铝合金T型接头激光—电弧两侧同步焊接技术研究
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摘要
在飞机、汽车和机车车辆等制造业中,为了减轻运载工具的自重,提高运载能力,越来越多地采用轻金属合金与薄壁型轻量化结构。尤其在飞机蒙皮、筋板等制造中,采用焊接代替传统的铆接工艺,减重效果显著。然而由于铝合金特性及T型接头结构特点,无论传统焊接还是先进的激光焊接都遇到了焊缝气孔、裂纹、变形等依靠单独焊接方式难以解决的问题。本文采用激光-电弧两侧同步焊接方法成功焊接了3mm厚铝合金T型接头,既发挥了两种热源的优势,又弥补了各自的不足。
首先,根据激光-电弧两侧同步焊接试验要求和T型接头特点,设计与优化了定位装置、电弧焊枪及工装夹具,为工艺研究提供了装备条件。
其次,研究了铝合金激光-电弧两侧同步立板横焊的工艺参数对焊缝成形的影响,得出一组焊缝成形好的参数范围,为T型接头焊接试验打下基础。结果表明:激光-电弧两侧同步焊接关键是实现两侧熔池相互贯通。当两侧能量较匹配,两熔池完全贯通、熔为一体、两侧熔宽相差较小时,激光与电弧相互作用强,焊接过程稳定,焊缝成形好。
最后,研究了6061铝合金T型接头激光-电弧两侧同步焊接工艺参数、接头形式对焊缝成形的影响,并对焊接头显微组织、力学性能进行了考察与分析。结果表明:采用激光-电弧两侧同步焊接在合适的工艺参数下T型接头焊缝成形好,两侧焊缝组织相似且以等轴晶为主,过度均匀。十字架焊接接头的抗拉伸强度达247.7MPa,断于母材;弯曲角度超过15°,裂纹呈锯齿状。
研究成果有助于进一步了解激光-电弧两侧同步焊接相互作用,有助于进一步降低焊缝气孔、变形等焊接缺陷,提高焊接过程稳定性和能量利用率,从而提高我国高强铝合金焊接技术在航空航天、快速列车、高速轮船及汽车等制造行业的应用。
Today, light metal alloys and thin-walled lightweight structure are increasingly used in manufacturing industries such as aircraft, automobile and rolling stock in order to reduce vehicle weight and improve carrying capacity. It is prominent to reduce weight that using welding crafts replace traditional rivet bond especially in the manufacturing of the aircraft skin, panel, etc... However, due to the properties of aluminum alloy and the structural characteristics of T-joint, whether traditional TIG welding or advanced laser welding has to face with some problems in formation of weld, such as pores, cracks, deformation, which are difficult to solve by single way. In this paper, the fillet weld for T-joint of 3.0 mm thick 6061 aluminum alloy has been completed through Laser–TIG Both-Side Synchronization Welding (LTBSW), which provides many advantages which are not found in either.
First of all, the positioning device, arc torch and fixture which offer the equipment condition for craft investigation have been designed and optimized according to requirements of LTBLW experiments and structural characteristics of T-joint.
In addition, we have studied with the LTBSW horizontal welding in vertical board on different welding parameters which effect formation of weld, obtained good parameter range, and lay the groundwork for welding of T-joint. The results show that the key of LTBSW is to realize the linking up of the molten pool on both sides each other in T-joint. When the laser and arc energies on both sides are properly matched, both molten pools can be integrated, and the interaction of laser-arc is strengthened, such as melting into organic whole, smaller differences on welding width. In this case, a stable welding process and good formations of the welds are achieved.
Finally, the effects of weld parameters for 6061 aluminum alloy of T-joint and forms of weld joints on the welding seam have been studied. Then, microstructure and mechanical properties of weld have been studied and analyzed as well. The results show that right process parameters of LTBSW in T-joint can complete good formations of weld which has similar organizations on both sides and has properties of grain-based and transitional uniform. Tensile strength for welding joints which has been broken in the parent material is up to 247.7Mpa. Bending angle has reached more than 15°and the crackle has taken the form of saw tooth.
The research results can help to understand the interaction between laser and arc hybrid processing, reduce porosity deformation in T-joint, as well as improve the stability of weld process and energy utilization. This research helps to improve welding technology of the high-strength aluminum alloy and applications in the fields of Aero-Space, fast trains, ships and automobiles, etc...
首先,根据激光-电弧两侧同步焊接试验要求和T型接头特点,设计与优化了定位装置、电弧焊枪及工装夹具,为工艺研究提供了装备条件。
其次,研究了铝合金激光-电弧两侧同步立板横焊的工艺参数对焊缝成形的影响,得出一组焊缝成形好的参数范围,为T型接头焊接试验打下基础。结果表明:激光-电弧两侧同步焊接关键是实现两侧熔池相互贯通。当两侧能量较匹配,两熔池完全贯通、熔为一体、两侧熔宽相差较小时,激光与电弧相互作用强,焊接过程稳定,焊缝成形好。
最后,研究了6061铝合金T型接头激光-电弧两侧同步焊接工艺参数、接头形式对焊缝成形的影响,并对焊接头显微组织、力学性能进行了考察与分析。结果表明:采用激光-电弧两侧同步焊接在合适的工艺参数下T型接头焊缝成形好,两侧焊缝组织相似且以等轴晶为主,过度均匀。十字架焊接接头的抗拉伸强度达247.7MPa,断于母材;弯曲角度超过15°,裂纹呈锯齿状。
研究成果有助于进一步了解激光-电弧两侧同步焊接相互作用,有助于进一步降低焊缝气孔、变形等焊接缺陷,提高焊接过程稳定性和能量利用率,从而提高我国高强铝合金焊接技术在航空航天、快速列车、高速轮船及汽车等制造行业的应用。
Today, light metal alloys and thin-walled lightweight structure are increasingly used in manufacturing industries such as aircraft, automobile and rolling stock in order to reduce vehicle weight and improve carrying capacity. It is prominent to reduce weight that using welding crafts replace traditional rivet bond especially in the manufacturing of the aircraft skin, panel, etc... However, due to the properties of aluminum alloy and the structural characteristics of T-joint, whether traditional TIG welding or advanced laser welding has to face with some problems in formation of weld, such as pores, cracks, deformation, which are difficult to solve by single way. In this paper, the fillet weld for T-joint of 3.0 mm thick 6061 aluminum alloy has been completed through Laser–TIG Both-Side Synchronization Welding (LTBSW), which provides many advantages which are not found in either.
First of all, the positioning device, arc torch and fixture which offer the equipment condition for craft investigation have been designed and optimized according to requirements of LTBLW experiments and structural characteristics of T-joint.
In addition, we have studied with the LTBSW horizontal welding in vertical board on different welding parameters which effect formation of weld, obtained good parameter range, and lay the groundwork for welding of T-joint. The results show that the key of LTBSW is to realize the linking up of the molten pool on both sides each other in T-joint. When the laser and arc energies on both sides are properly matched, both molten pools can be integrated, and the interaction of laser-arc is strengthened, such as melting into organic whole, smaller differences on welding width. In this case, a stable welding process and good formations of the welds are achieved.
Finally, the effects of weld parameters for 6061 aluminum alloy of T-joint and forms of weld joints on the welding seam have been studied. Then, microstructure and mechanical properties of weld have been studied and analyzed as well. The results show that right process parameters of LTBSW in T-joint can complete good formations of weld which has similar organizations on both sides and has properties of grain-based and transitional uniform. Tensile strength for welding joints which has been broken in the parent material is up to 247.7Mpa. Bending angle has reached more than 15°and the crackle has taken the form of saw tooth.
The research results can help to understand the interaction between laser and arc hybrid processing, reduce porosity deformation in T-joint, as well as improve the stability of weld process and energy utilization. This research helps to improve welding technology of the high-strength aluminum alloy and applications in the fields of Aero-Space, fast trains, ships and automobiles, etc...
引文
1左铁钏等.高强铝合金的激光加工.国防工业出版社,2002:1~32
2张少华.铝合金在汽车上应用的进展[J].汽车工业研究,2003(3): 36～39
3 Rich H. Profile of Kentucky’s Aluminum Industry[R].Office of Research and Information Technology Kentucky Cabinet for Economic Development, 2005:1～56
4丁向群,何国求,刘小山等.6000系汽车车用铝合金的研究应用进展[J].材料科学与工程学报, 2005, 23(3): 302～305
5左郭桂,李芳,华学明等.铝合金焊接新技术在汽车制造中的应用[J].电阻机,2007,37(7)1～5
6周振丰.金属熔焊原理及工艺.机械工艺出版社.1981:146~151
7 Lawrence F, Munse W. E?ects of porosity on tensile properties of 5083 and 6061 aluminum alloys weldments. Welding Res Counc Bull 1973:7～12.
8 Katayama S, Matsunawa A, Kojima K. CO2 laser weld ability of aluminum alloys (2nd report): Defect formation conditions and causes. Welding Int 1998(12):44～48.
9周万盛,姚君山等.铝及铝合金的焊接.机械工业出版社,2006:226～337
10张志勇,田志凌,彭云.铝合金先进焊接工艺[J].焊接,2007(7):5～11
11 Walduck R P, Biffin J. Plasma arc augmented laser welding. Welding & Metal Fabrication, 1994(4) :172～176
12陈彦斌,徐庆鸿,苏彦东.激光-同轴电弧复合焊接热源焊接.焊接学报, 1995, 16(4):239~243
13张旭东,陈武柱,双元卿等. CO2激光-MIG同轴复合焊方法及铝合金焊接的研究.应用激光, 2005, 25(1):1~3
14 Liu L M, Wang J F, and Song G. Hybrid laser-TIG welding, laser beam welding and gas tungsten arc welding of AZ31B magnesium alloy. Materials Science and Engineering, 2004, 381:129~133
15 Song G, Liu L M, and Wang P C. Overlap welding of magnesium AZ31B sheets using laser-arc hybrid process. Materials Science and Engineering, 2006, 429:312~319
16 Liu L M, Liu X J, and S H Liu. Microstructure of laser-TIG hybrid welds of dissimilar Mg alloy and Al alloy with Ce as interlayer. Scripter Material, 2006, 55:383~386
17 Huang R S, Liu L M, and Song G. Infrared temperature measurement and interference analysis of magnesium alloy in hybrid laser-TIG welding process. Materials Science and Engineering, 2007, 447:239~243
18 Simon O, Reisgen U, Ulrich D. Robot application for laser-GMA hybrid welding in shipbuilding. Laser Materials Processing Conference , 2007:308～315
19 Kutsuna M, Yan Q. Study on porosity formation in laser welds in aluminum alloys (Report 1). Effect of hydrogen and alloying elements. Welding International.1998,12: 20～32.
20 Katayama S, Mastunawa A. CO2 laser welding of aluminum alloys (2nd Report): Defect formation conditions and causes. Welding International.1998,Volume 12, No.10: 44～59.
21 Alexander F. Kaplan H, Masami Mizutani,Seiji Katayama and Akira Matsunawa. Analysis of different methods for the prevention of pore formation in keyhole laser spot welding.Welding in the world. 2002,9:32～38
22 Kutsuna M, Kitamura S, Shibata K. Tsushima, K. Improvement of the joint performance inlaser welding of aluminum alloys. Welding in the World. Volume 50, No. 1-2: 22～27
23 Friedrich D. Laser welding of aluminum alloys: from fundamental investigation to industrial application. Proceedings of SPIE.2000,3888:367～379
24张盛海.高强铝合金T型接头的激光焊接.北京工业大学工学硕士论文.2005:1～9
25 Zhang Y M, Zhang S B. Welding Aluminum Alloy 6061 with the Opposing Dual-Torch GTAW Process [J]welding journal, 1999(6):202～206
26 Zhang Y M, Pan C,Male A T. Improved Microstructure and Properties of 6061 Aluminum Alloy Walden’s Using a Double-Sided Arc Welding Process[J] Metallurgical and Materials Transactions 2000(10):2537～2543
27陈彦宾,苗玉刚,李俐群等.铝合金激光-钨极氩弧双面焊的焊接特性(J).中国激光,2007,34(12):1716～1720
28 Teng T L, Fung C P, Chang P H, et al. Analysis of residual stresses and distortion in T-joint filler welds [J]. International Journal of Pressure Vessel and Piping, 2001, 78: 523-538.
29丁林,周永涛,李明喜.T型接头激光焊接的温度场和应力场的数值模拟(J).安徽工业大学学报,2007,24(4):384～388
30薛小龙,王志亮等.薄板T型接头焊接温度场的研究(J).热加工工艺,2006,35(3):46～48
31徐琳,严仁军.T型焊接接头残余应力与变形的三维数值模拟.江苏船舶,2007,24(1):5～8
32蔺海荣,魏星等.拘束焊T形接头的拘束长度与面外拘束力.焊接学报,2002,23(4):69～71
33徐建设,陈以一.搭接接头与T型接头焊接角变形的分析.钢结构,2002,17(2):43～45
34 M.Ohata等.铝合金薄板角焊焊接变形的控制.国外机车车辆工艺(J),2002,1(1),13～21
35张铁山,盛陈,郑力军.大型构件T形焊接接头横向变形的研究.焊接,2001(8):15～19
36张盛海,陈铠,肖荣诗等.高强铝合金T型接头激光焊接的研究现状.激光杂志,2005, 4:45～48
37 Binroth C, Zuo T, Sepold G. CO2-laser beam welding with filler material of high strength aluminum alloy.Proc.of 2nd Int. Power beam Technology Conference.Sept,1990, 119～127
38 Rongshi X, Kai C, Tiechuan Z et al.. Influence of the wire addition direction in CO2 laser welding of aluminum.Proceedings of SPIE-The International Society for Optical Engineering, v 4915,2002, p 128～137
39 Salminen A. The effects of filler wire feed on the efficiency of laser welding.Proceedings of SPIE-The International Society for Optical Engineering, v 4831,2002, p 26～268
40张盛海,陈铠,肖荣诗等.高强铝合金T型接头激光焊接的研究现状.激光杂志.2005年第4期:45～48
41张振海.钛合金T型接头复合焊接结构件综合力学性能研究.北京工业大学工学硕士论文.2008:8～15
42周振丰等.焊接冶金与金属焊接性.机械工业出版社,1994:10～11
43张士林,任颂赞.简明铝合金手册.上海科学技术文献出版社, 2001:9～10
44 Sudnik.W. A, Erofeev. V. A. Computational simulation of laser fillet and tailored blank welding [C]. SPIE , 2006 , 6053 :60531521～60531529
45 Casalino G, Curcio F, L udovico A D. FEM simulation of metal sheets laser
46 Kross J, Gratzke U, Vicanek M. Dynamic behavior of the key hole in laser welding [ J ]. J. Phys. D: Appl. Phys. 1993, 26 (3):481～486
47何德孚,焊接与连接工程学导论,上海交通大学出版社,1998年12月,113～115
48 Drauglates, Ulrich, etal.. Welding of magnesium alloys by means non-vacuum Electron-beamwelding[J].Welding and Cutting,2000,54(4):62～67
49 David S A, Vitek J M, Proc. On International Trends in Welding Science and Technology, Gatlinburg, ASM international, Materials Park, OH, 1993, p147～56
50 Brooks J A. On Trends in Welding Research, Gatlinburg, ASM international, Materials Park, OH, 1996, p 123～34
2张少华.铝合金在汽车上应用的进展[J].汽车工业研究,2003(3): 36～39
3 Rich H. Profile of Kentucky’s Aluminum Industry[R].Office of Research and Information Technology Kentucky Cabinet for Economic Development, 2005:1～56
4丁向群,何国求,刘小山等.6000系汽车车用铝合金的研究应用进展[J].材料科学与工程学报, 2005, 23(3): 302～305
5左郭桂,李芳,华学明等.铝合金焊接新技术在汽车制造中的应用[J].电阻机,2007,37(7)1～5
6周振丰.金属熔焊原理及工艺.机械工艺出版社.1981:146~151
7 Lawrence F, Munse W. E?ects of porosity on tensile properties of 5083 and 6061 aluminum alloys weldments. Welding Res Counc Bull 1973:7～12.
8 Katayama S, Matsunawa A, Kojima K. CO2 laser weld ability of aluminum alloys (2nd report): Defect formation conditions and causes. Welding Int 1998(12):44～48.
9周万盛,姚君山等.铝及铝合金的焊接.机械工业出版社,2006:226～337
10张志勇,田志凌,彭云.铝合金先进焊接工艺[J].焊接,2007(7):5～11
11 Walduck R P, Biffin J. Plasma arc augmented laser welding. Welding & Metal Fabrication, 1994(4) :172～176
12陈彦斌,徐庆鸿,苏彦东.激光-同轴电弧复合焊接热源焊接.焊接学报, 1995, 16(4):239~243
13张旭东,陈武柱,双元卿等. CO2激光-MIG同轴复合焊方法及铝合金焊接的研究.应用激光, 2005, 25(1):1~3
14 Liu L M, Wang J F, and Song G. Hybrid laser-TIG welding, laser beam welding and gas tungsten arc welding of AZ31B magnesium alloy. Materials Science and Engineering, 2004, 381:129~133
15 Song G, Liu L M, and Wang P C. Overlap welding of magnesium AZ31B sheets using laser-arc hybrid process. Materials Science and Engineering, 2006, 429:312~319
16 Liu L M, Liu X J, and S H Liu. Microstructure of laser-TIG hybrid welds of dissimilar Mg alloy and Al alloy with Ce as interlayer. Scripter Material, 2006, 55:383~386
17 Huang R S, Liu L M, and Song G. Infrared temperature measurement and interference analysis of magnesium alloy in hybrid laser-TIG welding process. Materials Science and Engineering, 2007, 447:239~243
18 Simon O, Reisgen U, Ulrich D. Robot application for laser-GMA hybrid welding in shipbuilding. Laser Materials Processing Conference , 2007:308～315
19 Kutsuna M, Yan Q. Study on porosity formation in laser welds in aluminum alloys (Report 1). Effect of hydrogen and alloying elements. Welding International.1998,12: 20～32.
20 Katayama S, Mastunawa A. CO2 laser welding of aluminum alloys (2nd Report): Defect formation conditions and causes. Welding International.1998,Volume 12, No.10: 44～59.
21 Alexander F. Kaplan H, Masami Mizutani,Seiji Katayama and Akira Matsunawa. Analysis of different methods for the prevention of pore formation in keyhole laser spot welding.Welding in the world. 2002,9:32～38
22 Kutsuna M, Kitamura S, Shibata K. Tsushima, K. Improvement of the joint performance inlaser welding of aluminum alloys. Welding in the World. Volume 50, No. 1-2: 22～27
23 Friedrich D. Laser welding of aluminum alloys: from fundamental investigation to industrial application. Proceedings of SPIE.2000,3888:367～379
24张盛海.高强铝合金T型接头的激光焊接.北京工业大学工学硕士论文.2005:1～9
25 Zhang Y M, Zhang S B. Welding Aluminum Alloy 6061 with the Opposing Dual-Torch GTAW Process [J]welding journal, 1999(6):202～206
26 Zhang Y M, Pan C,Male A T. Improved Microstructure and Properties of 6061 Aluminum Alloy Walden’s Using a Double-Sided Arc Welding Process[J] Metallurgical and Materials Transactions 2000(10):2537～2543
27陈彦宾,苗玉刚,李俐群等.铝合金激光-钨极氩弧双面焊的焊接特性(J).中国激光,2007,34(12):1716～1720
28 Teng T L, Fung C P, Chang P H, et al. Analysis of residual stresses and distortion in T-joint filler welds [J]. International Journal of Pressure Vessel and Piping, 2001, 78: 523-538.
29丁林,周永涛,李明喜.T型接头激光焊接的温度场和应力场的数值模拟(J).安徽工业大学学报,2007,24(4):384～388
30薛小龙,王志亮等.薄板T型接头焊接温度场的研究(J).热加工工艺,2006,35(3):46～48
31徐琳,严仁军.T型焊接接头残余应力与变形的三维数值模拟.江苏船舶,2007,24(1):5～8
32蔺海荣,魏星等.拘束焊T形接头的拘束长度与面外拘束力.焊接学报,2002,23(4):69～71
33徐建设,陈以一.搭接接头与T型接头焊接角变形的分析.钢结构,2002,17(2):43～45
34 M.Ohata等.铝合金薄板角焊焊接变形的控制.国外机车车辆工艺(J),2002,1(1),13～21
35张铁山,盛陈,郑力军.大型构件T形焊接接头横向变形的研究.焊接,2001(8):15～19
36张盛海,陈铠,肖荣诗等.高强铝合金T型接头激光焊接的研究现状.激光杂志,2005, 4:45～48
37 Binroth C, Zuo T, Sepold G. CO2-laser beam welding with filler material of high strength aluminum alloy.Proc.of 2nd Int. Power beam Technology Conference.Sept,1990, 119～127
38 Rongshi X, Kai C, Tiechuan Z et al.. Influence of the wire addition direction in CO2 laser welding of aluminum.Proceedings of SPIE-The International Society for Optical Engineering, v 4915,2002, p 128～137
39 Salminen A. The effects of filler wire feed on the efficiency of laser welding.Proceedings of SPIE-The International Society for Optical Engineering, v 4831,2002, p 26～268
40张盛海,陈铠,肖荣诗等.高强铝合金T型接头激光焊接的研究现状.激光杂志.2005年第4期:45～48
41张振海.钛合金T型接头复合焊接结构件综合力学性能研究.北京工业大学工学硕士论文.2008:8～15
42周振丰等.焊接冶金与金属焊接性.机械工业出版社,1994:10～11
43张士林,任颂赞.简明铝合金手册.上海科学技术文献出版社, 2001:9～10
44 Sudnik.W. A, Erofeev. V. A. Computational simulation of laser fillet and tailored blank welding [C]. SPIE , 2006 , 6053 :60531521～60531529
45 Casalino G, Curcio F, L udovico A D. FEM simulation of metal sheets laser
46 Kross J, Gratzke U, Vicanek M. Dynamic behavior of the key hole in laser welding [ J ]. J. Phys. D: Appl. Phys. 1993, 26 (3):481～486
47何德孚,焊接与连接工程学导论,上海交通大学出版社,1998年12月,113～115
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