船用5083铝合金CO_2激光焊接焊缝成形质量研究
|
摘要
在全球交通工具向轻型化发展的背景下,铝合金在造船工业中得到了越来越广泛的应用,铝合金焊接在生产中常采用熔化极氩弧焊的方法,面临的主要问题是焊接速度慢、焊后变形大、接头性能差等,进而影响了船舶制造的质量和效率。在船舶制造中采用激光焊接可以提高生产效率、减小变形,提高焊缝性能和船舶制造质量。造船工业中使用较多的是5083铝合金,但是激光焊接过程稳定性差、深熔焊时焊缝成形较差、表面容易出现孔洞等问题成为5083铝合金焊接的难点。
本文主要针对5083铝合金的焊缝成形问题进行研究,首先对船用5083铝合金激光焊接工艺参数进行试验,分析了影响5083铝合金激光焊接焊缝成形的主要因素,找出了激光功率和焊接速度、辅助气体、离焦量、光束聚焦对焊缝成形的影响规律。
然后对激光焊接工艺参数对焊缝成形的影响规律进行了理论分析,对5083铝合金激光焊接焊缝成形较差的原因进行了分析,进而从小孔、熔池的受力方面对焊接过程中产生孔洞的原因进行分析。文章对几种主要缺陷的产生原因进行了分析,并提出了改善焊缝成形的方案。
基于上述研究结果,文章最后对5083铝合金进行了长焊缝的激光对接焊试验,找出了优化的焊接工艺参数,并进行了金相试验、显微硬度试验和力学性能试验(如拉伸试验、弯曲试验)。
研究成果有助于进一步了解铝合金激光焊接过程中激光与材料相互作用及所发生的物理现象,有助于进一步提高激光焊接过程的稳定性、提高铝合金激光焊接质量,从而提高我国铝合金高速船舶制造业水平,同时对车辆、航空航天等行业的铝合金焊接技术具有重要的指导意义。
Under the background of the global light–duty trend of transport facility aluminum alloys have been applied widely in the shipbuilding industry more and more. In the manufacturing process of production, MIG is often used for welding of aluminum alloys. There are some problems that have effect on the quality and efficiency of the ship building, such as slower weld speed, bigger deformation and inferior joint performance. The Application of laser welding in shipbuilding can increase the production efficiency, reduce weld deformation and improve weld performance and ship building quality. However the instability of laser welding process, bad surface of weld seam, blowholes on the surface are the primary difficulties by the application of the 5083 aluminum alloy laser welding for ship building.
This thesis aimed at the surface quality of laser weld seam of 5083 aluminum alloy. Firstly, a lot of experiments for technology parameters of laser welding of 5083 aluminum alloy have been made. Then the paper analyses the main factor which has effect on the laser welding seam quality, find the effects of the laser power, weld speed, auxiliary gas, defocusing distance and beam focused degree on the quality of the weld seam surface.
Secondly, the thesis analyses abstractly the effect of laser welding parameters on the surface quality of weld seam and the possible reasons of the poor weld seam according to the keyhole and pressure of welding pool. Furthermore the investigations under improvement of surface quality of weld seam have been made.
Based on the results mentioned above, the laser jointing experiments of long weld seams of 5083 aluminum alloy have been made using optimized weld parameters, and then some experiments such as metallographic test, micro-hardness test, mechanical properties of tensile and bending have been made.
The research results contribute to understanding the interaction between laser beam and materials and related physical phenomena during weld progress. The study helps to improve the stability of process of laser welding and the quality of laser weld seam, what will enhance manufacturing level of high-speed ship and has an important guiding significance to the aluminum laser welding technology confronted with vehicles, aerospace industries.
本文主要针对5083铝合金的焊缝成形问题进行研究,首先对船用5083铝合金激光焊接工艺参数进行试验,分析了影响5083铝合金激光焊接焊缝成形的主要因素,找出了激光功率和焊接速度、辅助气体、离焦量、光束聚焦对焊缝成形的影响规律。
然后对激光焊接工艺参数对焊缝成形的影响规律进行了理论分析,对5083铝合金激光焊接焊缝成形较差的原因进行了分析,进而从小孔、熔池的受力方面对焊接过程中产生孔洞的原因进行分析。文章对几种主要缺陷的产生原因进行了分析,并提出了改善焊缝成形的方案。
基于上述研究结果,文章最后对5083铝合金进行了长焊缝的激光对接焊试验,找出了优化的焊接工艺参数,并进行了金相试验、显微硬度试验和力学性能试验(如拉伸试验、弯曲试验)。
研究成果有助于进一步了解铝合金激光焊接过程中激光与材料相互作用及所发生的物理现象,有助于进一步提高激光焊接过程的稳定性、提高铝合金激光焊接质量,从而提高我国铝合金高速船舶制造业水平,同时对车辆、航空航天等行业的铝合金焊接技术具有重要的指导意义。
Under the background of the global light–duty trend of transport facility aluminum alloys have been applied widely in the shipbuilding industry more and more. In the manufacturing process of production, MIG is often used for welding of aluminum alloys. There are some problems that have effect on the quality and efficiency of the ship building, such as slower weld speed, bigger deformation and inferior joint performance. The Application of laser welding in shipbuilding can increase the production efficiency, reduce weld deformation and improve weld performance and ship building quality. However the instability of laser welding process, bad surface of weld seam, blowholes on the surface are the primary difficulties by the application of the 5083 aluminum alloy laser welding for ship building.
This thesis aimed at the surface quality of laser weld seam of 5083 aluminum alloy. Firstly, a lot of experiments for technology parameters of laser welding of 5083 aluminum alloy have been made. Then the paper analyses the main factor which has effect on the laser welding seam quality, find the effects of the laser power, weld speed, auxiliary gas, defocusing distance and beam focused degree on the quality of the weld seam surface.
Secondly, the thesis analyses abstractly the effect of laser welding parameters on the surface quality of weld seam and the possible reasons of the poor weld seam according to the keyhole and pressure of welding pool. Furthermore the investigations under improvement of surface quality of weld seam have been made.
Based on the results mentioned above, the laser jointing experiments of long weld seams of 5083 aluminum alloy have been made using optimized weld parameters, and then some experiments such as metallographic test, micro-hardness test, mechanical properties of tensile and bending have been made.
The research results contribute to understanding the interaction between laser beam and materials and related physical phenomena during weld progress. The study helps to improve the stability of process of laser welding and the quality of laser weld seam, what will enhance manufacturing level of high-speed ship and has an important guiding significance to the aluminum laser welding technology confronted with vehicles, aerospace industries.
引文
1 左铁钏等. 高强铝合金的激光焊接, 国防工业出版社, 2002
2 何兵. 铝合金高速船的焊接. 焊接. 1996 年 8 月:14~16
3 李敬勇, 李标峰. 铝合金焊接船及其发展. 材料开发与应用. 1994年, 第9卷, 第3期:33~38
4 李维博. 铝制高速船的焊接技术. 造船技术. 1998年, 第8期:21~23
5 何兵. 铝合金高速船的焊接工艺认可. 广东造船. 1996年, 第3期:8~10
6 殷浩澍. 激光焊接在欧洲造船业的应用. 电焊机. 2005 年, 第 35 卷, 第 7 期:1~5
7 王珏. 铝合金在造船中的应用与发展. 轻金属. 1994年, 第4期:49~54
8 王珏. 船舶用铝合金材料. 轻金属. 1994年, 第6期:58~64
9 王珏. 船用铝合金的物理性能. 轻金属. 1994年, 第5期:55~57
10 李念奎. 船用铝合金的机械性能(1). 轻金属. 1994年, 第7期:50~55
11 李念奎. 船用铝合金的机械性能(2). 轻金属. 1994年, 第9期:53~58
12 李标峰. 船用铝合金焊接及其船体建造工艺. 国防工业出版社, 2005 年 3 月:46~56
13 辜磊, 刘建华, 王兴均. 激光-电弧复合焊接技术在船舶建造中的应用研究. 造船技术. 2005 年, 第 5 期:38~40
14 王治宇, 王春明, 胡伦骥, 胡席远. 湖北武汉激光-电弧复合焊接的应用, 电焊机. 2006年 2 月第 36 卷第 2 期:38~41
15 Shigeki FUJINAGA, Ryoji OHASHI, Seiji KATAYAMA. Improvements of Welding Characteristics of Aluminum Alloys with YAG Laser and TIG Arc Hybrid System. First International Symposium on High-Power Laser Macroprocessing, Proceedings of SPIE Vol. 4831, 2003:301~306
16 郭泽亮. 激光焊接技术在舰船建造中的应用. 舰船科学技术. 2005 年, 第 27 卷, 第 4 期: 81~84
17 Antti Salminen. The Effects of Filler Wire Feed on the Efficiency of Laser Welding. First International Symposium on High-Power Laser Macroprocessing, Proceedings of SPIE Vol. 4831, 2003:263~268
18 H.C. Tse, H.C. Man, T.M. Yue. Effect of Magnetic Field on Plasma Control During CO2 Laser Welding. Optics & Technology, 1999(31):363-368
19 H. Zhao, T. DebRoy. Macroporosity Free Aluminium Alloy Weldments through Numerical Simulation of Keyhole Mode Laser Welding. Journal of Applied Physics, Vol. 93, No. 12, 15 June 2003:10089~10096
20 Mark Faerber, Joachim Berkmann. Process Gases for Laser Welding. SPIE Vol. 1979(30):656~661
21 E.H. Amara, R. Fabbro, A. Bendib. Modeling of the Compressible Vapor Flow Induced in a Keyhole during Laser Welding. Journal of Applied Physics, Vol. 93, No. 7, 1 April 2003:4289~4296
22 Hong Lei, Cheng Wuzhu, Wu Gang. Influence of Shielded Gas Flow in CO2 Laser Welding of A5083 Aluminium Alloy. Lasers in Material Processing and Manufacturing Ⅱ ,Proceeding of SPIE, Vol.5629, 2005:179~186
23 Helmut Hügel, Matthias G.Müller, Bernd Hohenberger. Laser Beam Welding: Recent Developments on Process Conduction and Quality Assurance. SPIE Vol.3571, 1999:52~60
24 Tommi Jokinen, Veli Kujanp??. High Power Nd:YAG Laser Welding in Manufacturing of Vacuum Vessel of Fusion Rector. Fusion Engineering and Design, 2003(69):349-353
25 王家淳, 王希哲. 钛合金激光焊接稳定性计算模型. 焊接学报. 2000 年, 第 21 卷, 第 4期:13~16
26 Martin Klassen, Jochen Skupin, Gerd Sepold. Process Instabilities by Laser Beam Welding of Aluminium Alloys Generated by Laser Modulations. SPIE Vol. 3097:137~146
27 陈涛, 陈铠等. CO2 激光焊接不稳定性的直接监测. 北京工业大学学报. 2001 年 9 月, 第27 卷, 第 3 期:282~286
28 段爱琴, 陈俐等. CO2激光焊接不锈钢光致等离子体动态特性分析. 焊接学报. 2005年11月, 第 26 卷, 第 11 期: 17~20
29 肖荣诗, 左铁钏等. 采用填充焊丝的外加电流铝合金 CO2激光焊接. 焊接学报. 2006 年5月, 第 27 卷, 第 5 期:9~12
30 郑启光等. 激光深熔焊接的熔池行为与焊接缺陷的研究.激光技术. 2000 年 4 月, 第 24卷, 第 2 期:90~94
31 张峄, 李力钧等, 激光深熔焊接小孔孔内等离子体的试验研究. 应用激光. 2004 年 12 月,第 24 卷, 第 6 期:387~389
32 包刚等. 激光焊接过程中电磁场控制等离子体的研究.激光技术. 2002 年 4 月, 第 26 卷,第 2 期:81~83
33 Sindo Kou. Welding Metallurgy. A John Wiley & Sons, Inc., Publication. 2002:102~146
34 洪蕾, 陈武柱, CO2 激光焊接铝合金的试验研究. 应用激光. 2003 年 2 月, 第 23 卷, 第 1期:16~18
35 洪蕾, 吴刚, 陈武柱. 保护气流对 CO2 激光焊接铝合金的影响. 中国激光. 2005 年 11 月,第 32 卷, 第 11 期:1572~1576
36 陈俐等. 薄板钛合金激光焊熔透稳定性临界条件的计算.焊接学报. 2005 年 11 月, 第 26卷, 第 11 期:35~38
37 王家淳等. 工艺因素对钛合金激光焊接不稳定性的影响. 焊接. 2000 年, 第 9 期:17~19
38 秦国梁, 林尚扬. Nd:YAG 激光深熔焊接过程中同轴保护气流量对小孔的影响. 2005 年 3月, 第 26 卷, 第 3 期:33~36
39 赵贺等, 激光焊接热过程数值模拟研究进展. 航天制造技术. 2004 年 10 月第 5 期: 31~35
40 Wen-Hai ZHANG, Jun ZHOU, Hai-Lung TSAI. Numerical Modeling of Keyhole Dynamics in Laser Welding. First International Symposium on High-Power Laser Macroprocessing, Proceedings of SPIE Vol. 4831, 2003:180~185
41 J. C. Ion. Laser Beam Welding of Wrought Aluminium Alloys. Science and Technology of Welding and Joining, 2000 Vol. 5, No. 5:265~276
42 Tommi Jokinen, Veli Kujanp??. High Power Nd:YAG Laser Welding in Manufacturing of Vacuum Vessel of Fusion Rector. Fusion Engineering and Design, 2003(69):349-353
43 H.C. Tse, H.C. Man, T.M. Yue. Effect of Magnetic Field on Plasma Control During CO2 Laser Welding. Optics & Technology, 1999(31):363-368
44 W. Bartel, D. P?the, R. Roatzsch, J.-M. Weick. Influence of Beam Quality when With Nd:YAG and CO2 Lasers. SPIE Vol. 1997(30):147~156
45 王希靖, 铝合金 5083 和 5052 的焊接, 甘肃工业大学学报, 1994(4):1-6
46 李加良, 张志生, 李践桥. 对5083, 6061, 608铝合金中厚板焊接工艺试验. 焊接, 2004, 10:34～36
47 Remy FABBRO and Karim CHOUF. Keyhole description in deep penetration laser welding.
48 胡效军, 齐淑改, 陈波. 铝合金5083及6061的焊接. 焊工之友, 2006, 35 (4):72～73
2 何兵. 铝合金高速船的焊接. 焊接. 1996 年 8 月:14~16
3 李敬勇, 李标峰. 铝合金焊接船及其发展. 材料开发与应用. 1994年, 第9卷, 第3期:33~38
4 李维博. 铝制高速船的焊接技术. 造船技术. 1998年, 第8期:21~23
5 何兵. 铝合金高速船的焊接工艺认可. 广东造船. 1996年, 第3期:8~10
6 殷浩澍. 激光焊接在欧洲造船业的应用. 电焊机. 2005 年, 第 35 卷, 第 7 期:1~5
7 王珏. 铝合金在造船中的应用与发展. 轻金属. 1994年, 第4期:49~54
8 王珏. 船舶用铝合金材料. 轻金属. 1994年, 第6期:58~64
9 王珏. 船用铝合金的物理性能. 轻金属. 1994年, 第5期:55~57
10 李念奎. 船用铝合金的机械性能(1). 轻金属. 1994年, 第7期:50~55
11 李念奎. 船用铝合金的机械性能(2). 轻金属. 1994年, 第9期:53~58
12 李标峰. 船用铝合金焊接及其船体建造工艺. 国防工业出版社, 2005 年 3 月:46~56
13 辜磊, 刘建华, 王兴均. 激光-电弧复合焊接技术在船舶建造中的应用研究. 造船技术. 2005 年, 第 5 期:38~40
14 王治宇, 王春明, 胡伦骥, 胡席远. 湖北武汉激光-电弧复合焊接的应用, 电焊机. 2006年 2 月第 36 卷第 2 期:38~41
15 Shigeki FUJINAGA, Ryoji OHASHI, Seiji KATAYAMA. Improvements of Welding Characteristics of Aluminum Alloys with YAG Laser and TIG Arc Hybrid System. First International Symposium on High-Power Laser Macroprocessing, Proceedings of SPIE Vol. 4831, 2003:301~306
16 郭泽亮. 激光焊接技术在舰船建造中的应用. 舰船科学技术. 2005 年, 第 27 卷, 第 4 期: 81~84
17 Antti Salminen. The Effects of Filler Wire Feed on the Efficiency of Laser Welding. First International Symposium on High-Power Laser Macroprocessing, Proceedings of SPIE Vol. 4831, 2003:263~268
18 H.C. Tse, H.C. Man, T.M. Yue. Effect of Magnetic Field on Plasma Control During CO2 Laser Welding. Optics & Technology, 1999(31):363-368
19 H. Zhao, T. DebRoy. Macroporosity Free Aluminium Alloy Weldments through Numerical Simulation of Keyhole Mode Laser Welding. Journal of Applied Physics, Vol. 93, No. 12, 15 June 2003:10089~10096
20 Mark Faerber, Joachim Berkmann. Process Gases for Laser Welding. SPIE Vol. 1979(30):656~661
21 E.H. Amara, R. Fabbro, A. Bendib. Modeling of the Compressible Vapor Flow Induced in a Keyhole during Laser Welding. Journal of Applied Physics, Vol. 93, No. 7, 1 April 2003:4289~4296
22 Hong Lei, Cheng Wuzhu, Wu Gang. Influence of Shielded Gas Flow in CO2 Laser Welding of A5083 Aluminium Alloy. Lasers in Material Processing and Manufacturing Ⅱ ,Proceeding of SPIE, Vol.5629, 2005:179~186
23 Helmut Hügel, Matthias G.Müller, Bernd Hohenberger. Laser Beam Welding: Recent Developments on Process Conduction and Quality Assurance. SPIE Vol.3571, 1999:52~60
24 Tommi Jokinen, Veli Kujanp??. High Power Nd:YAG Laser Welding in Manufacturing of Vacuum Vessel of Fusion Rector. Fusion Engineering and Design, 2003(69):349-353
25 王家淳, 王希哲. 钛合金激光焊接稳定性计算模型. 焊接学报. 2000 年, 第 21 卷, 第 4期:13~16
26 Martin Klassen, Jochen Skupin, Gerd Sepold. Process Instabilities by Laser Beam Welding of Aluminium Alloys Generated by Laser Modulations. SPIE Vol. 3097:137~146
27 陈涛, 陈铠等. CO2 激光焊接不稳定性的直接监测. 北京工业大学学报. 2001 年 9 月, 第27 卷, 第 3 期:282~286
28 段爱琴, 陈俐等. CO2激光焊接不锈钢光致等离子体动态特性分析. 焊接学报. 2005年11月, 第 26 卷, 第 11 期: 17~20
29 肖荣诗, 左铁钏等. 采用填充焊丝的外加电流铝合金 CO2激光焊接. 焊接学报. 2006 年5月, 第 27 卷, 第 5 期:9~12
30 郑启光等. 激光深熔焊接的熔池行为与焊接缺陷的研究.激光技术. 2000 年 4 月, 第 24卷, 第 2 期:90~94
31 张峄, 李力钧等, 激光深熔焊接小孔孔内等离子体的试验研究. 应用激光. 2004 年 12 月,第 24 卷, 第 6 期:387~389
32 包刚等. 激光焊接过程中电磁场控制等离子体的研究.激光技术. 2002 年 4 月, 第 26 卷,第 2 期:81~83
33 Sindo Kou. Welding Metallurgy. A John Wiley & Sons, Inc., Publication. 2002:102~146
34 洪蕾, 陈武柱, CO2 激光焊接铝合金的试验研究. 应用激光. 2003 年 2 月, 第 23 卷, 第 1期:16~18
35 洪蕾, 吴刚, 陈武柱. 保护气流对 CO2 激光焊接铝合金的影响. 中国激光. 2005 年 11 月,第 32 卷, 第 11 期:1572~1576
36 陈俐等. 薄板钛合金激光焊熔透稳定性临界条件的计算.焊接学报. 2005 年 11 月, 第 26卷, 第 11 期:35~38
37 王家淳等. 工艺因素对钛合金激光焊接不稳定性的影响. 焊接. 2000 年, 第 9 期:17~19
38 秦国梁, 林尚扬. Nd:YAG 激光深熔焊接过程中同轴保护气流量对小孔的影响. 2005 年 3月, 第 26 卷, 第 3 期:33~36
39 赵贺等, 激光焊接热过程数值模拟研究进展. 航天制造技术. 2004 年 10 月第 5 期: 31~35
40 Wen-Hai ZHANG, Jun ZHOU, Hai-Lung TSAI. Numerical Modeling of Keyhole Dynamics in Laser Welding. First International Symposium on High-Power Laser Macroprocessing, Proceedings of SPIE Vol. 4831, 2003:180~185
41 J. C. Ion. Laser Beam Welding of Wrought Aluminium Alloys. Science and Technology of Welding and Joining, 2000 Vol. 5, No. 5:265~276
42 Tommi Jokinen, Veli Kujanp??. High Power Nd:YAG Laser Welding in Manufacturing of Vacuum Vessel of Fusion Rector. Fusion Engineering and Design, 2003(69):349-353
43 H.C. Tse, H.C. Man, T.M. Yue. Effect of Magnetic Field on Plasma Control During CO2 Laser Welding. Optics & Technology, 1999(31):363-368
44 W. Bartel, D. P?the, R. Roatzsch, J.-M. Weick. Influence of Beam Quality when With Nd:YAG and CO2 Lasers. SPIE Vol. 1997(30):147~156
45 王希靖, 铝合金 5083 和 5052 的焊接, 甘肃工业大学学报, 1994(4):1-6
46 李加良, 张志生, 李践桥. 对5083, 6061, 608铝合金中厚板焊接工艺试验. 焊接, 2004, 10:34～36
47 Remy FABBRO and Karim CHOUF. Keyhole description in deep penetration laser welding.
48 胡效军, 齐淑改, 陈波. 铝合金5083及6061的焊接. 焊工之友, 2006, 35 (4):72～73