轨道客车用SUS301L奥氏体不锈钢激光叠焊技术研究
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摘要
论文针对轨道客车不锈钢车体制造过程中电阻点焊变形大、密封性差、接头静强度和疲劳强度低以及生产效率低等难题,充分利用激光焊接技术所具有的焊接变形小焊接速度快以及连续焊接密封性好等优点,提出了轨道客车用奥氏体不锈钢小变形、高强度的非熔透型激光叠焊方法。
本文以轨道客车用SUS301L奥氏体不锈钢为研究对象,采用4kW连续的Nd:YAG激光器对奥氏体不锈钢进行了非熔透型激光叠焊技术研究。利用三维非线性瞬态热传导微分方程,建立了奥氏体不锈钢激光叠焊传热模型。在对激光焊接物理过程分析的基础上,利用SYSWELD焊接仿真软件对奥氏体不锈钢激光叠焊过程进行了数值模拟,获得了熔池形貌、熔化区热循环曲线以及接头焊接变形情况等数值模拟结果。与实际激光焊接过程中测量的数据对比发现,二者十分吻合,表明所建立的奥氏体不锈钢激光叠焊传热模型正确,数值模拟结果可信度高。
为了获得奥氏体不锈钢小变形、高强度的非熔透型激光叠焊接头,本研究首次提出了倾斜激光入射角度的非熔透型激光叠焊方法。理论分析结果和实际实验结果表明,倾斜激光入射角度可以更容易地获得小熔深、大结合宽度的焊接接头(即小变形、高强度焊接接头)。此外,通过倾斜激光入射角度还能减小激光焊接过程中焊接熔深的波动范围,从而提高焊接接头质量的可靠性。
为了避免单因素试验过程由于忽略了因素间的相互关系而导致的试验误差,文中还对激光叠焊工艺进行了多因素交互试验研究。并利用Design-Expert V7试验设计软件建立了试验输入因子与响应因子之间的数学关系式。试验验证结果表明,该数学关系式的误差较小,其误差范围小于5%。根据该数学关系式和试验优化目标,获得了SUS301L奥氏体不锈钢激光叠焊最优的工艺参数范围：激光功率为3.50-3.79kW、焊接速度为7.40～8.00m/min、激光入射角度为65°、离焦量为0mm、保护气体成分为N2以及其流量为30L/min。
为了进一步减小奥氏体不锈钢激光叠焊接头的焊接变形量,本研究在分析其焊接变形特点和变形产生机理的基础上首次提出了一种针对奥氏体不锈钢激光叠焊接头微小角变形的激光热矫形方法。并通过对该方法的数值模拟仿真和试验研究,获得了与最优焊接工艺参数相匹配的激光热矫形工艺参数：激光功率P=0.15kW、扫描速度v=3m/min、激光入射角度θ=90°、离焦量Δf=+8mm和N2保护气体流量fg30L/min,与焊接方向同向扫描4次。通过该矫形工艺可以将最优工艺参数条件下所获得的焊接接头的角变形量由0.88°降低至0.3°左右。
通过对奥氏体不锈钢激光叠焊工艺和激光热矫形方法的研究,获得了最佳的奥氏体不锈钢激光叠焊接头,并将其与电阻点焊接头进行对比研究。其研究结果表明,40mm宽的激光叠焊接头的最大静拉伸力为23.326kN,约为电阻点焊接头的2.4倍；在相同疲劳载荷条件下,置信度为99%时,激光叠焊试样的中值疲劳寿命是电阻点焊试样的1.80～11.72倍。
最后,通过对本文的研究实现了0.8mm厚的SUS301L-ST奥氏体不锈钢板和1.5mm厚的SUS301L-DLT奥氏体不锈钢板搭接接头的高效率、高强度、无变色以及小变形的密封焊接。
For the manufacturing process of stainless steel vehicles by resistance spot welding, some problems have not been well solved up until now, such as larger welding distortion, poorer sealing of joints, lower static tensile strength, lower fatigue strength, and lower production efficiency. Because laser welding technique has many advantages, such as smaller welding distortion, faster welding speed, and better sealing of continuous welded joints. Therefore, in this study, a new method was proposed which carried out non-penetration laser lap joints of austenitic stainless steel for railway vehicles by means of changing the laser irradiation angle technology, and this strategy was also one of the innovations.
The research object was austenitic stainless steel for railway vehicles, which was joined by a4kW continuous Nd:YAG laser using non-penetration laser lap welding technology. Heat conduction model of laser lap welding of austenitic stainless steel was established by using the three-dimensional nonlinear transient heat conduction differential equations. On the basis of the analysis of the physical processes of laser welding, the numerical calculation was made using SYSWELD welding simulation software, and the temperature field contours of upper surface and transverse section was obtained, the temperature cycle curve of melting zone, and the distortion distribution contours of the joints, et al.. Compared with the actual measurement data, it was found that the measurement data and simulation data were very consistent, which demonstrated that the high accuracy of the heat conduction model.
In order to get laser lap welding joints of smaller distortion and higher strength, this study first proposed a non-penetration laser lap welding method, which utilized the changing the laser irradiation angle. Through the results of theoretical analysis and actual experiment, it can be found that changing the laser irradiation angle can easily get the joints of smaller distortion and higher strength. In addition, changing the laser irradiation angle could effectively reduce the fluctuation range of welding depth of the joints, and then improve reliability of the joints.
In order to avoid the experimental errors generated by univariate tests since the relationship among the different factors were usually neglected, the multi-factors interaction tests research was done for the laser lap welding. Meanwhile, the mathematical formulas between input factors and response factors have been given using Design-Expert V7software. The verification results showed that the error range was less than5%. According to the mathematical formulas and the optimization goals, the optimal parameters range were obtained, as laser power of3.50-3.79kW, welding speed of7.40～8.00m/min, laser irradiation angle of65°, focusing distance of Omm, type of shielding gas of N2, and flux of30L/min.
For the purpose of reducing the distortion of laser lap welding joints of austenitic stainless steel, this study first proposed a new laser orthopedic method which focused on angular distortion through the analysis of welding deformation feature and mechanism. Based on the numerical simulations and actual experimental studies of this new method, the laser orthopedic process parameters with optimal welding parameters were obtained, as laser power of0.15kW, scanning speed of3m/min, laser irradiation angle of90°, focusing distance of8mm, type of shielding gas of N2, and flux of30L/min, need to scan4times, and the scanning direction same as the welding direction. Through laser welding and laser orthopedic processing, using the optimal laser processing parameters, the angular distortion of welding joints can be reduced by0.88°to0.3°.
Through the research of laser lap welding and laser orthopedic of austenitic stainless steel, the optimal laser lap welding joints were obtained, and compared them with the resistance welding joints. The comparison results showed that the static tensile force of laser welding joint with its width of40mm was23.326kN, about2.4times of the resistance welding joint. Under the same condition, and the confidence level of99%, the median fatigue life of laser welding specimens was about1.80-11.72times of the resistance welding specimens.
Finally, through the research on this study, laser lap welding of0.8mm thick SUS301L-ST and1.5mm thick SUS301L-DLT austenitic stainless steel plate have been implemented with high efficiency, high strength, no discoloration and smaller deformation.
本文以轨道客车用SUS301L奥氏体不锈钢为研究对象,采用4kW连续的Nd:YAG激光器对奥氏体不锈钢进行了非熔透型激光叠焊技术研究。利用三维非线性瞬态热传导微分方程,建立了奥氏体不锈钢激光叠焊传热模型。在对激光焊接物理过程分析的基础上,利用SYSWELD焊接仿真软件对奥氏体不锈钢激光叠焊过程进行了数值模拟,获得了熔池形貌、熔化区热循环曲线以及接头焊接变形情况等数值模拟结果。与实际激光焊接过程中测量的数据对比发现,二者十分吻合,表明所建立的奥氏体不锈钢激光叠焊传热模型正确,数值模拟结果可信度高。
为了获得奥氏体不锈钢小变形、高强度的非熔透型激光叠焊接头,本研究首次提出了倾斜激光入射角度的非熔透型激光叠焊方法。理论分析结果和实际实验结果表明,倾斜激光入射角度可以更容易地获得小熔深、大结合宽度的焊接接头(即小变形、高强度焊接接头)。此外,通过倾斜激光入射角度还能减小激光焊接过程中焊接熔深的波动范围,从而提高焊接接头质量的可靠性。
为了避免单因素试验过程由于忽略了因素间的相互关系而导致的试验误差,文中还对激光叠焊工艺进行了多因素交互试验研究。并利用Design-Expert V7试验设计软件建立了试验输入因子与响应因子之间的数学关系式。试验验证结果表明,该数学关系式的误差较小,其误差范围小于5%。根据该数学关系式和试验优化目标,获得了SUS301L奥氏体不锈钢激光叠焊最优的工艺参数范围：激光功率为3.50-3.79kW、焊接速度为7.40～8.00m/min、激光入射角度为65°、离焦量为0mm、保护气体成分为N2以及其流量为30L/min。
为了进一步减小奥氏体不锈钢激光叠焊接头的焊接变形量,本研究在分析其焊接变形特点和变形产生机理的基础上首次提出了一种针对奥氏体不锈钢激光叠焊接头微小角变形的激光热矫形方法。并通过对该方法的数值模拟仿真和试验研究,获得了与最优焊接工艺参数相匹配的激光热矫形工艺参数：激光功率P=0.15kW、扫描速度v=3m/min、激光入射角度θ=90°、离焦量Δf=+8mm和N2保护气体流量fg30L/min,与焊接方向同向扫描4次。通过该矫形工艺可以将最优工艺参数条件下所获得的焊接接头的角变形量由0.88°降低至0.3°左右。
通过对奥氏体不锈钢激光叠焊工艺和激光热矫形方法的研究,获得了最佳的奥氏体不锈钢激光叠焊接头,并将其与电阻点焊接头进行对比研究。其研究结果表明,40mm宽的激光叠焊接头的最大静拉伸力为23.326kN,约为电阻点焊接头的2.4倍；在相同疲劳载荷条件下,置信度为99%时,激光叠焊试样的中值疲劳寿命是电阻点焊试样的1.80～11.72倍。
最后,通过对本文的研究实现了0.8mm厚的SUS301L-ST奥氏体不锈钢板和1.5mm厚的SUS301L-DLT奥氏体不锈钢板搭接接头的高效率、高强度、无变色以及小变形的密封焊接。
For the manufacturing process of stainless steel vehicles by resistance spot welding, some problems have not been well solved up until now, such as larger welding distortion, poorer sealing of joints, lower static tensile strength, lower fatigue strength, and lower production efficiency. Because laser welding technique has many advantages, such as smaller welding distortion, faster welding speed, and better sealing of continuous welded joints. Therefore, in this study, a new method was proposed which carried out non-penetration laser lap joints of austenitic stainless steel for railway vehicles by means of changing the laser irradiation angle technology, and this strategy was also one of the innovations.
The research object was austenitic stainless steel for railway vehicles, which was joined by a4kW continuous Nd:YAG laser using non-penetration laser lap welding technology. Heat conduction model of laser lap welding of austenitic stainless steel was established by using the three-dimensional nonlinear transient heat conduction differential equations. On the basis of the analysis of the physical processes of laser welding, the numerical calculation was made using SYSWELD welding simulation software, and the temperature field contours of upper surface and transverse section was obtained, the temperature cycle curve of melting zone, and the distortion distribution contours of the joints, et al.. Compared with the actual measurement data, it was found that the measurement data and simulation data were very consistent, which demonstrated that the high accuracy of the heat conduction model.
In order to get laser lap welding joints of smaller distortion and higher strength, this study first proposed a non-penetration laser lap welding method, which utilized the changing the laser irradiation angle. Through the results of theoretical analysis and actual experiment, it can be found that changing the laser irradiation angle can easily get the joints of smaller distortion and higher strength. In addition, changing the laser irradiation angle could effectively reduce the fluctuation range of welding depth of the joints, and then improve reliability of the joints.
In order to avoid the experimental errors generated by univariate tests since the relationship among the different factors were usually neglected, the multi-factors interaction tests research was done for the laser lap welding. Meanwhile, the mathematical formulas between input factors and response factors have been given using Design-Expert V7software. The verification results showed that the error range was less than5%. According to the mathematical formulas and the optimization goals, the optimal parameters range were obtained, as laser power of3.50-3.79kW, welding speed of7.40～8.00m/min, laser irradiation angle of65°, focusing distance of Omm, type of shielding gas of N2, and flux of30L/min.
For the purpose of reducing the distortion of laser lap welding joints of austenitic stainless steel, this study first proposed a new laser orthopedic method which focused on angular distortion through the analysis of welding deformation feature and mechanism. Based on the numerical simulations and actual experimental studies of this new method, the laser orthopedic process parameters with optimal welding parameters were obtained, as laser power of0.15kW, scanning speed of3m/min, laser irradiation angle of90°, focusing distance of8mm, type of shielding gas of N2, and flux of30L/min, need to scan4times, and the scanning direction same as the welding direction. Through laser welding and laser orthopedic processing, using the optimal laser processing parameters, the angular distortion of welding joints can be reduced by0.88°to0.3°.
Through the research of laser lap welding and laser orthopedic of austenitic stainless steel, the optimal laser lap welding joints were obtained, and compared them with the resistance welding joints. The comparison results showed that the static tensile force of laser welding joint with its width of40mm was23.326kN, about2.4times of the resistance welding joint. Under the same condition, and the confidence level of99%, the median fatigue life of laser welding specimens was about1.80-11.72times of the resistance welding specimens.
Finally, through the research on this study, laser lap welding of0.8mm thick SUS301L-ST and1.5mm thick SUS301L-DLT austenitic stainless steel plate have been implemented with high efficiency, high strength, no discoloration and smaller deformation.
引文
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