铝—钢异种金属脉冲旁路耦合电弧MIG熔钎焊方法及机理研究
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摘要
针对铝-钢现有焊接方法或效率低或成本高或对工件形状有特殊要求的问题，本文创新性地提出了机理上不同于现有精确控制型电弧焊技术的一种新型的脉冲旁路耦合电弧MIG焊(Pulsed DE-GMAW)方法，有利于精确控制焊接熔滴过渡及母材热输入，理论和实践上证明有利于铝-钢异种金属的焊接。
根据脉冲旁路耦合电弧MIG焊的特点和控制要求，建立了基于快速原型的铝-钢脉冲旁路耦合电弧MIG焊软硬件试验系统。该系统能够实现主路电流波形和旁路电流波形的控制与协调，并能够完成对焊接过程电信号和视觉信号的采集、显示、处理和存储，而且可以实时的输出控制信号，优化铝-钢焊接工艺参数，完成对铝-钢焊接过程的控制。
建立了脉冲旁路耦合电弧MIG焊数学模型，提出了通过控制主路电弧来稳定整个耦合电弧的控制方案。对脉冲旁路耦合电弧MIG焊过程弧长稳定性及脉冲电流参数对焊接过程及熔滴过渡的影响进行了仿真，并在此基础上分别采用主路平均电弧电压反馈和视觉反馈两种不同的弧长反馈方式，对铝-钢脉冲旁路耦合电弧MIG焊过程弧长稳定性进行了控制试验，均得到了理想的控制效果。
通过铝-钢脉冲旁路耦合电弧MIG焊平板堆焊工艺试验，研究了主路电流和旁路电流对铝-钢焊缝成形的影响，结果表明，主路电流的增大有利于熔滴的铺展润湿，而旁路电流对熔滴铺展润湿的作用相对较小。通过高速摄像试验研究了脉冲电流参数对铝-钢脉冲旁路耦合电弧MIG焊过程熔滴过渡的影响，研究表明，为实现更小电流下熔滴的稳定自由过渡，在保持总电流不变的情况下，除了可以增大旁路平均电流外，还可以提高主路和旁路的峰值电流、峰值时间，以提高熔滴过渡的稳定性。同时，在铝-钢脉冲旁路耦合电弧MIG焊过程中，由于旁路的稳弧作用，可设置小的主路和旁路基值电流，使得总的热输入减小。
对铝-钢脉冲旁路耦合电弧MIG焊过程的热循环曲线进行了测量分析，研究了不同旁路耦合电弧参数对热循环曲线的影响规律；在提出的热源模型和试验得到的热循环曲线数据的基础上，对铝-钢界面处温度场分布进行了模拟。利用得到的铝-钢界面处温度场的分布特点，对金属间化合物层的生长进行了数值计算，计算结果与试验结果能较好的吻合，验证了所假设的扩散模型的正确性。在温度场模拟和扩散层厚度模拟的基础上，研究了冷却时间、峰值温度及热循环曲线积分三个因素对金属间化合物层厚度的影响；冷却时间对铝-钢界面处金属间化合物层厚度的影响最大，峰值温度和热循环曲线积分的影响较小。
对铝-钢搭接试样进行了力学性能测试，结果发现，5052铝合金与镀锌钢板的搭接试样平均拉伸强度达到了144.85Mpa，最高拉伸强度186.73Mpa，达到了铝合金母材强度的88.5%；研究了旁路耦合电弧参数对铝-钢焊接接头力学性能的影响，结果表明，铝-钢接头的强度不仅取决于母材热输入的大小，同时还要受焊缝几何参数的影响，在铝-钢脉冲旁路耦合电弧MIG焊过程中，要选择合适的旁路电弧参数，既要保证较低的母材热输入，抑制有害的铝-钢金属间化合物的生长，减小铝侧热影响区的软化，又要保证较大的焊缝形状因数，使得熔滴在母材能较好的润湿铺展。
通过对铝-钢显微组织分析发现，脉冲旁路耦合电弧MIG焊得到的铝-钢接头，界面区金属间化合物主要是由靠近钢侧的均匀连续的Fe2Al5或Fe2Al5ZnX，以及靠近铝侧的呈针片状分布的FeAl3相组成，焊趾部位存在富锌区，其主要成分是铝锌固溶体。在显微组织分析的基础上，提出了铝-钢金属间化合物生长模型，主要分为以下几个阶段：液态铝与固态铁之间的互扩散、铝-钢界面处Fe2Al5形核生长、Fe2Al5形成连续相层阻碍铁原子的扩散、铝原子穿过Fe2Al5相层继续与铁原子反应、FeAl3在铝熔化区结晶析出。锌在铝-钢脉冲旁路耦合电弧MIG焊接过程中主要起着辅助熔滴铺展润湿及稳定耦合电弧的作用。
Aiming at the problems of existing welding methods for joining aluminum to steel,such as low efficiency, high cost or having special requirements on the shape of thework piece, a novel welding method was proposed innovatively in this paper conduciveto control metal transfer and heat input of base metal precisely in welding process. Thewelding method has different mechanism from the existing precise-control-type arcwelding technology, and was proved to be conducive to dissimilar metal joining ofaluminum to steel from theory and practice.
A rapid prototyping test system was established to sense, observe and control thewelding process according to the characteristics and control requirements of PulsedDE-GMAW, and the corresponding software control program was also developed.Control and coordination of current waveform of the main and bypass was also realizedby the developed control system.
A mathematics model for Pulsed DE-GMAW was developed and a control schemethat stabilizing the whole coupling arc by controlling the main arc was proposed. Thensimulation for arc length stability in welding process and influence of pulse currentparameters to metal transfer were carried out. On this basis, control tests for arc lengthstability in Pulsed DE-GMAW for joining aluminum to steel were done adopting twodifferent feedback modes, average arc voltage feedback of main welding arc and visionfeedback. Both the control effect of the two control schemes was well.
The influence of main and bypass arc parameters to weld formation was studied bythe flat surfacing technology tests for Pulsed DE-GMAW. The results show thatincreasing the main current makes for good spreading and wetting of aluminum droplet,but the effect of the bypass current to droplet wetting is relative small. Then theinfluence of pulse current parameters to metal transfer of Pulsed DE-GMAW processwas researched by high-speed camera tests, and the results show that the peak currentand peak time can be also increased to improve the metal transfer frequency andstabilize the welding process in addition to increasing the bypass current in order torealize the stable spray transfer, in the case of maintaining the same total current. At thesame time, the base current of main and bypass can be set small to decrease the totalwelding heat input due to the stability role of bypass arc in Pulsed DE-GMAW processfor joining aluminum to steel.
The thermal cycle curves for Pulsed DE-GMAW were measured and influence lawof different bypass parameters to thermal cycle curve was studied. On the basis of builtheat source model and obtained thermal cycle curves, the temperature field distributionat the interface of aluminum-steel was simulated and analyzed. With the obtainedtemperature field distribution, the growth of the intermetallic compound(IMC) layerwas then simulated and the results was consistent with the tests, which proved thecorrectness of the assumed diffusion model. On this basis of simulation for temperaturefield distribution and growth of the IMC layer, the influence of the cooling time, peaktemperature and integral of thermal cycle on the thickness of IMC was identified anddiscussed. It was identified that cooling time has the biggest influence on the thicknessof the IMC and the effect of peak temperature and integral of thermal cycle is small.
Mechanical properties tests were carried out for lap joint specimens of5052 aluminum alloy and galvanized steel. The results show that the average tensile strengthis144.85MPa and the maximum tensile strength is up to186.73MPa, about88.5%ofthe base metal strength. The influence of bypass arc parameters on mechanicalproperties of lap joint was studied. The results show that the strength of aluminum-steellap joints depends not only on the base metal heat input, but also by the influence ofweld geometry parameters. In Pulsed DE-GMAW process for joining aluminum to steel,the bypass arc parameters should be selected appropriately. Not only the lower basemetal heat input should be ensured to inhibit the growth of harmful IMC of aluminumand steel and reduce the softening of HAZ of aluminum side, but also a larger weldshape factor should be ensured to make the droplet wetting and spreading better ongalvanized steel.
By observing and analyzing the microstructure of the aluminum-steel joint, it isfound that the interface zone of aluminum-steel joints made by Pulsed DE-GMAWmainly consisted of a uniform continuous Fe2Al5, or Fe2Al5ZnXnear the steel side andelongated FeAl3phase near the aluminum side. Zinc-rich zone is located at the edge ofweld bead, and the main component is Al-Zn solid solution. An IMC growth model wasproposed based on microstructure analysis. The IMC growth stages could be as follows:diffusion of solid iron and molten aluminum, the nucleation and growth of Fe2Al5at thealuminum-steel interface, formation of the continuous Fe2Al5phase layer and hinderingthe diffusion of iron atoms, aluminum atoms diffusing through Fe2Al5layer to continuereacting with the iron atom, FeAl3crystallization in the aluminum melting zone. Theroles of zinc on droplet spreading wetting and stabilizing coupling arc are played inPulsed DE-GMAW process for joining aluminum to steel.
根据脉冲旁路耦合电弧MIG焊的特点和控制要求，建立了基于快速原型的铝-钢脉冲旁路耦合电弧MIG焊软硬件试验系统。该系统能够实现主路电流波形和旁路电流波形的控制与协调，并能够完成对焊接过程电信号和视觉信号的采集、显示、处理和存储，而且可以实时的输出控制信号，优化铝-钢焊接工艺参数，完成对铝-钢焊接过程的控制。
建立了脉冲旁路耦合电弧MIG焊数学模型，提出了通过控制主路电弧来稳定整个耦合电弧的控制方案。对脉冲旁路耦合电弧MIG焊过程弧长稳定性及脉冲电流参数对焊接过程及熔滴过渡的影响进行了仿真，并在此基础上分别采用主路平均电弧电压反馈和视觉反馈两种不同的弧长反馈方式，对铝-钢脉冲旁路耦合电弧MIG焊过程弧长稳定性进行了控制试验，均得到了理想的控制效果。
通过铝-钢脉冲旁路耦合电弧MIG焊平板堆焊工艺试验，研究了主路电流和旁路电流对铝-钢焊缝成形的影响，结果表明，主路电流的增大有利于熔滴的铺展润湿，而旁路电流对熔滴铺展润湿的作用相对较小。通过高速摄像试验研究了脉冲电流参数对铝-钢脉冲旁路耦合电弧MIG焊过程熔滴过渡的影响，研究表明，为实现更小电流下熔滴的稳定自由过渡，在保持总电流不变的情况下，除了可以增大旁路平均电流外，还可以提高主路和旁路的峰值电流、峰值时间，以提高熔滴过渡的稳定性。同时，在铝-钢脉冲旁路耦合电弧MIG焊过程中，由于旁路的稳弧作用，可设置小的主路和旁路基值电流，使得总的热输入减小。
对铝-钢脉冲旁路耦合电弧MIG焊过程的热循环曲线进行了测量分析，研究了不同旁路耦合电弧参数对热循环曲线的影响规律；在提出的热源模型和试验得到的热循环曲线数据的基础上，对铝-钢界面处温度场分布进行了模拟。利用得到的铝-钢界面处温度场的分布特点，对金属间化合物层的生长进行了数值计算，计算结果与试验结果能较好的吻合，验证了所假设的扩散模型的正确性。在温度场模拟和扩散层厚度模拟的基础上，研究了冷却时间、峰值温度及热循环曲线积分三个因素对金属间化合物层厚度的影响；冷却时间对铝-钢界面处金属间化合物层厚度的影响最大，峰值温度和热循环曲线积分的影响较小。
对铝-钢搭接试样进行了力学性能测试，结果发现，5052铝合金与镀锌钢板的搭接试样平均拉伸强度达到了144.85Mpa，最高拉伸强度186.73Mpa，达到了铝合金母材强度的88.5%；研究了旁路耦合电弧参数对铝-钢焊接接头力学性能的影响，结果表明，铝-钢接头的强度不仅取决于母材热输入的大小，同时还要受焊缝几何参数的影响，在铝-钢脉冲旁路耦合电弧MIG焊过程中，要选择合适的旁路电弧参数，既要保证较低的母材热输入，抑制有害的铝-钢金属间化合物的生长，减小铝侧热影响区的软化，又要保证较大的焊缝形状因数，使得熔滴在母材能较好的润湿铺展。
通过对铝-钢显微组织分析发现，脉冲旁路耦合电弧MIG焊得到的铝-钢接头，界面区金属间化合物主要是由靠近钢侧的均匀连续的Fe2Al5或Fe2Al5ZnX，以及靠近铝侧的呈针片状分布的FeAl3相组成，焊趾部位存在富锌区，其主要成分是铝锌固溶体。在显微组织分析的基础上，提出了铝-钢金属间化合物生长模型，主要分为以下几个阶段：液态铝与固态铁之间的互扩散、铝-钢界面处Fe2Al5形核生长、Fe2Al5形成连续相层阻碍铁原子的扩散、铝原子穿过Fe2Al5相层继续与铁原子反应、FeAl3在铝熔化区结晶析出。锌在铝-钢脉冲旁路耦合电弧MIG焊接过程中主要起着辅助熔滴铺展润湿及稳定耦合电弧的作用。
Aiming at the problems of existing welding methods for joining aluminum to steel,such as low efficiency, high cost or having special requirements on the shape of thework piece, a novel welding method was proposed innovatively in this paper conduciveto control metal transfer and heat input of base metal precisely in welding process. Thewelding method has different mechanism from the existing precise-control-type arcwelding technology, and was proved to be conducive to dissimilar metal joining ofaluminum to steel from theory and practice.
A rapid prototyping test system was established to sense, observe and control thewelding process according to the characteristics and control requirements of PulsedDE-GMAW, and the corresponding software control program was also developed.Control and coordination of current waveform of the main and bypass was also realizedby the developed control system.
A mathematics model for Pulsed DE-GMAW was developed and a control schemethat stabilizing the whole coupling arc by controlling the main arc was proposed. Thensimulation for arc length stability in welding process and influence of pulse currentparameters to metal transfer were carried out. On this basis, control tests for arc lengthstability in Pulsed DE-GMAW for joining aluminum to steel were done adopting twodifferent feedback modes, average arc voltage feedback of main welding arc and visionfeedback. Both the control effect of the two control schemes was well.
The influence of main and bypass arc parameters to weld formation was studied bythe flat surfacing technology tests for Pulsed DE-GMAW. The results show thatincreasing the main current makes for good spreading and wetting of aluminum droplet,but the effect of the bypass current to droplet wetting is relative small. Then theinfluence of pulse current parameters to metal transfer of Pulsed DE-GMAW processwas researched by high-speed camera tests, and the results show that the peak currentand peak time can be also increased to improve the metal transfer frequency andstabilize the welding process in addition to increasing the bypass current in order torealize the stable spray transfer, in the case of maintaining the same total current. At thesame time, the base current of main and bypass can be set small to decrease the totalwelding heat input due to the stability role of bypass arc in Pulsed DE-GMAW processfor joining aluminum to steel.
The thermal cycle curves for Pulsed DE-GMAW were measured and influence lawof different bypass parameters to thermal cycle curve was studied. On the basis of builtheat source model and obtained thermal cycle curves, the temperature field distributionat the interface of aluminum-steel was simulated and analyzed. With the obtainedtemperature field distribution, the growth of the intermetallic compound(IMC) layerwas then simulated and the results was consistent with the tests, which proved thecorrectness of the assumed diffusion model. On this basis of simulation for temperaturefield distribution and growth of the IMC layer, the influence of the cooling time, peaktemperature and integral of thermal cycle on the thickness of IMC was identified anddiscussed. It was identified that cooling time has the biggest influence on the thicknessof the IMC and the effect of peak temperature and integral of thermal cycle is small.
Mechanical properties tests were carried out for lap joint specimens of5052 aluminum alloy and galvanized steel. The results show that the average tensile strengthis144.85MPa and the maximum tensile strength is up to186.73MPa, about88.5%ofthe base metal strength. The influence of bypass arc parameters on mechanicalproperties of lap joint was studied. The results show that the strength of aluminum-steellap joints depends not only on the base metal heat input, but also by the influence ofweld geometry parameters. In Pulsed DE-GMAW process for joining aluminum to steel,the bypass arc parameters should be selected appropriately. Not only the lower basemetal heat input should be ensured to inhibit the growth of harmful IMC of aluminumand steel and reduce the softening of HAZ of aluminum side, but also a larger weldshape factor should be ensured to make the droplet wetting and spreading better ongalvanized steel.
By observing and analyzing the microstructure of the aluminum-steel joint, it isfound that the interface zone of aluminum-steel joints made by Pulsed DE-GMAWmainly consisted of a uniform continuous Fe2Al5, or Fe2Al5ZnXnear the steel side andelongated FeAl3phase near the aluminum side. Zinc-rich zone is located at the edge ofweld bead, and the main component is Al-Zn solid solution. An IMC growth model wasproposed based on microstructure analysis. The IMC growth stages could be as follows:diffusion of solid iron and molten aluminum, the nucleation and growth of Fe2Al5at thealuminum-steel interface, formation of the continuous Fe2Al5phase layer and hinderingthe diffusion of iron atoms, aluminum atoms diffusing through Fe2Al5layer to continuereacting with the iron atom, FeAl3crystallization in the aluminum melting zone. Theroles of zinc on droplet spreading wetting and stabilizing coupling arc are played inPulsed DE-GMAW process for joining aluminum to steel.
引文
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