全铝结构船长甲板的CO_2激光焊接技术研究
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摘要
本文以全铝结构高速船长甲板为主要应用背景,以中厚度船用铝合金长焊缝焊接为主要研究对象,针对目前全铝结构船舶长甲板焊接技术存在的诸多问题,在分析船舶工业中CO_2激光加工系统应用特点及对CO_2激光长焊缝焊接光学系统参数进行计算的基础上,利用SlabCO_2激光器的飞行光学加工系统对4.0mm和6.0mm的5083铝合金及6.0mm的6061铝合金进行了激光焊接基础工艺和长焊缝焊接工艺的研究,并对两种船用铝合金的CO_2激光焊接接头性能进行了综合评定,探讨了CO_2激光焊接技术在全铝结构船舶制造工业中应用的可行性问题。采用高速摄像装置和光谱分析技术对铝合金CO_2激光焊接光致等离子体行为进行了研究。
5083铝合金由于易挥发性元素Mg含量大,实现深熔焊的阈值功率要低于6061铝合金;内径为5.0mm的辅助气体喷嘴既具有良好的层流干伸长度,又能提供足够的辅助气体以稀释等离子体,且对于5083铝合金采用_20l/min氦气和_2l/min氩气的混合气体能够获得良好的焊缝表面,对于6061铝合金应采用30l/min氦气和_2l/min氩气的混合气体作为辅助气体。激光功率、焊接速度、送丝速度的合理匹配对焊缝成形至关重要。对于三种规格材料,采用激光扫描焊接和激光填丝焊接的方法,实现了船用铝合金中厚板长焊缝的CO_2激光焊接,获得了成形美观且无明显外观缺陷的焊缝,得到了八套焊接工艺方案。
根据全铝结构船舶长甲板焊接光学系统的设计要求,利用高斯光束传输和聚焦的基本理论,分析计算了激光器光束质量、聚焦镜焦距以及材料焊接所要求的聚焦光斑最大值的设定对飞行光束光学参数的影响。对比了扩散冷却板条DC035CO_2激光器和快速轴流RS_200CO_2激光器用于飞行光学加工系统的差别。理论上两种CO_2激光器都可以用于实现大范围激光加工的飞行光学系统,但从实际系统的实现而言,光束质量较好的DC035CO_2激光器比光束质量较差的RS200CO_2激光器更加适用于船用铝合金长焊缝焊接的飞行光学系统。
船用铝合金厚度越小,实现长焊缝全熔透焊接所允许的聚焦光束束腰半径变化量ωivar和聚焦光束束腰位置变化量范围越大。在实验条件下,对于4mm厚的5083铝合金实现全熔透焊且焊缝表面成形较好,要求sivarωivar小于30μm,小于4.0mm;对于6mm厚的5083铝合金实现全熔透焊且焊缝表面成形较好,要求sivarωivar小于_20μm,小于3.0mm;对于6mm厚的6061铝合金实现全熔透焊且焊缝表面成形较好,要求sivarωivar小于15μm,小于_2.0mm。对于I型坡口,激光扫描焊和填丝焊所允许的最大间隙分别为0.5mm和0.7mm。由于铝合金长甲板激光焊接对试样的坡口准备和装夹精度要求甚高,在实际生产过程中目前的坡口加工方式和工装夹具,无法满足激光焊接的要求,因此成为全铝结构船长甲板激光焊接技术实际应用的最大障碍。
5083铝合金激光填丝焊接头和双面焊接头拉伸强度可达到母材强度的95%,而屈服强度基本与母材的屈服强度持平,拉伸断口位于熔合线附近;6061铝合金激光填丝焊接头和双面焊接头拉伸强度可达到母材强度的82%,而屈服强度低于母材,拉伸断口沿焊缝45°对角线开裂。5083铝合金激光焊接接头经150°三点弯曲试验而不开裂,6061铝合金激光焊接接头弯曲90°沿熔合线发生开裂。5083铝合金激光焊缝冲击韧性值高于母材,而6061铝合金激光焊缝冲击韧性值低于母材。
当激光功率超过材料深熔焊接阈值功率后,激光功率对光致等离子体温度的影响不大;激光聚焦光斑位于工件表面附近时,光致等离子体温度较大离焦情况下低;焊接速度对光致等离子体温度的影响表现为倒“U”形曲线规律,即在焊接速度较高和较低情况下,光致等离子体温度均为下降趋势;He气对光致等离子体有良好的冷却效果,对于一定内径的辅助气体喷嘴,等离子体温度随辅助气体流量呈现先增加后减小的趋势;在He气中加入Ar气会导致光致等离子体温度升高,且升高幅度随加入Ar气含量的增加而增加。光致等离子体温度位于6000±200K温度范围内时,焊缝表面成形质量普遍较好;工件表面的等离子体对焊缝的熔深没有贡献,对焊缝熔宽的影响也不明显。
对全铝结构船长甲板的激光焊接技术研究,具有重大的实际工程应用价值,同时也具有一定的理论研究价值。在工程应用方面,研究成果能够为论证CO2激光焊接技术在全铝结构船舶制造工业中应用的可行性问题提供必要的技术基础,对相关部门制定全铝结构船舶长甲板的工业激光解决方案,具有重大现实意义。在理论研究方面,研究涉及的铝合金大功率激光焊接技术、大功率激光深熔焊接小孔和等离子体行为的分析研究,对车辆、航空航天等行业铝合金的激光焊接技术具有重要指导意义。
The main application backgrounds of this paper are the long deck of full-aluminum structure high speed vessels, and its investigated subjects are long distance laser welding of aluminum alloys in ship building industry. Against the problems existed in the present welding technology for the long deck of full-aluminum structure vessels, basic CO_2 laser welding technologies and long distance CO_2 laser welding technologies of 4.0 mm and 6.0mm thickness 5083 aluminum alloy and 6.0 mm thickness 6061 aluminum alloy have been investigated on the base of analyzing the characteristics of CO_2 laser welding system in ship industry and calculating the optical parameters of long distance welding system. The properties of welded joints are also evaluated. The application feasibility in ship building industries of CO_2 laser welding the long deck of full-aluminum structure vessels has been discussed. The behavior of CO_2 laser induced plasma in laser welding of aluminum alloys is investigated through high speed camera and spectroscopic technology.
The penetration welding threshold of 5083 aluminum alloy is lower than that of 6061 aluminum alloy, because Magnesium is easily volatilized. When the diameter of shielding gas nozzle is 5 mm, it can not only offer good laminar flow length, but also offer enough shielding gas for diluting the density of plasma. The optimized flow rates of shielding gas for laser welding of 5083 aluminum alloy are 20 l/min Helium gas and 2 l/min Argon gas, and those are 30 l/min Helium gas and 2 l/min Argon gas for laser welding of 6061 aluminum alloy. The match of laser power, welding speed and wire feeding speed plays a great role for the formation of welds. For the three kinds of aluminum plates, long distance CO_2 laser welding of aluminum alloys in ship industry has been completed through laser scanning welding and wire feed laser welding method, and the weld with good appearance and no defects is acquired. At laser, eight programs of welding technology have been obtained.
Based on the acquires of laser welding optical system of long full-aluminum structure vessels decks, the influence of laser beam quality, focal length and the required maximum radius of focal spots for welded materials on optical parameters of flying optical system is calculated and analyzed based on the theory of Gauss-beam propagation and focus. The differences of the DC035 and RS200 CO_2 lasers used in flying optical processing system are compared. In theory, tow kinds of CO_2 lasers both can use for long distance processing optical system, but in practice, DC035 CO_2 laser with good beam quality would better use for long distance CO_2 laser welding of aluminum alloys in ship industry than RS200 CO_2 laser.
The thinner the aluminum alloy plate in ship industries is, the more the allowable variation of focal spot radius (ωivar) and positions ( ) for producing full penetration welds in long distance CO_2 laser welding is. Under the condition of experiments, full penetration welds of 4mm thickness 5083 aluminum alloy with good appearance could be obtained when sivarωivar and were smaller than 30μm and 4.0 mm; full penetration welds of 6mm thickness 5083 aluminum alloy with good appearance could be obtained when sivarωivar and were smaller than 20μm and 3.0 mm; full penetration welds of 6mm thickness 6061 aluminum alloy with good appearance could be obtained when sivarωivar and were smaller than 15μm and 2.0 mm. For the groove of I-type, the allowable gaps of laser scanning welding and wire feed laser welding are 0.5mm and 0.7mm. The requirements of grooves preparation and clamps accuracy in laser welding can not be achieved in actual production process and that becomes the biggest barrier in the application of laser welding technologies for the long deck of full-aluminum structure vessels.
The tensile strength values of 5083 welded joints with filler wire and double-pass welded joints are up to 95 percent of base mental, and the yield strength are equivalent to those of base metal. The tensile fracture of laser beam welded specimens takes place in the area close to the weld bond. The tensile strength values of 6061 welded joints with filler wire and double-pass welded joints are up to 82 percent of base mental, and the yield strength are lower than those of base metal. The tensile fracture of laser beam welded specimens takes place along the 45°diagonal line of welds. Laser welded joints of 5083 aluminum alloy would not crack after 150°three-point bending tests, but laser welded joints of 6061 aluminum alloy would crack along weld bond after 90°three-point bending tests. The impacting toughness of 5083 aluminum welded joints is much higher than that of base mental, and the impacting toughness of 6061 aluminum welded joints is lower than that of base mental.
Under the experimental conditions, the increment of laser power played little role for laser-induced plasma temperature when the laser power extended the threshold power of penetration welding. The plasma temperature was lower when laser focal spot was near the surface of the plate than far from it. The effect rule of welding speeds on laser-induced plasma temperature likes inverted U curve. Helium provided good cooling effects on the plasma temperature. For a given diameter of nozzle, laser-induced plasma temperature had been increasing before decreasing when the flow rate of shielding gas was increasing. That would also increase when adding Argon in Helium and increasing Argon in Helium. The weld appearance was good when the temperature of laser-induced plasma was in the range of 6000±200K. The plasma above the plates has no influence on the weld depth and weld width.
Investigations of laser welding technologies for the long deck of full-aluminum structure vessels have great values in the engineering application and also in the theory study. On one hand, the achievement of investigations can offer basic technologies for demonstrating the feasibility of CO_2 laser welding the long deck of full-aluminum structure vessels, and it also plays an important role in determining the industrial laser solution of the long deck of full-aluminum structure vessels. On the other hand, high power laser welding technologies of aluminum alloy, the analysis for behaviors of the keyhole and plasma in high power laser penetration welding have instructive significance for the laser welding technology of aluminum alloys in automobiles, aircrafts and aerospace industries.
5083铝合金由于易挥发性元素Mg含量大,实现深熔焊的阈值功率要低于6061铝合金;内径为5.0mm的辅助气体喷嘴既具有良好的层流干伸长度,又能提供足够的辅助气体以稀释等离子体,且对于5083铝合金采用_20l/min氦气和_2l/min氩气的混合气体能够获得良好的焊缝表面,对于6061铝合金应采用30l/min氦气和_2l/min氩气的混合气体作为辅助气体。激光功率、焊接速度、送丝速度的合理匹配对焊缝成形至关重要。对于三种规格材料,采用激光扫描焊接和激光填丝焊接的方法,实现了船用铝合金中厚板长焊缝的CO_2激光焊接,获得了成形美观且无明显外观缺陷的焊缝,得到了八套焊接工艺方案。
根据全铝结构船舶长甲板焊接光学系统的设计要求,利用高斯光束传输和聚焦的基本理论,分析计算了激光器光束质量、聚焦镜焦距以及材料焊接所要求的聚焦光斑最大值的设定对飞行光束光学参数的影响。对比了扩散冷却板条DC035CO_2激光器和快速轴流RS_200CO_2激光器用于飞行光学加工系统的差别。理论上两种CO_2激光器都可以用于实现大范围激光加工的飞行光学系统,但从实际系统的实现而言,光束质量较好的DC035CO_2激光器比光束质量较差的RS200CO_2激光器更加适用于船用铝合金长焊缝焊接的飞行光学系统。
船用铝合金厚度越小,实现长焊缝全熔透焊接所允许的聚焦光束束腰半径变化量ωivar和聚焦光束束腰位置变化量范围越大。在实验条件下,对于4mm厚的5083铝合金实现全熔透焊且焊缝表面成形较好,要求sivarωivar小于30μm,小于4.0mm;对于6mm厚的5083铝合金实现全熔透焊且焊缝表面成形较好,要求sivarωivar小于_20μm,小于3.0mm;对于6mm厚的6061铝合金实现全熔透焊且焊缝表面成形较好,要求sivarωivar小于15μm,小于_2.0mm。对于I型坡口,激光扫描焊和填丝焊所允许的最大间隙分别为0.5mm和0.7mm。由于铝合金长甲板激光焊接对试样的坡口准备和装夹精度要求甚高,在实际生产过程中目前的坡口加工方式和工装夹具,无法满足激光焊接的要求,因此成为全铝结构船长甲板激光焊接技术实际应用的最大障碍。
5083铝合金激光填丝焊接头和双面焊接头拉伸强度可达到母材强度的95%,而屈服强度基本与母材的屈服强度持平,拉伸断口位于熔合线附近;6061铝合金激光填丝焊接头和双面焊接头拉伸强度可达到母材强度的82%,而屈服强度低于母材,拉伸断口沿焊缝45°对角线开裂。5083铝合金激光焊接接头经150°三点弯曲试验而不开裂,6061铝合金激光焊接接头弯曲90°沿熔合线发生开裂。5083铝合金激光焊缝冲击韧性值高于母材,而6061铝合金激光焊缝冲击韧性值低于母材。
当激光功率超过材料深熔焊接阈值功率后,激光功率对光致等离子体温度的影响不大;激光聚焦光斑位于工件表面附近时,光致等离子体温度较大离焦情况下低;焊接速度对光致等离子体温度的影响表现为倒“U”形曲线规律,即在焊接速度较高和较低情况下,光致等离子体温度均为下降趋势;He气对光致等离子体有良好的冷却效果,对于一定内径的辅助气体喷嘴,等离子体温度随辅助气体流量呈现先增加后减小的趋势;在He气中加入Ar气会导致光致等离子体温度升高,且升高幅度随加入Ar气含量的增加而增加。光致等离子体温度位于6000±200K温度范围内时,焊缝表面成形质量普遍较好;工件表面的等离子体对焊缝的熔深没有贡献,对焊缝熔宽的影响也不明显。
对全铝结构船长甲板的激光焊接技术研究,具有重大的实际工程应用价值,同时也具有一定的理论研究价值。在工程应用方面,研究成果能够为论证CO2激光焊接技术在全铝结构船舶制造工业中应用的可行性问题提供必要的技术基础,对相关部门制定全铝结构船舶长甲板的工业激光解决方案,具有重大现实意义。在理论研究方面,研究涉及的铝合金大功率激光焊接技术、大功率激光深熔焊接小孔和等离子体行为的分析研究,对车辆、航空航天等行业铝合金的激光焊接技术具有重要指导意义。
The main application backgrounds of this paper are the long deck of full-aluminum structure high speed vessels, and its investigated subjects are long distance laser welding of aluminum alloys in ship building industry. Against the problems existed in the present welding technology for the long deck of full-aluminum structure vessels, basic CO_2 laser welding technologies and long distance CO_2 laser welding technologies of 4.0 mm and 6.0mm thickness 5083 aluminum alloy and 6.0 mm thickness 6061 aluminum alloy have been investigated on the base of analyzing the characteristics of CO_2 laser welding system in ship industry and calculating the optical parameters of long distance welding system. The properties of welded joints are also evaluated. The application feasibility in ship building industries of CO_2 laser welding the long deck of full-aluminum structure vessels has been discussed. The behavior of CO_2 laser induced plasma in laser welding of aluminum alloys is investigated through high speed camera and spectroscopic technology.
The penetration welding threshold of 5083 aluminum alloy is lower than that of 6061 aluminum alloy, because Magnesium is easily volatilized. When the diameter of shielding gas nozzle is 5 mm, it can not only offer good laminar flow length, but also offer enough shielding gas for diluting the density of plasma. The optimized flow rates of shielding gas for laser welding of 5083 aluminum alloy are 20 l/min Helium gas and 2 l/min Argon gas, and those are 30 l/min Helium gas and 2 l/min Argon gas for laser welding of 6061 aluminum alloy. The match of laser power, welding speed and wire feeding speed plays a great role for the formation of welds. For the three kinds of aluminum plates, long distance CO_2 laser welding of aluminum alloys in ship industry has been completed through laser scanning welding and wire feed laser welding method, and the weld with good appearance and no defects is acquired. At laser, eight programs of welding technology have been obtained.
Based on the acquires of laser welding optical system of long full-aluminum structure vessels decks, the influence of laser beam quality, focal length and the required maximum radius of focal spots for welded materials on optical parameters of flying optical system is calculated and analyzed based on the theory of Gauss-beam propagation and focus. The differences of the DC035 and RS200 CO_2 lasers used in flying optical processing system are compared. In theory, tow kinds of CO_2 lasers both can use for long distance processing optical system, but in practice, DC035 CO_2 laser with good beam quality would better use for long distance CO_2 laser welding of aluminum alloys in ship industry than RS200 CO_2 laser.
The thinner the aluminum alloy plate in ship industries is, the more the allowable variation of focal spot radius (ωivar) and positions ( ) for producing full penetration welds in long distance CO_2 laser welding is. Under the condition of experiments, full penetration welds of 4mm thickness 5083 aluminum alloy with good appearance could be obtained when sivarωivar and were smaller than 30μm and 4.0 mm; full penetration welds of 6mm thickness 5083 aluminum alloy with good appearance could be obtained when sivarωivar and were smaller than 20μm and 3.0 mm; full penetration welds of 6mm thickness 6061 aluminum alloy with good appearance could be obtained when sivarωivar and were smaller than 15μm and 2.0 mm. For the groove of I-type, the allowable gaps of laser scanning welding and wire feed laser welding are 0.5mm and 0.7mm. The requirements of grooves preparation and clamps accuracy in laser welding can not be achieved in actual production process and that becomes the biggest barrier in the application of laser welding technologies for the long deck of full-aluminum structure vessels.
The tensile strength values of 5083 welded joints with filler wire and double-pass welded joints are up to 95 percent of base mental, and the yield strength are equivalent to those of base metal. The tensile fracture of laser beam welded specimens takes place in the area close to the weld bond. The tensile strength values of 6061 welded joints with filler wire and double-pass welded joints are up to 82 percent of base mental, and the yield strength are lower than those of base metal. The tensile fracture of laser beam welded specimens takes place along the 45°diagonal line of welds. Laser welded joints of 5083 aluminum alloy would not crack after 150°three-point bending tests, but laser welded joints of 6061 aluminum alloy would crack along weld bond after 90°three-point bending tests. The impacting toughness of 5083 aluminum welded joints is much higher than that of base mental, and the impacting toughness of 6061 aluminum welded joints is lower than that of base mental.
Under the experimental conditions, the increment of laser power played little role for laser-induced plasma temperature when the laser power extended the threshold power of penetration welding. The plasma temperature was lower when laser focal spot was near the surface of the plate than far from it. The effect rule of welding speeds on laser-induced plasma temperature likes inverted U curve. Helium provided good cooling effects on the plasma temperature. For a given diameter of nozzle, laser-induced plasma temperature had been increasing before decreasing when the flow rate of shielding gas was increasing. That would also increase when adding Argon in Helium and increasing Argon in Helium. The weld appearance was good when the temperature of laser-induced plasma was in the range of 6000±200K. The plasma above the plates has no influence on the weld depth and weld width.
Investigations of laser welding technologies for the long deck of full-aluminum structure vessels have great values in the engineering application and also in the theory study. On one hand, the achievement of investigations can offer basic technologies for demonstrating the feasibility of CO_2 laser welding the long deck of full-aluminum structure vessels, and it also plays an important role in determining the industrial laser solution of the long deck of full-aluminum structure vessels. On the other hand, high power laser welding technologies of aluminum alloy, the analysis for behaviors of the keyhole and plasma in high power laser penetration welding have instructive significance for the laser welding technology of aluminum alloys in automobiles, aircrafts and aerospace industries.
引文
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