高速激光热丝钎焊表面成形质量的控制

高速激光钎焊会引起熔池流动紊乱导致焊缝成形质量恶化,从而限制了其在汽车制造领域的应用。通过正交试验研究了高速下激光功率、送丝角度等工艺参数对焊缝成形质量的影响,发现焊缝成形质量随激光功率增加和送丝角度减小而提升。激光功率是通过影响熔池获得的热输入,从而影响熔池表面扰动的铺展来影响焊缝成形质量的。送丝角度是通过影响焊丝送入熔池的位置,从而影响焊丝对熔池的扰动强度和扰动的铺展速度来影响焊缝成形质量的。采用正交试验获得的最优工艺参数组合进行试验,获得了表面光滑平整无缺陷的高质量焊缝,为激光钎焊在高速下的应用发展奠定了基础。     

低碳钢电弧熔覆增材层摩擦磨损及抗腐蚀性能

目的 针对低碳钢零件的破损失效采用TIG焊电弧熔覆增材制造工艺，研究低碳钢电弧熔覆修复使其达到再制造零件性能要求的可行性，为实现TIG焊修复应用提供保证。方法 通过TIG焊熔覆在低碳钢坡口处，对熔覆接头的显微组织进行分析，并测试修复后的增材层表面硬度性能。使用Nanovea Tribometer摩擦磨损仪和NanoveaPS50表面轮廓仪，对基体和增材层进行摩擦性能测试，并表征摩擦磨损后的表面形貌，探究磨损机理。采用电化学工作站对基体和增材层的腐蚀性能进行分析。结果 修复后的增材层显微硬度（220.17HV）高于基体且其摩擦性能和腐蚀性能优于基体，随着磨损载荷的增加，增材层的摩擦系数逐渐降低，磨损机制主要为磨粒磨损和粘着磨损。增材层表面组织均匀细小，在NaCl溶液中点蚀坑小且分散，增材层的腐蚀电流密度（1.8349×10-6 A/cm2）小于基体的腐蚀电流密度（6.5251×10-5 A/cm2），增材层表面的抗腐蚀能力明显提高。结论 电弧熔覆低碳钢可满足低碳钢零部件现场电弧快速修复对再制造性能的要求，实现了低碳钢破损零部件的表面修复与强化。     

Mg-Gd-Y-Zr合金TIG电弧熔覆层微观组织演变及力学性能研究

目的 在AZ91D镁合金表面熔覆Mg-Gd-Y-Zr合金，分析熔覆层微观组织演变规律及其对熔覆层力学性能的影响。方法 采用直流脉冲钨极氩弧焊（DC PTIG welding），在不同平均电流下，将Mg-Gd-Y-Zr合金焊丝送入AZ91D镁合金熔池，制备熔覆层。采用金相显微镜、扫描电子显微镜、能谱仪及X射线衍射仪，分析不同平均电流条件下的熔覆层微观组织。基于显微维氏硬度仪与往复式滑动摩擦磨损设备，表征熔覆层硬度及摩擦学性能。结果 熔覆层微观组织主要由α-Mg、Mg24(Gd,Y)5及Al2(Gd,Y)相组成。熔覆层呈现明显分层特征，主要是由晶界Mg24(Gd,Y)5相分布差异造成。平均电流增大，熔覆层中心晶粒尺寸先保持不变，而后快速增大，Al2(Gd,Y)相由细小弥散颗粒变为团聚状分布，晶界Mg24(Gd,Y)5相则由连续网状演变为不连续岛状，直至变为细小颗粒状。熔覆层硬度随平均电流增加，呈现略微上升，随后快速下降的趋势，其最高硬度达90.8HV。摩擦磨损测试过程中，平均电流为110 A所得熔覆层失重速率小于AZ91D基材。结论 采用DC PTIG在AZ91D基体表面成功制备了耐磨性能优于基体的含Gd、Y稀土元素的熔覆层，稀释率决定熔覆层Al2(Gd,Y)相形貌及分布规律。     

Effects of welding parameters and welding sequence on residual stress and distortion in Al6061-T6 aluminum alloy for T-shaped welded joint

The distribution of temperature and then the distribution of residual stress and distortion in the stiffened aluminum alloy Al6061-T6 plates under the metal inert gas (MIG) welding process were investigated by three dimensional thermo-mechanical coupled finite element model using Ansys software. The properties of materials were considered temperature-dependent and the filler metal was added to the workpiece by the element birth and death technique. In three modes of current, two different speeds and two various sequences, the distribution of residual stress and distortion were calculated and analyzed. The results showed that increase in welding speed decreased the vertical deflection in the plate, transverse shrinkage and angular distortion of plate and the lateral deflection of stiffener, but increased the maximum longitudinal tensile stress in the plate and stiffener. Furthermore, increase in current increased the residual stress and deformation in the plate and stiffener, and the change in the welding sequence changed the distribution of the distortion in the plate and the stiffener without significant change in the distribution of the longitudinal residual stress.     

Local inhomogeneity of mechanical properties in stir zone of friction stir welded AA1050 aluminum alloy

The local inhomogeneity of the stir zone in friction stir welded face-centered cubic metal was investigated, which has multiple activated slip systems during plastic deformation, by selecting commercial AA1050 aluminum alloy as an ideal experimental material. The local inhomogeneity was evaluated by uniaxial tensile tests using small samples with a 1 mm gauge length. The corresponding microstructural parameters such as grain size, misorientation angle distribution, and micro-texture, were quantified by the backscattered electron diffraction technique. A comprehensive model was used to reveal the microstructure−mechanical property relationship. The experimental results showed that the uniaxial tensile property changes significantly across the weld. The maximum ultimate tensile strength (UTS) occurred in the center of the stir zone, which was 99.0 MPa. The weakest regions were located at the two sides of the stir zone. The largest difference value in UTS reached 14.9 MPa, accounting for 15% of the maximum UTS. The analysis on the structure−mechanical property relationship suggests that the micro-texture change with the location formed during the rotational material flow is the main reason for the local inhomogeneity.     

Microstructure and tensile properties of rapid-cooling friction-stir-welded AZ31B Mg alloy along thickness direction

Rapid-cooling friction-stir-welding (FSW) was used to join AZ31B magnesium alloy plates of 6 mm in thickness. The microstructure and mechanical properties in thickness direction were carefully investigated with electron backscattered diffractometer, and transmission electron microscope. The obtained results showed that ultrafine grains with high dislocation density were obtained in the top region of the weld due to liquid CO₂ cooling. A large number of twins and second-phase particles were also induced in these refined grains. The basal texture intensity was significantly reduced due to the appearance of twins. The top region showed the higher strength and elongation compared with the bottom region, and the welding efficiency reached 93%. This work provided a simple and efficient strategy for manufacturing a gradient structure in the FSW Mg alloy joint.     

Al3Zr/Al基原位复合材料等离子体焊接区的组织及表面腐蚀行为

摘要： 本文以5wt%Al3Zr/铝基复合材料为研究对象，以Ar气体为离子气体，Al-Ti-B为丝材进行等离子焊接。用电化学综合测试仪测定了焊接区在3.5%NaCl溶液中的腐蚀极化曲线。采用扫描电子显微镜（SEM）、X射线衍射仪（XRD）对复合材料及其焊缝的组织和相组成进行了分析和表征，研究了Al3Zr/Al基复合材料等离子焊接后在3.5%NaCl溶液中的腐蚀行为和腐蚀机理。SEM分析结果表明，等离子弧焊接可获得较好的焊缝组织，焊缝组织主要由Al3Ti相和Al基体组成，Al3Ti相呈条状和球形。电化学极化曲线表明，材料在熔核处的耐蚀性略低于母材，焊缝处浸泡腐蚀机理为Al3Ti相和基体相的电极电位不同形成原电池反应造成。     

2195铝锂合金电子束焊接头的焊后热处理

采用光学显微镜、扫描电镜、能谱仪及X射线衍射仪等微观分析手段,研究不同热处理工艺条件下2195铝锂合金电子束焊接头焊缝区的显微组织演变,探讨接头的焊后热处理强化机制。结果表明,焊后热处理可显著改善接头区域的显微组织,促进强化相的析出,有利于提高接头的力学性能。经过焊后固溶+双级时效热处理,焊态下接头熔合线附近存在的等轴细晶区消失,β′、θ′和T₁等强化相在接头焊缝区析出,与单级时效处理工艺相比,双级时效处理的析出强化效果更为显著。力学性能测试表明,经过双级时效热处理后,接头的抗拉强度达到492.5 MPa,为母材强度的90.4%。接头拉伸断口表面存在许多小韧窝,并伴随出现解理面,接头呈韧-脆混合型断裂特征。     

双光束激光焊匙孔动态特征分析

文中研究了高功率单光束激光焊与双光束激光焊过程中匙孔动态特征的差别. 结果表明，单光束激光焊及双光束激光焊接过程中匙孔均处于从产生到湮灭的剧烈波动的过程，不同于单光束激光焊匙孔的形成、长大、维持、缩小、湮灭过程，双光束激光焊的匙孔还存在分离长大及合并缩小的过程；在相同的焊接参数及焊缝具有相同熔深的条件下，双光束激光焊匙孔的波动频率约为单光束激光焊的2/3，单光束激光焊匙孔的开口面积均值约为双光束激光焊匙孔开口面积的1/2，开口面积的波动变异系数约为单光束激光的2倍，即双光束激光焊过程中匙孔较单光束激光焊的具有较高稳定性.     

An integrated model for analysing the effects of ultrasonic vibration on tool torque and thermal processes in friction stir welding

An integrated model of ultrasonic vibration enhanced friction stir welding (UVeFSW) is developed by integrating the thermal-fluid model with the ultrasonic field model and tool torque model. The tool torque and the heat generation rate at tool/workpiece contact interfaces are coupled with the interfacial temperature, strain rate and ultrasonic energy density. The model is used in quantitatively analysing the effects of ultrasonic vibration on tool torque and thermal processes in friction stir welding (FSW). The results show that ultrasonic vibration reduces the flow stress, which results in a decreasing of tool torque, interfacial heat generation rate and interfacial temperature. The complicated interaction of ultrasonic energy with the thermal processes in FSW leads to a gentle thermal gradient and an enhanced plastic material flow in UVeFSW. The model is validated by a comparison of the calculated thermal cycles and tool torque at various welding parameters with the experimentally measured ones.