锆/镍超声波焊接界面IMCs生长行为及其性能分析
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摘要
锆/镍异种金属焊接结构在现代工业应用中日益广泛,但因母材热物理和化学性能存在较大差异,导致焊接难度大。超声波焊接作为一种固态连接工艺适应于异种金属焊接。研究不同焊接能量对锆/镍异质金属超声波焊接金属间化合物(IMCs)生长行为与机械性能的影响机制。以锆箔、镍箔为原材料,采用焊接功率1600 W,通过改变焊接时间300,～400,～500,～600 ms调控焊接能量设计异质金属超声波焊接试验。使用扫描电子显微镜(SEM)、能谱仪(EDS)、 X射线衍射(XRD)、 3D景深显微分析、显微硬度仪及拉剪强度测试等研究微观组织形貌、相结构、景深及显微硬度的变化规律,确定焊接能量与接头拉剪强度之间的定量关系,理解其连接机理和IMCs生长历程。结果表明:接头触点区无明显宏观裂纹等缺陷;随焊接能量增大,触点区原子互扩散层迅速增厚并趋于稳态,过厚的IMCs层诱导产生新的焊接缺陷;在焊接能量640 J时高应变率加速连接界面析出厚度约3.2μm的Ni_7Zr_2, Ni_(10)Zr_7和NiZr_2 IMCs相层,析出顺序为:Ni_(10)Zr_7, Ni_7Zr_2, NiZr_2;塑性变形在整个薄板厚度间传播,剧烈塑性变形促进了位错增殖,形成了由纳米晶和非晶相组成的过渡层;工件连接强度取决于机械互锁、纳米晶和非晶相过渡层与互扩散的综合作用。所获得的最优焊接工艺参数对提升接头力学性能和分析其界面组织变化具有重要意义。
Zr/Ni dissimilar metal welding structures have become more and more widely used in modern industrial applications. However, welding is difficult due to large differences with parent metal in thermal physical and chemical properties. Ultrasonic welding is a solid state joining process suitable for dissimilar metal welding. The influence mechanism of different welding energy on the intermetallic compounds(IMCs) growth behavior and mechanical properties of Zr/Ni dissimilar metal ultrasonic welding was investigated. Using zirconium foil and nickel foil as raw materials, welding power of 1600 W was adopted, and ultrasonic welding experiments for dissimilar metals were designed by changing welding time 300, ～400, ～500, ～600 ms to regulate the welding energy. The scanning electron microscope(SEM), energy dispersive spectroscopy(EDS), X-ray diffraction(XRD), 3 D depth-of-field microscopic analysis, micro-hardness tester and tensile strength tester were used to study the variation of microstructure morphology, phase structure, depth of field and hardness, to determine the quantitative relationship between weld energy and tensile strength of the joint, and to understand the mechanism of connection and IMCs growth history. The results showed that there was no obvious macro crack and other defects in the joint contact area. As the welding energy increased, the atomic interdiffusion layer in the contact area rapidly thickened and tended to a steady state, and excessively thick IMCs induced new welding defects. When the welding energy was 640 J, high strain rates accelerated the precipitation of Ni_7Zr_2, Ni_(10)Zr_7 and NiZr_2 IMCs phase at the interface, and its thickness was about 3.2 μm. The precipitation order was Ni_(10)Zr_7, Ni_7Zr_2, NiZr_2. The plastic deformation propagated throughout the thickness of the foil, and the severe plastic deformation promoted the proliferation of dislocations. A transition layer consisting nanocrystalline and amorphous phases was formed. The strength of the workpiece connection depended on the combined effect of mechanical interlocking, transition layers and element interdiffusion. The optimal welding process parameters obtained had important significance for improving the mechanical properties of the joints and analyzing the changes of the interface structure.
Zr/Ni dissimilar metal welding structures have become more and more widely used in modern industrial applications. However, welding is difficult due to large differences with parent metal in thermal physical and chemical properties. Ultrasonic welding is a solid state joining process suitable for dissimilar metal welding. The influence mechanism of different welding energy on the intermetallic compounds(IMCs) growth behavior and mechanical properties of Zr/Ni dissimilar metal ultrasonic welding was investigated. Using zirconium foil and nickel foil as raw materials, welding power of 1600 W was adopted, and ultrasonic welding experiments for dissimilar metals were designed by changing welding time 300, ～400, ～500, ～600 ms to regulate the welding energy. The scanning electron microscope(SEM), energy dispersive spectroscopy(EDS), X-ray diffraction(XRD), 3 D depth-of-field microscopic analysis, micro-hardness tester and tensile strength tester were used to study the variation of microstructure morphology, phase structure, depth of field and hardness, to determine the quantitative relationship between weld energy and tensile strength of the joint, and to understand the mechanism of connection and IMCs growth history. The results showed that there was no obvious macro crack and other defects in the joint contact area. As the welding energy increased, the atomic interdiffusion layer in the contact area rapidly thickened and tended to a steady state, and excessively thick IMCs induced new welding defects. When the welding energy was 640 J, high strain rates accelerated the precipitation of Ni_7Zr_2, Ni_(10)Zr_7 and NiZr_2 IMCs phase at the interface, and its thickness was about 3.2 μm. The precipitation order was Ni_(10)Zr_7, Ni_7Zr_2, NiZr_2. The plastic deformation propagated throughout the thickness of the foil, and the severe plastic deformation promoted the proliferation of dislocations. A transition layer consisting nanocrystalline and amorphous phases was formed. The strength of the workpiece connection depended on the combined effect of mechanical interlocking, transition layers and element interdiffusion. The optimal welding process parameters obtained had important significance for improving the mechanical properties of the joints and analyzing the changes of the interface structure.
引文
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[3] Zhang Y F,Zhu Z Q,Zhang D Q,Su Z Z.Temperature sensing of fiber bragg grating with Ni coating by ultrasonic welding [J].Materials Review,2014,28(24):103.(张义福,朱政强,张德勤,苏展展.超声波焊接埋入镍基光纤光栅的温度传感 [J].材料导报,2014,28(24):103.)
[4] Zhao Y Y,Li D,Zhang Y S.Effect of welding energy on interface zone of Al-Cu ultrasonic welded joint [J].Science and Technology of Welding and Joining,2013,18(4):354.
[5] Chen K K,Zhang Y S,Wang H Z.Study of plastic deformation and interface friction process for ultrasonic welding [J].Science and Technology of Welding and Joining,2017,22(3):208.
[6] Satpathy M P,Sahoo S K.Experimental and numerical studies on ultrasonic welding of dissimilar metals [J].The International Journal of Advanced Manufacturing Technology,2017,93(5-8):2531.
[7] Ni Z L,Ye F X.Effect of lap configuration on the microstructure and mechanical properties of dissimilar ultrasonic metal welded copper-aluminum joints [J].Journal of Materials Processing Technology,2017,245:180.
[8] Zhang Z,Wang K,Li J,Yu Q,Cai W.Investigation of interfacial layer for ultrasonic spot welded aluminum to copper joints [J].Scientific Reports,2017,7(1):12505.
[9] Li H,Cao B,Liu J,Yang J.Modeling of high-power ultrasonic welding of Cu/Al joint [J].The International Journal of Advanced Manufacturing Technology,2018.1.
[10] Yang J W,Cao B,He X C,Luo H S.Microstructure evolution and mechanical properties of Cu-Al joints by ultrasonic welding [J].Science and Technology of Welding and Joining,2014,19(6):500.
[11] Ahmad M,Akhter J I,Shaikh M A,Akhtar M,Lqbal M,Chaudhry M A.Hardness and microstructural studies of electron beam welded joints of Zircaloy-4 and stainless steel [J].Journal of Nuclear Materials,2002,301(2):118.
[12] Wang R X,Guo Z M,Luo J,Ye Q,Yang F.Preparation and properties of dispersion strengthening W-Ni-Fe heavy alloy [J].Chinese Journal of Rare Metals,2017,41(1):20.(王瑞欣,郭志猛,罗骥,叶青,杨芳.弥散强化钨镍铁高比重合金的制备及性能研究 [J].稀有金属,2017,41(1):20.)
[13] Ahmad M,Akhter J I,Akhtar M,Lqbal M.Microstructure and characterization of phases in TIG welded joints of Zircaloy-4 and stainless steel 304L [J].Journal of Materials Science,2007,42(1):328.
[14] Atabaki M M.Microstructural evolution in the partial transient liquid phase diffusion bonding of Zircaloy-4 to stainless steel 321 using active titanium filler metal [J].Journal of Nuclear Materials,2010,406(3):330.
[15] Zettler R,Rodrigues S,Blanco A,Dos Santos J.Dissimilar Al to Mg alloy friction stir welds [J].Advanced Engineering Materials,2010,8(5):415.
[16] Firouzdor V,Kou S.Formation of liquid and intermetallics in Al-to-Mg friction stir welding [J].Metallurgical and Materials Transactions A,2010,41(12):3238.
[17] Gunduz I E,Ando T,Shattuck E,Wong P Y,Doumanidis C C.Enhanced diffusion and phase transformations during ultrasonic welding of zinc and aluminum [J].Scripta Materialia,2005,52(9):939.
[18] Davis J P,Majzoub E H,Simmons J M,Kelton K F.Ternary phase diagram studies in Ti-Zr-Ni alloys [J].Materials Science and Engineering:A,2000,294:104.
[19] Henaff M P,Colinet C,Pasturel A,Buschow K H J.Study of the enthalpies of formation and crystallization in the system Zr-Ni [J].Journal of Applied Physics,1984,56(2):307.