镁合金（AZ91D、AZ31B）焊接性的研究
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摘要
本文采用钨极惰性气体保护焊(TIG)和熔化极惰性气体保护焊(MIG)对AZ91D、AZ31B镁合金的焊接性进行了较系统地研究,并且详尽探讨了常见的焊接性问题。
揭示了AZ91D镁合金TIG/MIG及AZ31B镁合金MIG焊接接头的组织结构特点。结果表明,镁合金焊接接头由焊缝区,热影响区和母材区构成。镁合金焊缝多为较细小的等轴晶,在焊缝中心晶粒相对较粗大,而接近熔合线处晶粒较细小。焊缝金属主要由α-Mg固溶体和β-Al12Mg17金属间化合物组成,晶界处存在由α-Mg固溶体和β-Al12Mg17金属间化合物组成的两相层片状交替分布的共晶组织,在α-Mg固溶体晶内有β-Al12Mg17金属间化合物析出,随着焊缝Al含量的降低,晶界无共晶组织,极少量的β-Al12Mg17相呈细粒状析出于晶界。AZ91D、AZ31B镁合金焊接热影响区组织整体上有粗化的趋势,半熔化区晶界局部熔化、晶界变宽。
研究了焊接电流和焊接速度对镁合金焊接接头组织及力学性能的影响规律。随着焊接电流的增加,AZ91D镁合金TIG/MIG及AZ31B镁合金MIG焊缝组织变化的突出特点是晶粒粗化,热影响区组织变化总的趋势是晶粒粗化、半熔化区晶界宽化,焊缝及半熔化区中β-Al12Mg17相的质量分数有增加的趋势。随着焊接速度的增加,焊缝组织变化的突出特点是晶粒细化,焊接热影响区组织变化总的趋势是晶粒细化和半熔化区晶界变窄。AZ91D镁合金MIG焊焊接电流为154A、TIG焊焊接电流为110A时,可获得相对较高的焊缝及接头的力学性能。AZ31B镁合金焊接,选择焊接电流160-170A、焊接速度400-450mm/min是有利的。
研究了AZ91D、AZ31B镁合金焊接接头的裂纹和气孔的特点,探讨了形成机理及影响因素。结果表明,镁合金焊缝金属具有高的裂纹敏感性,主要分布在焊缝中心线处和焊缝末端弧坑处,裂纹沿α-Mg晶界扩展,属于结晶裂纹。镁合金焊缝结晶裂纹产生的主要原因在于焊缝中存在低熔点液态薄膜和焊缝金属在凝固过程中受到拉伸应力的作用,控制焊缝中低熔点共晶体的含量,降低接头拉伸应力是改善镁合金焊缝结晶裂纹敏感性的有效措施。与AZ31B镁合金相比,AZ91D镁合金具有更高的裂纹敏感性。AZ91D镁合金焊接热影响区的裂纹属于液化裂纹。随着焊接速度提高,接头拉伸应力减小,液化裂纹敏感性降低,在AZ31B镁合金MIG焊热影响区没有发现液化裂纹。镁合金焊缝具有高的产生氢气孔的敏感性。根据焊缝气孔的分布特征,可分为孤立气孔、密集气孔、链状气孔、弥散气孔和熔合区气孔。镁合金焊缝易产生氢气孔主要归因于焊接熔池中氢的溶解度随温度下降而降低,在凝固点发生突变,氢在焊接熔池中显著过饱和而导致气泡形核长大;镁合金密度小导致减小气泡的上浮速度;镁合金的热导率高导致提高焊缝的结晶速度。
采用有限元模型研究了镁合金焊接接头温度场和应力场的分布特点及影响规律,有限元分析结果与试验结果基本吻合。
Magnesium alloys have recently attracted great attention owing to their unique properties such as low density, high specific strength and specific stiffness, good castability and machinability, excellent thermal conductivity and electromagnetic shielding efficiency, and recyclable characteristics. They are regarded as ideal materials to realize lightweight and reutilization. The development of materials showed that the wide application of advanced materials depended not only on their properties but also on the progress of welding (joining) technique. In recent years, welding of magnesium alloys is becoming a hot spot in welding field all over the world with the improvement of corrosion resistant property and the enlargement of application field of them. However, it is difficult to acquire reliable joint for magnesium alloy due to its unique physical and chemical properties. The weldability of magnesium alloys is the development foundation of welding technique and also the main content of theoretical study on material welding. No systematic research on weldability of magnesium alloy was found up to now, which has been one of the main problems to restrict the development of welding technique and affect the welding quality of magnesium alloys. Therefore, it is of great theoretical significance and practical value to study the weldability of magnesium alloys and reveal their weldability characteristics.
In this paper, the weldability of magnesium alloys (AZ91D and AZ31B) is systematically researched using TIG and MIG methods and the main weldability problems are explored in detail. The main conclusions are given as follows:
(1) The welded magnesium alloy joints manly consist of weld zone, heat affected zone and base metal. The microstructure is mostly fine equiaxed grains in weld zone. The grains are bigger in the weld center while they are finer adjoining the fusion line. The weld microstructure was mainlyα-Mg andβ-Al12Mg17 distributing along theα-Mg grain boundaries. The mass fraction ofα-Al12Mg17 has an increased tendency with increasing Al content in the weld.
(a) The average grain size in the weld zone of TIG welded AZ91D is not homogeneous. Under the condition of non-equilibrium solidification, in the grain boundaries of weld metal with 9.8wt.%Al there exists a layer eutectic structure composed ofα-Mg andβ-Al12Mg17 and in theα-Mg grains someβ-Al12Mg17 phases precipitate.
(b) The average grain size in the weld zone of MIG welded AZ91D is also not homogeneous. Compared with TIG weld metal, there exists eutectic or divorced eutectic structure composed ofα-Mg andβ-Al12Mg17 in the grain boundaries. The amount ofβ-Al12Mg17 precipitated fromα-Mg decreased.
(c) The microstructural characteristics of weld metal for MIG welded AZ31B are the decreased amount of β-Al12Mg17 and significant coarsening ofα-Mg grain. When the weld Al content decreased to 3.2wt.%, there was no eutectic structure, but a few granularβ-Al12Mg17 was precipitated in the grain boundaries.
(d) HAZ microstructure of AZ91D magnesium alloy has a tendency of grain coarsening. The grain boundary in PFZ partly melted and its width increased. PFZ microstructure mainly consists ofα-Mg andβ-Al12Mg17 distributing along the grain boundary, which has the characteristic of divorced eutectic structure. Compared with HAZ of AZ91D magnesium alloy, the prominent characteristic in HAZ of AZ31B is a narrower PFZ and the more obvious grain coarsening ofα-Mg.
(e) Microstructure of AZ91D magnesium alloy is composed of dendriticα-Mg and eutectic structure (α-Mg andβ-Al12Mg17) that distributes in interdendrites.
(2) Welding current and welding speed have obvious effects on microstructure and mechanical properties of magnesium alloy weld metal.
(a) The welding current has an obvious effect on microstructures of weld and HAZ for MIG welded magnesium alloys (AZ91D and AZ31B). With the increase of the welding current, in the weld the outstanding characteristic is grain coarsening, in HAZ the general tendency is grain coarsening with wide grain boundary in the PFZ and the mass fraction ofβ-Al12Mg17 in weld and PFZ has an increased tendency.
(b) The welding speed has an obvious effect on microstructures of weld and HAZ for MIG welded magnesium alloys (AZ91D and AZ31B). With increasing the welding speed, in the weld the prominent characteristic is grain refining and in HAZ the general tendency is grain refining with narrow grain boundary in PFZ.
(c) The welding current has some effects on microstructures of weld and HAZ for TIG welded AZ91D magnesium alloy. When the welding current increased from 80A to 130A, the average grain size of the weld metal increased from 22.8μm to 32μm, the width of PFZ increased from 120μm to 210μm and the mass fraction ofβ-Al12Mg17 in the weld had an increased tendency.
(d) The weld Al content has obvious effects on mechanical properties of AZ91D magnesium alloy weld. The tensile strength and elongation changed from 192MPa and 4.9% to 215MPa and 7.9%, with decreasing weld Al contents from 9.8wt.% to 6.9wt.%. The magnesium alloy weld had a characteristic of intergranular fracture. The tensile dimple had a large proportion in the fracture surface of weld with 6.9wt.% Al and only a few cleavage pattern was observed. The magnesium alloy weld with 9.8wt.% Al had a mixed fracture of dimple and cleavage.
(3) Defects such as solidification cracking in welds, liquation cracking in HAZ and weld pore easily formed during welding of magnesium alloys due to physical, chemical and mechanical properties of magnesium alloys.
(a) Magnesium alloy weld had a high cracking sensitivity. Cracks were mainly distributed in the center line and the end of the weld and belonged to solidification cracking. It was due to the fact that there were low melting point liquid film in the weld and it was subjected to tensile stress. It was effective to control the amount of low melting point eutectic and decrease the tensile stress to improve the solidification cracking sensitivity of magnesium alloy weld.
(b) Cracks in HAZ of magnesium alloy belonged to liquation cracking. With the increase of welding speed (300mm/min-400mm/min), welding heat input and the tensile stress decreased, and the liquation cracking sensitivity decreased. The liquation cracking was not found in the MIG welded AZ31B joint. It was attributed to the smaller Al content in AZ31B than that in AZ91D.
(c) The magnesium weld had high hydrogen gas pore sensitivity. The pores were classified as isolated pore, porosity, chain pore, dispersed pore and pore in fusion zone. Since the solubility of hydrogen in the weld pool of magnesium alloy decreased with the decrease of temperature, the supersaturated hydrogen aggregated and grew up. The low density of magnesium alloy caused the decreased rising velocity of pores and the high thermal conductivity of it led to the increased solidification speed.
(d) Since the liquid contraction and solidification contraction are larger than solid contraction, shrinkage cavity easily forms in magnesium alloy weld. Stress concentration will lead to forming microcrack at the tip of the shrinkage cavity.
(4) It was found, based on the FEM analysis, that with increasing welding current, welding thermal cycle peak temperature increased, cooling speed decreased, isothermal range increased and tensile stress in the welded joint increased. When the welding speed was increased, the isothermal range decreased, the temperature gradient along the weld cross section became larger and tensile stress in the welded joint had a decreased tendency. These results are consistent with the results obtained from experiments of effect of welding current and welding speed on weld microstructure and hot crack sensitivity.
揭示了AZ91D镁合金TIG/MIG及AZ31B镁合金MIG焊接接头的组织结构特点。结果表明,镁合金焊接接头由焊缝区,热影响区和母材区构成。镁合金焊缝多为较细小的等轴晶,在焊缝中心晶粒相对较粗大,而接近熔合线处晶粒较细小。焊缝金属主要由α-Mg固溶体和β-Al12Mg17金属间化合物组成,晶界处存在由α-Mg固溶体和β-Al12Mg17金属间化合物组成的两相层片状交替分布的共晶组织,在α-Mg固溶体晶内有β-Al12Mg17金属间化合物析出,随着焊缝Al含量的降低,晶界无共晶组织,极少量的β-Al12Mg17相呈细粒状析出于晶界。AZ91D、AZ31B镁合金焊接热影响区组织整体上有粗化的趋势,半熔化区晶界局部熔化、晶界变宽。
研究了焊接电流和焊接速度对镁合金焊接接头组织及力学性能的影响规律。随着焊接电流的增加,AZ91D镁合金TIG/MIG及AZ31B镁合金MIG焊缝组织变化的突出特点是晶粒粗化,热影响区组织变化总的趋势是晶粒粗化、半熔化区晶界宽化,焊缝及半熔化区中β-Al12Mg17相的质量分数有增加的趋势。随着焊接速度的增加,焊缝组织变化的突出特点是晶粒细化,焊接热影响区组织变化总的趋势是晶粒细化和半熔化区晶界变窄。AZ91D镁合金MIG焊焊接电流为154A、TIG焊焊接电流为110A时,可获得相对较高的焊缝及接头的力学性能。AZ31B镁合金焊接,选择焊接电流160-170A、焊接速度400-450mm/min是有利的。
研究了AZ91D、AZ31B镁合金焊接接头的裂纹和气孔的特点,探讨了形成机理及影响因素。结果表明,镁合金焊缝金属具有高的裂纹敏感性,主要分布在焊缝中心线处和焊缝末端弧坑处,裂纹沿α-Mg晶界扩展,属于结晶裂纹。镁合金焊缝结晶裂纹产生的主要原因在于焊缝中存在低熔点液态薄膜和焊缝金属在凝固过程中受到拉伸应力的作用,控制焊缝中低熔点共晶体的含量,降低接头拉伸应力是改善镁合金焊缝结晶裂纹敏感性的有效措施。与AZ31B镁合金相比,AZ91D镁合金具有更高的裂纹敏感性。AZ91D镁合金焊接热影响区的裂纹属于液化裂纹。随着焊接速度提高,接头拉伸应力减小,液化裂纹敏感性降低,在AZ31B镁合金MIG焊热影响区没有发现液化裂纹。镁合金焊缝具有高的产生氢气孔的敏感性。根据焊缝气孔的分布特征,可分为孤立气孔、密集气孔、链状气孔、弥散气孔和熔合区气孔。镁合金焊缝易产生氢气孔主要归因于焊接熔池中氢的溶解度随温度下降而降低,在凝固点发生突变,氢在焊接熔池中显著过饱和而导致气泡形核长大;镁合金密度小导致减小气泡的上浮速度;镁合金的热导率高导致提高焊缝的结晶速度。
采用有限元模型研究了镁合金焊接接头温度场和应力场的分布特点及影响规律,有限元分析结果与试验结果基本吻合。
Magnesium alloys have recently attracted great attention owing to their unique properties such as low density, high specific strength and specific stiffness, good castability and machinability, excellent thermal conductivity and electromagnetic shielding efficiency, and recyclable characteristics. They are regarded as ideal materials to realize lightweight and reutilization. The development of materials showed that the wide application of advanced materials depended not only on their properties but also on the progress of welding (joining) technique. In recent years, welding of magnesium alloys is becoming a hot spot in welding field all over the world with the improvement of corrosion resistant property and the enlargement of application field of them. However, it is difficult to acquire reliable joint for magnesium alloy due to its unique physical and chemical properties. The weldability of magnesium alloys is the development foundation of welding technique and also the main content of theoretical study on material welding. No systematic research on weldability of magnesium alloy was found up to now, which has been one of the main problems to restrict the development of welding technique and affect the welding quality of magnesium alloys. Therefore, it is of great theoretical significance and practical value to study the weldability of magnesium alloys and reveal their weldability characteristics.
In this paper, the weldability of magnesium alloys (AZ91D and AZ31B) is systematically researched using TIG and MIG methods and the main weldability problems are explored in detail. The main conclusions are given as follows:
(1) The welded magnesium alloy joints manly consist of weld zone, heat affected zone and base metal. The microstructure is mostly fine equiaxed grains in weld zone. The grains are bigger in the weld center while they are finer adjoining the fusion line. The weld microstructure was mainlyα-Mg andβ-Al12Mg17 distributing along theα-Mg grain boundaries. The mass fraction ofα-Al12Mg17 has an increased tendency with increasing Al content in the weld.
(a) The average grain size in the weld zone of TIG welded AZ91D is not homogeneous. Under the condition of non-equilibrium solidification, in the grain boundaries of weld metal with 9.8wt.%Al there exists a layer eutectic structure composed ofα-Mg andβ-Al12Mg17 and in theα-Mg grains someβ-Al12Mg17 phases precipitate.
(b) The average grain size in the weld zone of MIG welded AZ91D is also not homogeneous. Compared with TIG weld metal, there exists eutectic or divorced eutectic structure composed ofα-Mg andβ-Al12Mg17 in the grain boundaries. The amount ofβ-Al12Mg17 precipitated fromα-Mg decreased.
(c) The microstructural characteristics of weld metal for MIG welded AZ31B are the decreased amount of β-Al12Mg17 and significant coarsening ofα-Mg grain. When the weld Al content decreased to 3.2wt.%, there was no eutectic structure, but a few granularβ-Al12Mg17 was precipitated in the grain boundaries.
(d) HAZ microstructure of AZ91D magnesium alloy has a tendency of grain coarsening. The grain boundary in PFZ partly melted and its width increased. PFZ microstructure mainly consists ofα-Mg andβ-Al12Mg17 distributing along the grain boundary, which has the characteristic of divorced eutectic structure. Compared with HAZ of AZ91D magnesium alloy, the prominent characteristic in HAZ of AZ31B is a narrower PFZ and the more obvious grain coarsening ofα-Mg.
(e) Microstructure of AZ91D magnesium alloy is composed of dendriticα-Mg and eutectic structure (α-Mg andβ-Al12Mg17) that distributes in interdendrites.
(2) Welding current and welding speed have obvious effects on microstructure and mechanical properties of magnesium alloy weld metal.
(a) The welding current has an obvious effect on microstructures of weld and HAZ for MIG welded magnesium alloys (AZ91D and AZ31B). With the increase of the welding current, in the weld the outstanding characteristic is grain coarsening, in HAZ the general tendency is grain coarsening with wide grain boundary in the PFZ and the mass fraction ofβ-Al12Mg17 in weld and PFZ has an increased tendency.
(b) The welding speed has an obvious effect on microstructures of weld and HAZ for MIG welded magnesium alloys (AZ91D and AZ31B). With increasing the welding speed, in the weld the prominent characteristic is grain refining and in HAZ the general tendency is grain refining with narrow grain boundary in PFZ.
(c) The welding current has some effects on microstructures of weld and HAZ for TIG welded AZ91D magnesium alloy. When the welding current increased from 80A to 130A, the average grain size of the weld metal increased from 22.8μm to 32μm, the width of PFZ increased from 120μm to 210μm and the mass fraction ofβ-Al12Mg17 in the weld had an increased tendency.
(d) The weld Al content has obvious effects on mechanical properties of AZ91D magnesium alloy weld. The tensile strength and elongation changed from 192MPa and 4.9% to 215MPa and 7.9%, with decreasing weld Al contents from 9.8wt.% to 6.9wt.%. The magnesium alloy weld had a characteristic of intergranular fracture. The tensile dimple had a large proportion in the fracture surface of weld with 6.9wt.% Al and only a few cleavage pattern was observed. The magnesium alloy weld with 9.8wt.% Al had a mixed fracture of dimple and cleavage.
(3) Defects such as solidification cracking in welds, liquation cracking in HAZ and weld pore easily formed during welding of magnesium alloys due to physical, chemical and mechanical properties of magnesium alloys.
(a) Magnesium alloy weld had a high cracking sensitivity. Cracks were mainly distributed in the center line and the end of the weld and belonged to solidification cracking. It was due to the fact that there were low melting point liquid film in the weld and it was subjected to tensile stress. It was effective to control the amount of low melting point eutectic and decrease the tensile stress to improve the solidification cracking sensitivity of magnesium alloy weld.
(b) Cracks in HAZ of magnesium alloy belonged to liquation cracking. With the increase of welding speed (300mm/min-400mm/min), welding heat input and the tensile stress decreased, and the liquation cracking sensitivity decreased. The liquation cracking was not found in the MIG welded AZ31B joint. It was attributed to the smaller Al content in AZ31B than that in AZ91D.
(c) The magnesium weld had high hydrogen gas pore sensitivity. The pores were classified as isolated pore, porosity, chain pore, dispersed pore and pore in fusion zone. Since the solubility of hydrogen in the weld pool of magnesium alloy decreased with the decrease of temperature, the supersaturated hydrogen aggregated and grew up. The low density of magnesium alloy caused the decreased rising velocity of pores and the high thermal conductivity of it led to the increased solidification speed.
(d) Since the liquid contraction and solidification contraction are larger than solid contraction, shrinkage cavity easily forms in magnesium alloy weld. Stress concentration will lead to forming microcrack at the tip of the shrinkage cavity.
(4) It was found, based on the FEM analysis, that with increasing welding current, welding thermal cycle peak temperature increased, cooling speed decreased, isothermal range increased and tensile stress in the welded joint increased. When the welding speed was increased, the isothermal range decreased, the temperature gradient along the weld cross section became larger and tensile stress in the welded joint had a decreased tendency. These results are consistent with the results obtained from experiments of effect of welding current and welding speed on weld microstructure and hot crack sensitivity.
引文
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