Some Tribological Influences on the Electrode-Worksheet Interface During Resistance Spot Welding of Aluminum Alloys

In this study, the effect of worksheet surface characteristics on the electrical contact resistance of electrode-worksheet interface during resistance spot welding of aluminum alloy (AA5182) was discussed. The electrical contact resistance was influenced by both the oxide layer and surface roughness of the worksheet. However, the effect of oxide layer was more dominant, and the effect of surface roughness was likely to be linked with the damaging of oxide layer and not the contact area. The oxide layer on AA5182 was non-uniform with Mg-rich small spots dispersed on the surface. Grinding and scratching the worksheet surface was effective in reducing the oxide layer thickness and, hence, reduced the electrical contact resistance. It was observed that the surfaces with higher electrical contact resistances at this interface showed faster pitting rate of electrode. The study also suggested that the static electrical contact resistance measured before resistance spot welding could be useful for predicting materials likely behavior during the actual resistance spot welding process of AA5182.     

Empirical model of effects of pressure and temperature on electrical contact resistance of metals

Abstract

An important input property in the development of process models for resistance spot welding is electrical contact resistance. A model for the pressure and temperature dependence of electrical contact resistance was developed from established concepts of contact resistance. The key to developing the desired relationship is determining surface roughness characteristics, which is experimentally problematic. To overcome this difficulty the electrical resistance of contacting interfaces was measured as a function of the pressure applied across the interfaces. Using known information about the temperature dependence of bulk resistivity and mechanical properties, a curve fitting procedure was used to establish the desired relationship of contact resistance to pressure and temperature. This empirical model agrees well with experimental measurements in the regime of low applied pressure. At high pressures, predictions underestimate contact resistance, and this was attributed to strain hardening of asperities at the contacting interface. The model also predicts that the competing effects of bulk resistance and contact resistance will produce a peak in the variation of contact resistance with temperature. The model provides a suitable means for incorporating the pressure and temperature dependence of contact resistance into process models of the resistance spot welding process.     

金合金滑动接触电阻的动态特性

通过自行设计的计算机控制动态接触电阻测量分析系统对几种Au合金材料的动态接触电阻进行快速和大量的测量,并由计算机对测量数据进行分析和计算得出“瞬间”接触电阻概率密度分布,通过对比分析,研究了接触电阻稳定性和接触好坏程度与材料、接触压力、接触面相对运动速度和滑动路程之间的关系,分析讨论了这些因素对动态接触性能的影响及其规律。实验结果表明动态接触电阻概率密度的峰值Dpp是反映动态接触电阻稳定性的重要参数,它对材料和其它接触参量的变化十分敏感,在所研完的接触材料对申,在非贵金属材料环上电镀PdNi/Au的贵金属层能大幅度地改善动态接触电阻的稳定性和降低动态接触电阻值;接触压力与动态接触电阻稳定性和动态接触电阻之间可能不是一个单调关系,有极值存在;在低速度情况下材料摩擦面间的相对运动速度对接触电阻稳定性的影响非常明显,当超过某个速度后,影响很快变小,当速度增大时,动态接触电阻增大;动态接触电阻稳定性随滑动路程的增加而逐渐变坏,动态接触电阻随滑动路程的增加而增大,两者的变化关系接近线性规律。     

基于稳定分布的铝合金点焊接触电阻

接触电阻是电阻点焊熔核形成与数值模拟的重要参数,决定着点焊质量.采用电阻点焊接触电阻的计算模型与统计分析相结合的方法,通过模型计算工件/工件、工件/电极之间的接触电阻,并将其作为统计抽样检验的数据,研究接触电阻的分布规律.文中采用稳定分布去拟合工件间的接触电阻,并利用非参数统计Dn方法对拟合曲线进行检验.结果表明,所建立的计算模型正确,同时选用的稳定分布函数能更好的拟合工件间的接触点电阻,它们对研究电阻点焊有着重要的理论意义和实用价值.     

New technology for measuring resistance of electrical contact and estimating welding quality

Incomplete penetration is a common defect in the welding gap of large size (welding area is over 100 mm²) electrical contact, which leads to an instability of welding quality. Nevertheless, there was limited research dealing with non-destructive quality inspection of electrical contact. In this research, the resistance of CJ400 electrical contact was measured with the device medium frequency inverter resistance spot welding (MFI-RSW) machine. Multipulse measuring method was designed and proved efficient to reach a higher accuracy by restraining the influence of the contact resistance between electrodes and electrical contact. Moreover, the error of resistance caused by temperature rising in the measuring process is also eliminated effectively. Therefore, more accurate resistance of electrical contact could be extracted compared to the method of single pulse measuring. Then, the relationship between resistance and welding quality was studied and a new quality inspection method was proposed.     

提高渗碳钢多冲接触疲劳抗力的研究

研究了渗碳钢20CrMo表面滚压强化工艺,结果表明,钢渗碳、淬火、低温回火后进行滚压,具有高的多冲接触疲劳抗力,在一定深度范围内,多冲接触疲劳抗力随滚压层深的增加而提高.     

氧化时间对微弧氧化膜电接触微动磨损行为的影响

目的研究不同氧化时间的铝合金表面微弧氧化涂层在电接触条件下的微动磨损行为,并探讨其磨损机理。方法通过控制氧化时间(10、20、30、40、50、60、70 min),在铝合金表面制备不同表面状态的微弧氧化涂层,并利用四线接触法研究其在电接触条件下接触电阻的变化,通过分析摩擦系数、F-D曲线、磨损形貌、三维轮廓及磨痕化学成分来揭示其微动磨损机理。结果电接触微动磨损下,氧化不同时间形成的微弧氧化涂层在相同电接触微动磨损条件下的耐磨性存在明显差异,进而影响其电接触行为。氧化10 min时,涂层磨损最严重,磨损区域的涂层迅速失效,从而导致铝合金基体外露,接触电阻骤降至零;氧化50 min时,涂层厚度最大,具有良好的耐磨性,缓减了接触电阻的衰减,接触电阻曲线在衰减过程中受到磨斑表面裂纹的影响而产生波动。结论氧化时间会影响微弧氧化膜表面形貌、粗糙度以及厚度,对其在电接触条件下的微动磨损行为影响较大。     

硼钢板与模具间接触热阻实验研究及其在回弹仿真中的应用

接触热阻是影响热冲压过程中热能传导的一个重要因素,而零件不同区域的温差则直接影响热冲压的回弹,因此,获得准确的接触热阻数值对提高热冲压回弹仿真的精度具有重要意义。基于稳态法设计了22MnB5板件与Cr7V模具钢接触热阻的测量实验,推导出接触热阻的计算公式;并按照实验方法搭建了实验平台,获得了不同压强下两者的接触热阻值;最后拟合了接触热阻与压强的关系方程。将关系方程带入某B柱的热冲压回弹仿真中,与原始仿真对比发现,改进后的仿真结果与实际实验值较为接近,证明获得准确的接触热阻与压强的关系方程可提高硼钢板热冲压回弹的仿真精度。     

纳米二氧化钛浓缩浆对硼酚醛环氧涂料性能的影响

目的提高硼酚醛环氧涂料的耐腐蚀性、表面接触角、粘结强度及耐磨性等。方法用纳米二氧化钛浓缩浆改性硼酚醛环氧涂料,制备耐温耐蚀型纳米复合涂料。通过高温高硫原油浸泡试验评价纳米复合涂层的耐腐蚀性能,通过扫描电镜观察、表面接触角测试、粘结强度测试和耐磨性测试等手段分析纳米二氧化钛浓缩浆对涂层性能的影响。结果硼酚醛环氧纳米复合涂层在100℃高硫原油腐蚀浸泡后,微观上没有出现腐蚀坑和裂纹。添加2%纳米二氧化钛浓缩浆的硼酚醛环氧纳米复合涂层与未添加纳米粒子的硼酚醛环氧涂层相比,抗渗性与耐磨性有所提高。720 h腐蚀试验后,纳米复合涂料的粘结强度由试验前的7.7 MPa降低至6.9 MPa。腐蚀过程中,其表面接触角比非纳米涂层高4°~7°。结论高温高硫原油没有破坏硼酚醛环氧纳米复合涂层的形貌结构、粘结强度和耐磨性。添加2%纳米二氧化钛提高了涂层的抗渗透性和表面接触角。     

钌对铂合金接点材料抗熔焊性能的影响

利用ASTM触头材料模拟试验机、高温质量损失、摄谱仪、 SEM和WDS等研究了钌对铂合金接点材料的抗熔焊性能的影响. 由于Ru易氧化生成比IrO2更稳定的RuO2, RuO2的分解比IrO2需要更多的分解热, 因此, 接点的温度升高受到限制. RuO2增加了金属熔化液的粘度, 减少了因电弧引起的接点腐蚀. 此外, 选择性的金属转移有利于提高Pt-10Ru-2Ir合金接点的抗熔焊性能.     

氧化物添加剂对Ag-SnO2电接触材料抗蠕变性能的影响

为研究氧化物添加剂对Ag基电接触材料抗蠕变性能的影响,用粉末冶金法制备了分别含有CuO、WO_3和In_2O_3的Ag-SnO_2材料。室温下对拉伸试样进行蠕变实验,获得蠕变特征曲线及相关参数,构建了Ag-SnO_2材料的蠕变本构方程。借助扫描电子显微镜(SEM)对拉伸断口形貌进行分析,用ABAQUS有限元软件进一步对蠕变行为进行模拟。结果表明:由于SnO_2与Ag基体间的界面强度得到提高,氧化物添加剂可显著增强Ag-SnO_2电接触材料的抗蠕变性能,尤其是CuO添加剂的效果最佳。模拟结果与通过实验获得的蠕变数据基本吻合,误差小于3%。研究结果对预测Ag基电接触材料的蠕变行为及改善力学性能均具有一定参考价值。     

电极触头钎焊连接研究进展

电极触头是使电器导电相互接通形成回路的关键元件,其性能好坏直接影响着电器的可靠性、稳定性、耐蚀性和易加工等机械性能.由于对开关电器小型化、长寿命和工作可靠性要求的不断提高,对电极触头的连接研究也越来越受到广泛地关注.本文综述了电极触头钎焊连接研究现状及进展,主要从火焰钎焊、炉中钎焊、感应钎焊和电阻钎焊等四个方面进行介绍...     

AgCuO电触头材料的接触电阻及电弧侵蚀形貌分析

采用原位反应合成法制备CuO含量为10%的AgCuO电触头材料,使用接触电阻参数测试仪对试样在不同电流条件下开闭次数与接触电阻的关系进行研究,并通过扫描电镜对试样的阴/阳极表面微观形貌进行电侵蚀特性分析。结果表明,低电流条件下AgCuO电触头材料的接触电阻基本都是先升高,然后在某一开闭次数时急剧下降,最后基本趋于一定值,且AgCuO电触头材料接触电阻会随着试验电流的增加而逐渐降低;当电流达到25A时,AgCuO电触头材料的接触电阻最低,且随开闭次数的增加其接触电阻变化不大,材料的接触电阻表现出极佳的稳定性。电弧侵蚀后的形貌分析发现,阳极表面呈凹凸状,并有气孔和裂纹,而阴极表面呈现浆糊状尖峰结构。     

新型银基电接触材料的研究进展

综述了3种新型银基电接触材料的性能特点。以NiO、Bi2O3或CuO改性的Ag/SnO2MeO可以改善传统Ag/SnO2电接触材料的接触电阻稳定性、温升控制及室温加工性;以Ag/Ti3SiC2和Ag/Ti3AlC2为代表的三元层状化合物陶瓷相增强银基材料(Ag/MAX)可以改善AgNi材料大电流条件下的抗熔焊性能,降低直流负载条件下材料转移量;用石墨烯替代传统石墨研制的Ag/GNPs可以解决表面膜增厚、接触电阻增大、耐磨性不足等缺点。提出新型银基电接触材料的主要研发方向。     

铝合金电阻点焊过程的有限元模拟

建立了铝合金电阻点焊过程的有限元分析模型，采用基于显微接触理论的接触电阻模型模拟点焊过程中试件与试件界面上的接触电阻。计算获得了焊接过程中电极／试件和试件／试件接触界面上接触半径的变化，以及试件间界面上压应力、电流密度和温度的分布。试验考察了熔核的形成和长大过程。比较表明，计算与试验测量结果符合很好，证实了所采用的接触电阻模型在铝合金电阻点焊模拟中的正确性和适用性。     

Ag-La2NiO4触点材料电弧侵蚀研究

研究了Ag-La2NiO4触点材料在直流阻性负载条件下的材料转移,以及接触电阻等电接触性能.实验结果表明:不同电压(DC 8V、DC 18V)、电流条件下,材料的转移方向、转移量及损耗均不同;DC 18V下接触电阻和熔焊力很不稳定,且随电流值增加有不同程度的波动.     

电阻法用于扩散焊接头微孔缺陷评价的数值模拟

从扩散焊接头界面微孔实际形貌和分布特征出发,提出了界面微孔周期性分布的二维有限元模型,应用ANSYS电磁场分析模块,考察了界面焊合率、界面微孔宽度和长度对电阻增量的影响.结果表明,扩散连接接头的界面焊合率与电阻增量之间呈双曲线变化规律,界面微孔的宽度和长度对电阻增量均有影响.当界面焊合率在20%～80%范围内时,电阻增量与界面焊合率之间表现出更高的敏感性.基于Lodge等人提出的扩散焊界面焊合率与电阻增量关系式,建立了能够包含界面微孔几何尺寸影响的修正方法.     

Comparison of the Switching Behaviour of Electrodeposited Silver and Silver-Cadmium Alloys Contact Materials

The quality of contact materials depends on their physical properties, such as density, hardness and conductivity, as well as on their contact characteristics (contact resistance, weldability and erosion). An instrumentation system is described here, which measures the most important attributes of contact materials simultaneously. The measurements are taken under simulated service conditions. The rated electrical current is passed through contacts of reference and test materials in a relay controlled by an electronic module; the contact resistance, weldability and arc erosion are monitored. In this system two pairs of contact elements—one pair made of the test material, and the other made of reference material—are compared. The relay is an actual electrical device wich would use the test material as its contact elements in normal operation. The test material is silver-cadmium alloy electrodeposited from an iodide bath; and the reference material is electrodeposited silver from a cyanide bath.     

质子交换膜燃料电池双极板化学镀Ni-Cu-P表面改性

针对不锈钢作为燃料电池双极板存在的接触电阻高等问题,通过化学镀Ni-Cu-P对其进行表面改性,采用X射线衍射(XRD)、扫描电镜(SEM)、能谱(EDS)分析、界面接触电阻测试和模拟燃料电池环境腐蚀性能试验等方法,研究了表面改性对不锈钢双极板性能的影响。结果表明,经过化学镀Ni-Cu-P处理的双极板接触电阻大为降低,并且在模拟质子交换膜电池腐蚀环境下耐腐蚀性能得到较大提高。     

添加Bi2O3对AgSnO2触头物理及电接触性能的影响

以Bi2O3为添加剂,采用粉末冶金法制备不同掺杂量的AgSnO2触头材料试样。测量Ag对氧化物基片的润湿角,测试了试样的密度、电导率、接触电阻、燃弧能量等参数,分析了 Bi2O3对AgSnO2触头材料润湿性的影响。结果表明,添加适量的Bi2O3对AgSnO2触头材料的物理和电接触性能有明显的改善,Bi2O3含量为1.5%时AgSnO2触头材料的整体性能达到最佳。润湿角随着Bi2O3含量增大呈现出波动增大的规律,与AgSnO2触头材料接触电阻、燃弧能量的变化规律基本吻合。