铜/铝极耳超声波焊接响应曲面优化分析
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摘要
采用响应曲面法,设计锂电池铜/铝极耳异质金属超声波焊接试验,使用逐步回归法筛选出对响应值影响显著的因子,建立多元非线性回归数学模型。采用SEM、EDS、XRD、3D景深显微分析及显微硬度仪研究最优参数下铜/铝焊接接头的微观组织形貌、相结构、景深及硬度的变化规律,理解其连接机理和金属间化合物(IMCs)生成机制。结果表明:各工艺参数对拉剪力的影响有着非常复杂的交互作用,最优参数下连接界面实现无缺陷完全结合;高应变率加快了连接界面析出厚度约8μm的Cu_9Al_4、CuAl和CuAl_2IMCs相层;塑性变形在整个薄板厚度间传播,剧烈塑性变形促进了位错增殖,形成了由纳米晶和非晶相组成的过渡层;工件连接强度取决于机械互锁、纳米晶和非晶相过渡层与互扩散的综合作用。
The ultrasonic welding test of lithium battery copper/aluminum electrode lug dissimilar metal was designed by response surface method. A multivariate nonlinear regression mathematical model was established by using the stepwise regression method to screen out the significant factors affecting the responses. The SEM, EDS, XRD, 3 D depth-of-field microscopic analysis and micro-hardness tester were used to study the variation of microstructure morphology, phase structure, depth of field and hardness of copper/aluminum welded joints under optimal parameters, and to understand the mechanism of connection and intermetallic compounds(IMCs) generation. The results show that the influence of various process parameters on the tensile load has a very complex interaction, and the interface achieves no defect connection under optimal parameters. High strain rates accelerate the precipitation of Cu_9Al_4, CuAl and CuAl_2 IMCs phase at the interface, and its thickness is about 8 μm. The plastic deformation propagates throughout the thickness of the foil, and the severe plastic deformation promotes the proliferation of dislocations. A transition layer consisting of nanocrystalline and amorphous phases is formed. The strength of the workpiece connection depends on the combined effect of mechanical interlocking, transition layers and element interdiffusion.
The ultrasonic welding test of lithium battery copper/aluminum electrode lug dissimilar metal was designed by response surface method. A multivariate nonlinear regression mathematical model was established by using the stepwise regression method to screen out the significant factors affecting the responses. The SEM, EDS, XRD, 3 D depth-of-field microscopic analysis and micro-hardness tester were used to study the variation of microstructure morphology, phase structure, depth of field and hardness of copper/aluminum welded joints under optimal parameters, and to understand the mechanism of connection and intermetallic compounds(IMCs) generation. The results show that the influence of various process parameters on the tensile load has a very complex interaction, and the interface achieves no defect connection under optimal parameters. High strain rates accelerate the precipitation of Cu_9Al_4, CuAl and CuAl_2 IMCs phase at the interface, and its thickness is about 8 μm. The plastic deformation propagates throughout the thickness of the foil, and the severe plastic deformation promotes the proliferation of dislocations. A transition layer consisting of nanocrystalline and amorphous phases is formed. The strength of the workpiece connection depends on the combined effect of mechanical interlocking, transition layers and element interdiffusion.
引文
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2 Wang K,Shriver D,Li Y,et al.Journal of Manufacturing Processes,2017,29,124.
3 Zhang Y F,Zhu Z Q,Zhang D Q,et al.Materials Review B:Research Papers,2014,28(12),103(in Chinese).张义福,朱政强,张德勤,等.材料导报:研究篇,2014,28(12),103.
4 Hamon Y,Brousse T,Jousse F,et al.Journal of Power Sources,2001,97,185.
5 Zhao Y Y,Li D,Zhang Y S.Science and Technology of Welding and Joining,2013,18(4),354.
6 Chen K K,Zhang Y S,Wang H Z.Science and Technology of Welding and Joining,2017,22(3),208.
7 Satpathy M P,Sahoo S K.The International Journal of Advanced Manufacturing Technology,2017,93(5-8),2531.
8 Ni Z L,Ye F X.Journal of Materials Processing Technology,2017,245,180.
9 Zhang Z,Wang K,Li J,et al.Scientific Reports,2017,7(1),12505.
10 Li H,Cao B,Liu J,et al.The International Journal of Advanced Manufacturing Technology,2018,97(1),1.
11 Yang J W,Cao B,He X C,et al.Science and Technology of Welding and Joining,2014,19(6),500.
12 Zhang Y H,Ma C Y,Yang S W,et al.Welding Technology,2007,36(5),14(in Chinese).张铱洪,马传艺,杨圣文,等.焊接技术,2007,36(5),14.
13 Wang J,He Z S,Lu L S,et al.Welding Technology,2009,38(3),9(in Chinese).王军,贺占蜀,陆龙生,等.焊接技术,2009,38(3),9.
14 Balasundaram R,Patel V K,Bhole S D,et al.Materials Science and Engineering:A,2014,607,277.
15 Wu C F J,Hamada M S.Experiments:planning,analysis,and optimization,John Wiley & Sons,USA,2011.
16 Kim D,Rhee S,Park H.International Journal of Production Research,2002,40(7),1699.