焊接能量对Mg/Al超声波焊接接头微观组织与力学性能的影响
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摘要
在Mg/Al超声波焊接(USW)领域,现有研究侧重于接头的组织性能,但对焊接过程中的界面应力分布和成形机制报道较少。运用USW技术制备了Mg/Al异种金属搭接接头,通过FEA、OM、SEM、EDS、XRD及剪切试验等测试手段,研究不同焊接能量对接头的界面应力分布、界面峰值温度、界面连接状态、微观组织特点以及力学性能的影响规律。研究发现:焊接过程中Mg/Al界面应力分布较均匀,连接界面较平直,未出现明显的漩涡状塑性流动和机械咬合。随着焊接能量的增加,界面应力水平提高,峰值温度升高,界面冶金结合区域逐渐增大。以有限元仿真模拟为基础,系统地分析阐述界面成形机制,指导选择合适的热输入量,以期为Mg/Al超声波焊接在实际生产应用中提供必要的技术和数据支撑。当焊接能量为500 J时,界面处生成Al_(12)Mg_(17)金属间化合物(IMC),而且随着焊接能量的增加,IMC层增厚,导致接头剪切性能随着焊接能量的增加呈现出先增加后减小的趋势,厚度适中的IMC层对提高接头力学强度具有重要意义。
Existing studies focus on the microstructure and mechanical properties of joints, but there are few reports on the interfacial stress distribution and forming mechanism during welding process in the field of Mg/Al ultrasonic spot welding(USW). Mg/Al dissimilar metal lap joints are prepared by USW technology. The effects of different welding energies on the interfacial stress distribution, interfacial peak temperature, interfacial connection state, microstructure characteristics and mechanical properties of joints are investigated by means of FEA, OM, SEM, EDS, XRD and shear tests. It is shown that the Mg/Al interfacial stress distribution is uniform during the welding process, and the connected interface is relatively straight with no obvious whirlpool-like plastic flow and mechanical occlusion. The interfacial stress level and the peak temperature increase with the increase of welding energy, resulting in the metallurgical bonding area at the interface gradually increases. Based on the finite element simulation, the interface forming mechanism is systematically analyzed to guide the selection of appropriate heat input, in order to provide the necessary technical and data support for the actual production application of Mg/Al ultrasonic spot welding. When the welding energy is 500 J, the Al_(12) Mg_(17) intermetallic compound(IMC) is formed at the interface and the intermetallic compound layer gradually thickens as the welding energy increasing, leading to the shearing force of joints increase first, reach to a peak value and then decrease with the further increase of welding energy. The moderate thickness of the IMC layer plays an important role in improving the mechanical strength of the joint.
Existing studies focus on the microstructure and mechanical properties of joints, but there are few reports on the interfacial stress distribution and forming mechanism during welding process in the field of Mg/Al ultrasonic spot welding(USW). Mg/Al dissimilar metal lap joints are prepared by USW technology. The effects of different welding energies on the interfacial stress distribution, interfacial peak temperature, interfacial connection state, microstructure characteristics and mechanical properties of joints are investigated by means of FEA, OM, SEM, EDS, XRD and shear tests. It is shown that the Mg/Al interfacial stress distribution is uniform during the welding process, and the connected interface is relatively straight with no obvious whirlpool-like plastic flow and mechanical occlusion. The interfacial stress level and the peak temperature increase with the increase of welding energy, resulting in the metallurgical bonding area at the interface gradually increases. Based on the finite element simulation, the interface forming mechanism is systematically analyzed to guide the selection of appropriate heat input, in order to provide the necessary technical and data support for the actual production application of Mg/Al ultrasonic spot welding. When the welding energy is 500 J, the Al_(12) Mg_(17) intermetallic compound(IMC) is formed at the interface and the intermetallic compound layer gradually thickens as the welding energy increasing, leading to the shearing force of joints increase first, reach to a peak value and then decrease with the further increase of welding energy. The moderate thickness of the IMC layer plays an important role in improving the mechanical strength of the joint.
引文
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[2]胥国祥,郭庆虎,胡庆贤,等.中厚板铝合金光纤激光+MIG复合热源焊残余应力的数值分析[J].机械工程学报,2018,54(2):77-83.XU Guoxiang,GUO Qinghu,HU Qingxian,et al.Numerical analysis of welding residual stress in Laser+MIG hybrid butt welding of medium-thick aluminum alloy[J].Journal of Mechanical Engineering,2018,54(2):77-83.
[3]HIGASHI Y,IWAMOTO C,KAWAMURA Y.Microstructure evolution and mechanical properties of extruded Mg96Zn2Y2 alloy joints with ultrasonic spot welding[J].Materials Science&Engineering A,2016,651(3):925-934.
[4]李永兵,马运五,楼铭,等.轻量化多材料汽车车身连接技术进展[J].机械工程学报,2016,52(24):1-23.LI Yongbing,MA Yunwu,LOU Ming,et al.Advances in welding and joining processes of multi-material lightweight car body[J].Journal of Mechanical Engineering,2016,52(24):1-23.
[5]DING Y L,WANG J G,ZHAO M,et al.Effect of annealing temperature on joints of diffusion bonded Mg/Al alloys[J].Transactions of Nonferrous Metals Society of China,2018,28(2):251-258.
[6]帅朋,吴志生,赵菲,等.镁/铝异种材料焊接研究现状[J].焊接技术,2017,46(2):1-4.SHUAI Peng,WU Zhisheng,ZHAO Fei,et al.Research status of magnesium/aluminum dissimilar materials welding[J].Welding Technology,2017,46(2):1-4.
[7]刘政军,宫颖,苏允海.镁铝异种金属TIG焊接头性能的研究[J].材料工程,2015,43(3):18-22.LIU Zhengjun,GONG Ying,SU Yunhai.Study on characteristics in TIG welded joint of Mg/Al dissimilar materials[J].Journal of Materials Engineering,2015,43(3):18-22.
[8]SHAH L H,OTHMAN N H,GERLICH A.Review of research progress on aluminium-magnesium dissimilar friction stir welding[J].Science&Technology of Welding&Joining,2017,23(6):1-15.
[9]MACWAN A,PATEL V K,JIANG X Q,et al.Ultrasonic spot welding of Al/Mg/Al tri-layered clad sheets[J].Materials&Design,2014,62(10):344-351.
[10]MOHAMMADI J,BEHNAMIAN Y,MOSTAFAEI A,et al.Tool geometry,rotation and travel speeds effects on the properties of dissimilar magnesium/aluminum friction stir welded lap joints[J].Materials&Design,2015,75:95-112.
[11]LEE D,KANNATEY-ASIBU E,CAI W.Ultrasonic welding simulations for multiple layers of lithium-ion battery tabs[J].Journal of Manufacturing Science&Engineering,2013,135(6):061011.
[12]SHEN N,SAMANTA A,DING H,et al.Simulating microstructure evolution of ultrasonic welding of battery tabs[J].Journal of Manufacturing Processes,2016,5:399-416.
[13]崔庆波,李玉龙,杨瑾,等.化学镀锡层对镁铝异种金属超声波焊接的影响[J].材料科学与工艺,2017,25(2):35-38.CUI Qingbo,LI Yulong,YANG Jin,et al.Effects of chemical plating Sn coating on the ultrasonic spot welding of Mg/Al dissimilar metals[J].Materials Science&Technology,2017,25(2):35-38.
[14]MACWAN A,CHEN D L.Ultrasonic spot welding of rare-earth containing ZEK100 magnesium alloy to 5754aluminum alloy[J].Materials Science&Engineering A,2016,666:139-148.
[15]PATEL V K,BHOLE S D,CHEN D L.Microstructure and mechanical properties of dissimilar welded Mg-Al joints by ultrasonic spot welding technique[J].Science&Technology of Welding&Joining,2012,17(3):202-206.
[16]郭校峰.铝钢复合材料界面结合机理及金属间化合物生长行为的研究[D].广州:广东工业大学,2017.GUO Xiaofeng.Research on interfacial bonding mechanism of aluminium steel composites and growth behavior of intermetallic compounds[D].Guangzhou:Guangdong University of Technology,2017.
[17]ROBSON J,PANTELI A,PRANGNELL P B.Modelling intermetallic phase formation in dissimilar metal ultrasonic welding of aluminium and magnesium alloys[J].Science&Technology of Welding&Joining,2007,17(6):447-453.
[18]PANTELI A,ROBSON J D,BROUGH I,et al.The effect of high strain rate deformation on intermetallic reaction during ultrasonic welding aluminium to magnesium[J].Materials Science&Engineering A,2012,556:31-42.
[19]PATEL V K,BHOLE S D,CHEN D L.Improving weld strength of magnesium to aluminium dissimilar joints via tin interlayer during ultrasonic spot welding[J].Science&Technology of Welding&Joining,2013,17(5):342-347.
[20]PANTELI A,CHEN Y C,STRONG D,et al.Optimization of aluminium-to-magnesium ultrasonic spot welding[J].JOM,2012,64(3):414-420.