SiCp/2009Al复合材料的搅拌摩擦焊接
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摘要
搅拌摩擦焊接(FSW)作为一种新型固态焊接技术,可有效避免熔化焊产生的缺陷,获得性能良好的颗粒增强铝基复合材料(AMC)接头,被认为是实现AMC工业化焊接生产的理想选择。但由于增强相颗粒对焊接工具的严重磨损,使AMC的FSW工艺参数缺少系统的研究,同时控制接头性能的因素也缺乏深入的理解。本研究采用一种新型耐磨金属陶瓷材料作为焊接工具,选取目前应用最广泛的SiCp/2009Al复合材料作为研究对象。探讨采用新型焊接工具进行不同状态SiCp/2009Al的FSW可行性,并系统研究焊接工具形状、尺寸、焊接参数对接头微观组织和力学性能的影响,揭示影响接头力学性能和抗腐蚀性能的关键因素。主要研究工作如下：
选取不同热处理状态的SiCp/2009Al板材进行FSW。探讨采用新型焊接工具进行SiCp/2009Al的FSW可行性。研究表明,采用金属陶瓷焊接工具可以实现轧制态、固溶态、自然时效态的15vol.%SiCp/2009Al板材的FSW。接头表面质量良好,无明显焊接缺陷。轧制态板材的FSW接头中,焊核区大部分Al2Cu相溶解,部分Al2Cu相在冷却过程中重新析出。焊核区的硬度明显提高,接头横向拉伸时断裂在母材,强度为321MPa。在固溶态和自然时效态下进行FSW,可以取得类似的焊接效果。两种状态样品焊核区的晶粒尺寸、析出相(Al2Cu)分布及硬度基本相似。两种样品的热影响区均存在两个低硬度区,靠近焊核区的低硬度区在焊接热循环过程中温度较高,两种样品均发生Al2Cu相的粗化,硬度值相同;但在远离焊核区的低硬度区,固溶态样品不发生固溶原子团簇回溶,该区域的硬度略高于自然时效态样品,位置更靠近焊核区中心。两种接头横向拉伸时均断裂在靠近焊核区的低硬度区,强度基本相同,可达母材强度的83%。
研究了焊接工具形状、尺寸对T4态17vol.%SiCp/2009Al的FSW接头的微观组织和力学性能的影响。采用带螺纹的圆锥形搅拌针,研究了焊接转速、焊接速度、压下量等工艺参数对接头微观组织和力学性能的影响。研究表明,采用三棱柱搅拌针时,增加三棱柱搅拌针的倾斜角度和增大轴肩尺寸,有助于焊接过程中材料流动以及板材原始界面氧化皮的分散,但接头重新T4处理后强度仍低于母材。仅在高焊接转速(1000rpm)和低焊接速度(50mm/min)的参数条件下,可获得高性能的接头。带螺纹的圆锥形搅拌针有助于材料的流动,焊接速度为100mm/min时,焊接转速由600rpm提高到2000rpm,接头的拉伸强度基本不变,为母材的85%左右,接头断裂在热影响区的低硬度区。焊接过程中增加压下量可实现T4态17vol.%SiCp/2009Al板材的高速焊接。当焊接转速为1000rpm,接头强度随焊接速度的提高而提高,当焊接速度低于200mm/min,拉伸时样品断裂在热影响区的低硬度区。当焊接速度达到600mm/min时,热影响区和焊核区的硬度基本相同。焊接速度在300-600mm/min范围内,接头强度为母材的92%左右,断裂位置在热影响区和焊核区呈随机分布。
研究了SiCp/2009Al FSW过程中焊核区SiC颗粒的变化、SiC/Al界面的演化对接头力学性能的影响以及高速焊接条件下接头析出相的分布规律,探讨控制FSW接头室温力学性能的关键因素。研究表明,FSW过程中剧烈的塑性变形导致焊核区SiC颗粒的形状和尺寸发生变化,降低样品的屈服强度。SiC/Al界面上较大的化合物发生脱落,较小的化合物和非晶层仍保留在界面上。Al基体容易在破碎的SiC颗粒表面形核并形成纳米晶。变得相对干净的SiC/Al界面有助于增强载荷传递,提高样品的抗拉强度。在高速焊接时(800mm/min)焊核区存在～100nm的A12Cu相和～20nm的Al2CuMg相,硬度最低。热影响区只有一个低硬度区,在该区域只发生固溶原子团簇回溶。样品的拉伸强度可达母材的97%,断裂在焊核区。
研究了2009A1合金、17vol.%SiCp/2009Al以及17vol.%SiCp/2009Al在低焊接速度(50mm/min)和高焊接速度(800mm/min)下的FSW接头的局部腐蚀行为,探讨影响母材及FSW接头局部腐蚀性能的因素。研究表明,2009A1合金在57gNaCl+10ml H2O2+1LH2O溶液中浸泡时,内部聚集的第二相颗粒容易在表面形成腐蚀环,发生严重的点蚀和晶间腐蚀,并向材料内部扩展。17vol.%SiCp/2009Al中引入大量SiC/Al界面,腐蚀环被抑制。虽然在材料表面也会发生点蚀和晶间腐蚀,但材料腐蚀相对更均匀。低速焊接的FSW接头中,焊核区和热影响区中靠近焊核区的低硬度区的晶界析出相发生粗化,促进样品的晶间腐蚀。同时,在SiC/Al界面和晶内析出的Al2Cu相促进Al基体发生阳极溶解,造成腐蚀速率加快,这两个区域的自腐蚀电位和阻抗与母材相比明显降低。高速焊接的FSW接头中,焊核区晶界析出相的尺寸减小,促进腐蚀沿晶界进行,增加晶间腐蚀速率,导致焊核区底部材料发生脱落。
Friction stir welding (FSW), as a solid-state joining technique, is considered a promising welding method for joining the discontinuously reinforced aluminium matrix composites (AMCs) to avoid the drawbacks of the fusion welding. However, severe wear of the steel tool occurred during FSW due to the presence of hard ceramic reinforcements. This not only reduced the lifetime of the tool, but also limited the welding parameters of the AMCs. Furthermore, the factors determining the properties of the joints were not well understood. In this study, an ultra-hard cermet tool was used to join SiCp/2009A1plates, which have been widely applied in industry. The aims are to investigate possibility of joining SiCp/2009A1in various heat treatment conditions, to elucidate the effects of shape and dimension of the welding tools on the microstructure and mechanical properties of the FSW joints, and to clarify the mechanisms affecting mechanical properties and corrosion properties of the FSW joints
Hot-rolled, solutionized and naturally aged15vol.%SiCp/2009A1plates were successfully joined by FSW using the ultra-hard cermet tool. In the FSW joints of hot-rolled composite, part of Al2CU was dissolved into the aluminum matrix in the nugget zone (NZ) due to intensely plastic deformation and high temperature during FSW. The undissovled Al2Cu particles remained in the NZ and coarsened during the cooling process after FSW. The ultimate tensile strength (UTS) of the as-welded joint is only321MPa and failed in the BM zone due to the low strength of the BM. For both solutionized and naturally aged composites, a similar welding behavior was observed. In the NZ of both samples, the grain size and the distribution of the coarse Al2Cu phases and the hardness values were similar. In the heat affected zone, two low hardness zones (LHZs) were observed for both samples. The first LHZ adjacent to the NZ (LHZ I) had the lowest hardness. Both samples had the similar hardness in this zone.For the joint of solutionized composites, the LHZ far away from the NZ (LHZ II) had a higher hardness and was closer to the NZ.The ultimate tensile strength of both the samples was similar and reached83%of T4-tempered base metal.
The effects of shape and dimension of the welding tools on the microstructure and mechanical properties of the FSW joints were investigated. The welding tools with cylindrical pin was used to join17vol.%SiCp/2009Al. For a pin design with three inclined flats on the outer surface and the triangular end surface, increasing the degree of the inclined flats and the diameter of the shoulder is beneficial to the material flow and the disruption of the oxides on the butt interface during FSW. However, the strength of the joints achieved with these tools was not very good. Especially, with low heat input, the strength of joints re-treated to a T4temper was lower than that of the T4-temperaed base material. Only with the high heat input (rotation rate is1000rpm and welding speed is50mm/min), the stregnth of the joints re-treated to a T4temper were similar to that of the T4-temperaed base material. The effects of the rotation rate, welding speed, and the shoulder plunge depth on the microstructure and mechanical properties by the threaded pin with coniform shape. This tool promoted the materials deformation during FSW. The sound joints could be achieved at a welding speed of100mm/min and tool rotation rates of600-2000rpm. The strength of the joints was85%of the BM and failed in the LHZ I. The strength of the joints was not changing with the tool rotation rate increasing. Furthermore, the17vol.%SiCp/2009Al plates could be successfully joined at high welding speed with increasing the shoulder plunge depth during welding process. At a tool rotation rate of1000rpm, the strength of the joints increased as the welding speed increased. The strength of the joint at a welding speed of600mm/min reached92%of the base material. At low welding speeds of50to200mm/min, two low hardness zones were observed in the heat affected zones and the tensile samples failed in the LHZ I. At welding speeds of300to600mm/min, the hardness values of the NZ and HAZ were similar. The joints failed in the NZ or HAZ randomly.
The severe plastic deformation during FSW resulted in the variation of the size and shape of the SiC particles in the NZ. The yield strength of the NZ decreased slightly due to the variation of the SiC particles. Large compound particles on the interfaces were broken off during FSW, whereas the amorphous layer and small compound particles remained on the interfaces. The dynamically recrystallized Al grains nucleated on the surface of fractured SiC particles during FSW, forming nano-sized grains around the SiC particles. The clean interfaces were beneficial to the load transfer from Al matrix to SiC particles and then increased the UTS of the NZ. The microstructure and mechanical properties of the joints achieved at high welding speed (800mm/min) were different from that at low welding speed. The NZ exhibited the lowest hardness due to the formation of both0phases-100nm in size and S phases-20nm in size. In the heat affected zone, only part of the clusters dissolved into the Al matrix. The UTS of the joints reached97%of the based material and failed in the NZ.
The local corrosion resistance of2009A1,17vol.%SiCp/2009A1and the FSW joints of17vol.%SiCp/2009A1were investigated. Since the segregation of the intermetallic particles in the matrix, some corrosion rings formed on the surface of the2009Al, when the samples was immersed in the57g NaCl+10ml H2O2+1L H2O solution. The severe intergranular corrosion and pitting corrosion occurred in the rings and penetrated into the matrix. For the composite, the presence of the SiC/Al interface inhibited the formation of the corrosion ring in the surface of the sample. Although the intergranular corrosion and pitting corrosion would also occur in the composite, the corrosion became homogenously compared to that in the2009A1. At low welding speed (50mm/min), the intergranular corrosion occurred in the NZ and LHZ I due to the coarse precipitates on the grain boundaries. Meanwhile, the Al2Cu phases on the SiC/Al interface and within the grains also improved the anodic dissolution of the Al matrix. Therefore, the corrosion potential and electrochemical impedance of the NZ and LHZ I decreased compared to those of the based material. At high welding speed (800mm/min), the small precipitates on the grain boundaries accelerated the intergranular corrosion. The severe intergranular corrosion resulted in the exfoliation corrosion on the bottom of the NZ.
选取不同热处理状态的SiCp/2009Al板材进行FSW。探讨采用新型焊接工具进行SiCp/2009Al的FSW可行性。研究表明,采用金属陶瓷焊接工具可以实现轧制态、固溶态、自然时效态的15vol.%SiCp/2009Al板材的FSW。接头表面质量良好,无明显焊接缺陷。轧制态板材的FSW接头中,焊核区大部分Al2Cu相溶解,部分Al2Cu相在冷却过程中重新析出。焊核区的硬度明显提高,接头横向拉伸时断裂在母材,强度为321MPa。在固溶态和自然时效态下进行FSW,可以取得类似的焊接效果。两种状态样品焊核区的晶粒尺寸、析出相(Al2Cu)分布及硬度基本相似。两种样品的热影响区均存在两个低硬度区,靠近焊核区的低硬度区在焊接热循环过程中温度较高,两种样品均发生Al2Cu相的粗化,硬度值相同;但在远离焊核区的低硬度区,固溶态样品不发生固溶原子团簇回溶,该区域的硬度略高于自然时效态样品,位置更靠近焊核区中心。两种接头横向拉伸时均断裂在靠近焊核区的低硬度区,强度基本相同,可达母材强度的83%。
研究了焊接工具形状、尺寸对T4态17vol.%SiCp/2009Al的FSW接头的微观组织和力学性能的影响。采用带螺纹的圆锥形搅拌针,研究了焊接转速、焊接速度、压下量等工艺参数对接头微观组织和力学性能的影响。研究表明,采用三棱柱搅拌针时,增加三棱柱搅拌针的倾斜角度和增大轴肩尺寸,有助于焊接过程中材料流动以及板材原始界面氧化皮的分散,但接头重新T4处理后强度仍低于母材。仅在高焊接转速(1000rpm)和低焊接速度(50mm/min)的参数条件下,可获得高性能的接头。带螺纹的圆锥形搅拌针有助于材料的流动,焊接速度为100mm/min时,焊接转速由600rpm提高到2000rpm,接头的拉伸强度基本不变,为母材的85%左右,接头断裂在热影响区的低硬度区。焊接过程中增加压下量可实现T4态17vol.%SiCp/2009Al板材的高速焊接。当焊接转速为1000rpm,接头强度随焊接速度的提高而提高,当焊接速度低于200mm/min,拉伸时样品断裂在热影响区的低硬度区。当焊接速度达到600mm/min时,热影响区和焊核区的硬度基本相同。焊接速度在300-600mm/min范围内,接头强度为母材的92%左右,断裂位置在热影响区和焊核区呈随机分布。
研究了SiCp/2009Al FSW过程中焊核区SiC颗粒的变化、SiC/Al界面的演化对接头力学性能的影响以及高速焊接条件下接头析出相的分布规律,探讨控制FSW接头室温力学性能的关键因素。研究表明,FSW过程中剧烈的塑性变形导致焊核区SiC颗粒的形状和尺寸发生变化,降低样品的屈服强度。SiC/Al界面上较大的化合物发生脱落,较小的化合物和非晶层仍保留在界面上。Al基体容易在破碎的SiC颗粒表面形核并形成纳米晶。变得相对干净的SiC/Al界面有助于增强载荷传递,提高样品的抗拉强度。在高速焊接时(800mm/min)焊核区存在～100nm的A12Cu相和～20nm的Al2CuMg相,硬度最低。热影响区只有一个低硬度区,在该区域只发生固溶原子团簇回溶。样品的拉伸强度可达母材的97%,断裂在焊核区。
研究了2009A1合金、17vol.%SiCp/2009Al以及17vol.%SiCp/2009Al在低焊接速度(50mm/min)和高焊接速度(800mm/min)下的FSW接头的局部腐蚀行为,探讨影响母材及FSW接头局部腐蚀性能的因素。研究表明,2009A1合金在57gNaCl+10ml H2O2+1LH2O溶液中浸泡时,内部聚集的第二相颗粒容易在表面形成腐蚀环,发生严重的点蚀和晶间腐蚀,并向材料内部扩展。17vol.%SiCp/2009Al中引入大量SiC/Al界面,腐蚀环被抑制。虽然在材料表面也会发生点蚀和晶间腐蚀,但材料腐蚀相对更均匀。低速焊接的FSW接头中,焊核区和热影响区中靠近焊核区的低硬度区的晶界析出相发生粗化,促进样品的晶间腐蚀。同时,在SiC/Al界面和晶内析出的Al2Cu相促进Al基体发生阳极溶解,造成腐蚀速率加快,这两个区域的自腐蚀电位和阻抗与母材相比明显降低。高速焊接的FSW接头中,焊核区晶界析出相的尺寸减小,促进腐蚀沿晶界进行,增加晶间腐蚀速率,导致焊核区底部材料发生脱落。
Friction stir welding (FSW), as a solid-state joining technique, is considered a promising welding method for joining the discontinuously reinforced aluminium matrix composites (AMCs) to avoid the drawbacks of the fusion welding. However, severe wear of the steel tool occurred during FSW due to the presence of hard ceramic reinforcements. This not only reduced the lifetime of the tool, but also limited the welding parameters of the AMCs. Furthermore, the factors determining the properties of the joints were not well understood. In this study, an ultra-hard cermet tool was used to join SiCp/2009A1plates, which have been widely applied in industry. The aims are to investigate possibility of joining SiCp/2009A1in various heat treatment conditions, to elucidate the effects of shape and dimension of the welding tools on the microstructure and mechanical properties of the FSW joints, and to clarify the mechanisms affecting mechanical properties and corrosion properties of the FSW joints
Hot-rolled, solutionized and naturally aged15vol.%SiCp/2009A1plates were successfully joined by FSW using the ultra-hard cermet tool. In the FSW joints of hot-rolled composite, part of Al2CU was dissolved into the aluminum matrix in the nugget zone (NZ) due to intensely plastic deformation and high temperature during FSW. The undissovled Al2Cu particles remained in the NZ and coarsened during the cooling process after FSW. The ultimate tensile strength (UTS) of the as-welded joint is only321MPa and failed in the BM zone due to the low strength of the BM. For both solutionized and naturally aged composites, a similar welding behavior was observed. In the NZ of both samples, the grain size and the distribution of the coarse Al2Cu phases and the hardness values were similar. In the heat affected zone, two low hardness zones (LHZs) were observed for both samples. The first LHZ adjacent to the NZ (LHZ I) had the lowest hardness. Both samples had the similar hardness in this zone.For the joint of solutionized composites, the LHZ far away from the NZ (LHZ II) had a higher hardness and was closer to the NZ.The ultimate tensile strength of both the samples was similar and reached83%of T4-tempered base metal.
The effects of shape and dimension of the welding tools on the microstructure and mechanical properties of the FSW joints were investigated. The welding tools with cylindrical pin was used to join17vol.%SiCp/2009Al. For a pin design with three inclined flats on the outer surface and the triangular end surface, increasing the degree of the inclined flats and the diameter of the shoulder is beneficial to the material flow and the disruption of the oxides on the butt interface during FSW. However, the strength of the joints achieved with these tools was not very good. Especially, with low heat input, the strength of joints re-treated to a T4temper was lower than that of the T4-temperaed base material. Only with the high heat input (rotation rate is1000rpm and welding speed is50mm/min), the stregnth of the joints re-treated to a T4temper were similar to that of the T4-temperaed base material. The effects of the rotation rate, welding speed, and the shoulder plunge depth on the microstructure and mechanical properties by the threaded pin with coniform shape. This tool promoted the materials deformation during FSW. The sound joints could be achieved at a welding speed of100mm/min and tool rotation rates of600-2000rpm. The strength of the joints was85%of the BM and failed in the LHZ I. The strength of the joints was not changing with the tool rotation rate increasing. Furthermore, the17vol.%SiCp/2009Al plates could be successfully joined at high welding speed with increasing the shoulder plunge depth during welding process. At a tool rotation rate of1000rpm, the strength of the joints increased as the welding speed increased. The strength of the joint at a welding speed of600mm/min reached92%of the base material. At low welding speeds of50to200mm/min, two low hardness zones were observed in the heat affected zones and the tensile samples failed in the LHZ I. At welding speeds of300to600mm/min, the hardness values of the NZ and HAZ were similar. The joints failed in the NZ or HAZ randomly.
The severe plastic deformation during FSW resulted in the variation of the size and shape of the SiC particles in the NZ. The yield strength of the NZ decreased slightly due to the variation of the SiC particles. Large compound particles on the interfaces were broken off during FSW, whereas the amorphous layer and small compound particles remained on the interfaces. The dynamically recrystallized Al grains nucleated on the surface of fractured SiC particles during FSW, forming nano-sized grains around the SiC particles. The clean interfaces were beneficial to the load transfer from Al matrix to SiC particles and then increased the UTS of the NZ. The microstructure and mechanical properties of the joints achieved at high welding speed (800mm/min) were different from that at low welding speed. The NZ exhibited the lowest hardness due to the formation of both0phases-100nm in size and S phases-20nm in size. In the heat affected zone, only part of the clusters dissolved into the Al matrix. The UTS of the joints reached97%of the based material and failed in the NZ.
The local corrosion resistance of2009A1,17vol.%SiCp/2009A1and the FSW joints of17vol.%SiCp/2009A1were investigated. Since the segregation of the intermetallic particles in the matrix, some corrosion rings formed on the surface of the2009Al, when the samples was immersed in the57g NaCl+10ml H2O2+1L H2O solution. The severe intergranular corrosion and pitting corrosion occurred in the rings and penetrated into the matrix. For the composite, the presence of the SiC/Al interface inhibited the formation of the corrosion ring in the surface of the sample. Although the intergranular corrosion and pitting corrosion would also occur in the composite, the corrosion became homogenously compared to that in the2009A1. At low welding speed (50mm/min), the intergranular corrosion occurred in the NZ and LHZ I due to the coarse precipitates on the grain boundaries. Meanwhile, the Al2Cu phases on the SiC/Al interface and within the grains also improved the anodic dissolution of the Al matrix. Therefore, the corrosion potential and electrochemical impedance of the NZ and LHZ I decreased compared to those of the based material. At high welding speed (800mm/min), the small precipitates on the grain boundaries accelerated the intergranular corrosion. The severe intergranular corrosion resulted in the exfoliation corrosion on the bottom of the NZ.
引文
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