the Institution of Mechanical Engineers.Part C:Journal of Mechanical Engineering Science,1999,213:763-774.
[12]AGUDO L,WEBER S,PINTO H,ARENHOLZ E,WAGNER J,HACKL H,BRUCKNER J,PYZALLA A.Study of microstructure and residual stresses in dissimilar Al/Steels welds produced by cold metal transfer[J].Materials Science Forum,2008,571-572:347-353.
[13]HUANG Jian-kang,YANG Mao-hong,LIU Jian,FAN Ding,YUShu-rong.Residual stress field analysis of Al/steel butt joint using laser welding-brazing[J].Materials Science and Technology,2017,33:2053-2063.
[14]FAN Ding,WANG Bin,LI Chun-ling,HUANG Jian-kang,YUShu-rong.Method of fusion-brazed butt joint between aluminum alloy and galvanized steel by arc-assisted laser[J].Transactions of the China Welding Institution,2015,36:15-18,58.
[15]FENG Xiao-song,CHEN Yan-bin,LI Li-qun.Temperature filed simulation of laser brazing for galvanized steel sheets[J].Acta Metallurgica Sinica,2006,42:882-886.
[16]WU Su,ZHAO Hai-yan,WANG Yu,ZHANG Xiao-hong.A new heat source model in numerical simulation of high energy beam welding[J].Transactions of the China Welding Institution,2004,25:91-94.
[17]LIANG Wei,MURAKAWA H,DENG De-an.Investigation of welding residual stress distribution in a thick-plate joint with an emphasis on the features near weld end-start[J].Materials and Design,2015,67:303-312.
[18]ZHU X K,CHAO Y J.Effects of temperature-dependent material properties on welding[J].Computers and Structures,2002,80:967-976.
[19]SHI Jun-wei,HU Min-ying.Finite element numerical simulation of temperature field in deep penetration laser welding for aluminum alloys[J].Hot Working Technology,2009,38:120-122.
[20]DENG De-an,MURAKAWA H.Prediction of welding distortion and residual stress in a thin plate butt-welded joint[J].Computational Materials Science,2008,43:353-365.
[21]LIU C,ZHANG J X.Investigation of external restraining force effects on welding residual stresses using three-dimensional thermal elastic-plastic multi-body coupling finite element model[J].Proceedings of the Institution of Mechanical Engineers.Part B:Engineering Manufacture,2009,223:1591-1600.
[22]ZHANG Jian-qiang,ZHAO Hai-yan,LU An-li,LUO Chuan-hong,GUO Jia-lin,ZHANG Guo-dong.Effects of clamps on welding distortion in thin aluminum alloy plate[J].Rare Metal Materials and Engineering,2009,38:165-169.
[23]WANG Xue-dong,HE En-guang,CHEN Li.Influence of constraint on welding deformation of T joint welded by dual-beam laser[J].Transactions of the China Welding Institution,2016,37:101-105.
[24]ZHANG Zeng-lei,SHI Qing-yu,YAN Dong-yang,CAI Zhi-peng.Establishment and application of fixture constraint models in finite element analysis of welding process[J].Acta Metallurgica Sinica,2010,46:189-194.
[25]GUO Yu-quan,WU Dong-jiang,MA Guang-yi YANG Yi-bin,TONGYu,GUO Dong-ming.Influence of fixture restraint distance on pulsed laser welding distortion of Hastelloy C-276 thin sheet[J].Optics and Precision Engineering,2012,20:2465-2471.
[26]DENG De-an,LIU Xiao-zhan,HE Jing,LIANG Wei.Investigating the influence of external restraint on welding distortion in thin-plate bead-on joint by means of numerical simulation and experiment[J].The International Journal of Advanced Manufacturing Technology,2016,82:1049-1062.
[27]BANG H S,BANG H S,KIM Y C,OH I H,SUNG B S.Mechanical and microstructural characteristics of the dissimilar materials butt joints by hybrid CO2 laser-gas metal arc welding[J].Journal of Laser Applications,2011,23:012002-012008.
[28]DENGDA,KIYOSHIMA S.Numerical simulation of residual stresses induced by laser beam welding in a SUS316 stainless steel pipe with considering initial residual stress influences[J].Nuclear Engineering Design,2010,240:688-696.
[29]MANURUNG Y H P,SULAIMAN M S,ABAS S K,THAM G,HARUMAN E.Investigation on welding distortion of combined butt and T-joints with 9-mm thickness using FEM and experiment[J].The International Journal of Advanced Manufacturing Technology,2015,77:775-782.
[30]WANG Jiang-chao,YIN Xian-qing,MURAKAWA H.Experimental and computational analysis of residual buckling distortion of bead-on-plate welded joint[J].Journal of Materials Processing Technology,2013,213:1447-1458.