搅拌摩擦焊接过程中铝合金与不同外形搅拌头间的热力作用（英文）
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摘要
研究搅拌摩擦焊(FSW)过程中搅拌头形状对AA6061-T6工件与搅拌头间热力相互作用的影响。FSW加工过程中,采用定制的实验装置完成对特征点温度和搅拌头主轴扭矩的测量。同时对搅拌区(SZ)的组织和拉伸性能进行表征。结果表明,轴肩和搅拌针形状分别影响搅拌区的产热、插入阶段搅拌头扭矩和搅拌区截面的形状。轴肩上的凹槽和搅拌针上的螺纹使搅拌区中的晶粒更加细化,搅拌针上的切平面则导致不均匀的晶粒尺寸。采用圆柱形搅拌针的搅拌头可以得到0.2%屈服强度为173MPa的焊缝,而采用三平面螺纹形搅拌针的搅拌头可以得到伸长率32.0%的焊缝。
The influence of the tool profiles on the thermo-mechanical interaction between AA6061-T6 workpiece and tool during friction stir welding was investigated. A customized experimental setup was employed to measure the feature points temperature and tool spindle torque in the process of FSW. Microstructure and tensile properties of stir zone(SZ) were characterized. Results indicate that the shoulder and pin geometries were responsible for the heat generation, tool torque variation at the plunging stage as well as the cross section contour of SZ, respectively. Finer grains in SZ resulted from flutes on shoulder and grooves on pin. Flat faces on the pin resulted in inhomogeneous grain size. Weld with higher 0.2% yield strength of 173 MPa was obtained by using the cylindrical pin tool while higher elongation weld of 32.0% was produced with triflat threaded pin tool.
The influence of the tool profiles on the thermo-mechanical interaction between AA6061-T6 workpiece and tool during friction stir welding was investigated. A customized experimental setup was employed to measure the feature points temperature and tool spindle torque in the process of FSW. Microstructure and tensile properties of stir zone(SZ) were characterized. Results indicate that the shoulder and pin geometries were responsible for the heat generation, tool torque variation at the plunging stage as well as the cross section contour of SZ, respectively. Finer grains in SZ resulted from flutes on shoulder and grooves on pin. Flat faces on the pin resulted in inhomogeneous grain size. Weld with higher 0.2% yield strength of 173 MPa was obtained by using the cylindrical pin tool while higher elongation weld of 32.0% was produced with triflat threaded pin tool.
引文
[1]THOMAS W M,NICHOLAS E D,NEEDHAM J C,MURCH,M G,TEMPLESMITH P,DAWES C J.Friction stir butt welding:International patent application No.PCT/GB92102203 and Great Britain patent application,No.9125978.8[P].1991-12-01.
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[3]BHATT K D,PILLAI B.Simulation of peak temperature&flow stresses during friction stir welding of AA7050-T7451 aluminum alloy using hyper works[J].International Journal of Emerging Technology and Advanced Engineering,2012,2(5):212-216.
[4]ZHANG Z,QI W U,ZHANG H W.Numerical studies of effect of tool sizes and pin shapes on friction stir welding of AA2024-T3 alloy[J].Transactions of Nonferrous Metals Society of China 2014,24(10):3293-3301.
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[6]ELANGOVAN K,BALASUBRAMANIAN V.Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminum alloy[J].Journal of Materials Processing and Technology,2008,200(1):163-175.
[7]MEHTA K P,BADHEKA V J.Influence of tool pin design on properties of dissimilar copper to aluminum friction stir welding[J].Transactions of Nonferrous Metals Society of China,2017,27(1):36-54.
[8]KADIAN A K,BISWAS P.Effect of tool pin profile on the material flow characteristics of AA6061[J].Journal of Manufacturing Processes,2017,26:3 82-392.
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[10]KHODAVERdIZADEH H,MAHMOUDI A,HEIDARZADEH A,NAZARI E.Effect of friction stir welding(FSW)parameters on strain hardening behavior of pure copper joints[J].Materials&Design,2012,35:330-334.
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[12]MENDES N,LOUREIRO A,MARTINS C,NETO P,PIRES J N.Effect of friction stir welding parameters on morphology and strength of acrylonitrile butadiene styrene plate welds[J].Materials&Design,2014,58:457-464.
[13]KRASNOWSKI K,HAMILTON C,DYMEK S.Influence of the tool shape and weld configuration on microstructure and mechanical properties of the Al 6082 alloy FSW joints[J].Archives of Civil and Mechanical Engineering,2015,15(1):133-141.
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[15]ADAMOWSKI J,SZKODO M.Friction stir welds(FSW)of aluminum alloy AW6082-T6[J].Journal of Achievements in Materials and Manufacturing Engineering,2007,20(1-2):403-406.
[16]COLE E G,FEHRENBACHER A,DUFFIE N A,ZINN M R,PFEFFERKORN F E,FERRIER N J.Weld temperature effects during friction stir welding of dissimilar aluminum alloys 6061-T6and 7075-T6[J].International Journal of Advanced Manufacturing Technology,2014,71(1-4):643-652.
[17]LIU F C,MA Z Y.Influence of tool dimension and welding parameters on microstructure and mechanical properties of friction-stir-welded 6061-T651 aluminum alloy[J].Metal Mater trans A,2008,39(10):2378-2388.
[18]MERTIN C,NAUMOV A,MOSECKER L,BAMBACH M,HIRT G.Influence of the process temperature on the properties of friction stir welded blanks made of mild steel and aluminum[C]//Key Engineering Materials.Switzerland:Trans Tech Publications,2014:1429-1436.
[19]WANG T.Effect of friction stir welding parameters on the microstructure and properties of 6061-T6 aging hardenable aluminum alloy[D].Ji’nan:Shandong University,2018.(in Chinese)
[20]JIN Y Y.Material transfer behavior during the process of friction stir welding[D].Shenyang:Shenyang Aerospace University,2013.(in Chinese)
[21]LONGHURST W R,STRAUSS A M,COOK G E,FLEMING P A.Torque control of friction stir welding for manufacturing and automation[J].International Journal of Advanced Manufacturing Technology,2010,51(9):905-913.
[22]SU H,WU C S,PITTNER A,RETHMEIER M.Simultaneous measurement of tool torque,traverse force and axial force in friction stir welding[J].Journal of Manufacturing Processes,2013,15(4):495-500.
[23]WANG G Q,ZHAO Y H.The friction stir welding of Aluminum alloy[M].Beijing:China Astronautic Publishing House,2010.(in Chinese)
[24]JI S D,SHI Q Y,ZHANG L G,ZOU A L,GAO S S,ZAN L V.Numerical simulation of material flow behavior of friction stir welding influenced by rotational tool geometry[J].Computational Materials Science,2012,63:218-226.
[25]PAIDAR M,SADEGHI F,NAJAFI H,KHODABANDEH A R.Effect of pin and shoulder geometry on stir zone and mechanical properties of friction stir spot-welded aluminum alloy 2024-T3 sheets[J].Journal of Engineering Materials and Technology,2015,137:031004-1.
[26]RAJAKUMAR S,MURALIDHARAN C,BALASUBRAMANIANV.Establishing empirical relationships to predict grain size and tensile strength of friction stir welded AA 6061-T6 aluminum alloy joints[J].Transactions of Nonferrous Metals Society of China,2010,20(10):1863-1872.
[27]HAO H L,NI D R,ZHANG Z,WANG D,XIAO B L,MA Z Y.Microstructure and mechanical properties of Al-Mg-Er sheets jointed by friction stir welding[J].Materials&Design,2013,52:706-712.
[28]ZHANG Z,YANG R,GUO Y,CHEN G,LEI Y,CHENG Y,YUE Y.Microstructural evolution and mechanical properties of ZrB2/6061Al nanocomposites processed by multi-pass friction stir processing[J].Materials Science and Engineering A,2017,689:411-418.
[2]MISHRA R S,MA Z Y.Friction stir welding and processing[J].Materials Science and Engineering R,2005,50:1-78.
[3]BHATT K D,PILLAI B.Simulation of peak temperature&flow stresses during friction stir welding of AA7050-T7451 aluminum alloy using hyper works[J].International Journal of Emerging Technology and Advanced Engineering,2012,2(5):212-216.
[4]ZHANG Z,QI W U,ZHANG H W.Numerical studies of effect of tool sizes and pin shapes on friction stir welding of AA2024-T3 alloy[J].Transactions of Nonferrous Metals Society of China 2014,24(10):3293-3301.
[5]HATTINGH D G,BLIGNAULT C,van NIEKERK T I,JAMES M N.Characterization of the influences of FSW tool geometry on welding forces and weld tensile strength using an instrumented tool[J].Journal of Materials Processing and Technology,2008,203(1):46-57.
[6]ELANGOVAN K,BALASUBRAMANIAN V.Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminum alloy[J].Journal of Materials Processing and Technology,2008,200(1):163-175.
[7]MEHTA K P,BADHEKA V J.Influence of tool pin design on properties of dissimilar copper to aluminum friction stir welding[J].Transactions of Nonferrous Metals Society of China,2017,27(1):36-54.
[8]KADIAN A K,BISWAS P.Effect of tool pin profile on the material flow characteristics of AA6061[J].Journal of Manufacturing Processes,2017,26:3 82-392.
[9]BUFFA G,CAMPANILE G,FRATINI L,PRISC A.Friction stir welding of lap joints:Influence of process parameters on the metallurgical and mechanical properties[J].Materials Science and Engineering A,2009,519(1):19-26.
[10]KHODAVERdIZADEH H,MAHMOUDI A,HEIDARZADEH A,NAZARI E.Effect of friction stir welding(FSW)parameters on strain hardening behavior of pure copper joints[J].Materials&Design,2012,35:330-334.
[11]TRUEBA L,HEREDIA G,RYBICKI D,JOHANNES L B.Effect of tool shoulder features on defects and tensile properties of friction stir welded aluminum 6061-T6[J].Journal of Materials Processing and Technology,2015,219:271-277.
[12]MENDES N,LOUREIRO A,MARTINS C,NETO P,PIRES J N.Effect of friction stir welding parameters on morphology and strength of acrylonitrile butadiene styrene plate welds[J].Materials&Design,2014,58:457-464.
[13]KRASNOWSKI K,HAMILTON C,DYMEK S.Influence of the tool shape and weld configuration on microstructure and mechanical properties of the Al 6082 alloy FSW joints[J].Archives of Civil and Mechanical Engineering,2015,15(1):133-141.
[14]SU J Q,NELSON T W,STERLING C J.Microstructure evolution during FSW/FSP of high strength aluminum alloys[J].Materials Science and Engineering A,2005,405(1-2):277-286.
[15]ADAMOWSKI J,SZKODO M.Friction stir welds(FSW)of aluminum alloy AW6082-T6[J].Journal of Achievements in Materials and Manufacturing Engineering,2007,20(1-2):403-406.
[16]COLE E G,FEHRENBACHER A,DUFFIE N A,ZINN M R,PFEFFERKORN F E,FERRIER N J.Weld temperature effects during friction stir welding of dissimilar aluminum alloys 6061-T6and 7075-T6[J].International Journal of Advanced Manufacturing Technology,2014,71(1-4):643-652.
[17]LIU F C,MA Z Y.Influence of tool dimension and welding parameters on microstructure and mechanical properties of friction-stir-welded 6061-T651 aluminum alloy[J].Metal Mater trans A,2008,39(10):2378-2388.
[18]MERTIN C,NAUMOV A,MOSECKER L,BAMBACH M,HIRT G.Influence of the process temperature on the properties of friction stir welded blanks made of mild steel and aluminum[C]//Key Engineering Materials.Switzerland:Trans Tech Publications,2014:1429-1436.
[19]WANG T.Effect of friction stir welding parameters on the microstructure and properties of 6061-T6 aging hardenable aluminum alloy[D].Ji’nan:Shandong University,2018.(in Chinese)
[20]JIN Y Y.Material transfer behavior during the process of friction stir welding[D].Shenyang:Shenyang Aerospace University,2013.(in Chinese)
[21]LONGHURST W R,STRAUSS A M,COOK G E,FLEMING P A.Torque control of friction stir welding for manufacturing and automation[J].International Journal of Advanced Manufacturing Technology,2010,51(9):905-913.
[22]SU H,WU C S,PITTNER A,RETHMEIER M.Simultaneous measurement of tool torque,traverse force and axial force in friction stir welding[J].Journal of Manufacturing Processes,2013,15(4):495-500.
[23]WANG G Q,ZHAO Y H.The friction stir welding of Aluminum alloy[M].Beijing:China Astronautic Publishing House,2010.(in Chinese)
[24]JI S D,SHI Q Y,ZHANG L G,ZOU A L,GAO S S,ZAN L V.Numerical simulation of material flow behavior of friction stir welding influenced by rotational tool geometry[J].Computational Materials Science,2012,63:218-226.
[25]PAIDAR M,SADEGHI F,NAJAFI H,KHODABANDEH A R.Effect of pin and shoulder geometry on stir zone and mechanical properties of friction stir spot-welded aluminum alloy 2024-T3 sheets[J].Journal of Engineering Materials and Technology,2015,137:031004-1.
[26]RAJAKUMAR S,MURALIDHARAN C,BALASUBRAMANIANV.Establishing empirical relationships to predict grain size and tensile strength of friction stir welded AA 6061-T6 aluminum alloy joints[J].Transactions of Nonferrous Metals Society of China,2010,20(10):1863-1872.
[27]HAO H L,NI D R,ZHANG Z,WANG D,XIAO B L,MA Z Y.Microstructure and mechanical properties of Al-Mg-Er sheets jointed by friction stir welding[J].Materials&Design,2013,52:706-712.
[28]ZHANG Z,YANG R,GUO Y,CHEN G,LEI Y,CHENG Y,YUE Y.Microstructural evolution and mechanical properties of ZrB2/6061Al nanocomposites processed by multi-pass friction stir processing[J].Materials Science and Engineering A,2017,689:411-418.