轴肩下压量对搅拌摩擦焊搭接焊缝界面迁移的影响

采用左螺纹圆柱搅拌针对2mm厚的LF6铝合金板进行搅拌摩擦焊搭接实验,研究了轴肩下压量对搅拌摩擦焊搭接焊缝界面迁移的影响.结果表明:焊缝返回边和前进边的搭接界面均向焊缝上表面迁移,在返回边,界面迁移至焊缝顶部时,水平向焊缝中心迁移,最大可延伸至前进边;而前进边的界面仅分布在前进边侧.返回边的界面迁移高度随轴肩下压量增加...     

铝合金搅拌摩擦焊焊缝形成的物理机制

研究了一种铝合金焊缝成形的物理机制及焊接工艺参数对焊核尺寸的影响.结果表明:搅拌摩擦焊焊缝是由焊核、在前进边后方沿板材厚度方向流动的金属、由搅拌针两侧向其后方流动的金属组成,四个方向的金属流会在焊缝横截面上出现一交汇区,若金属流动不足,易在此区出现焊接缺陷.焊核的形成及其大小取决于搅拌针表面的螺纹和焊接工艺参数,若单位长度焊缝中有较多的金属在螺纹的驱动下向下流动,则会在焊缝下部出现较大的焊核.过高的搅拌头旋转速度或过低的焊接速度,使搅拌针周围金属易于朝焊缝上部流动,焊核尺寸减小.     

基于搅拌摩擦焊驱动模式分析压铸态AZ91D镁合金接头隧道状缺陷形成原因

采用不同焊接规范对压铸态AZ91D镁合金进行搅拌摩擦焊连接,并采用光学显微镜、扫描电镜等方式对焊缝接头微观形貌进行研究。结果表明,焊接速率高于60mm/min时,焊缝中均产生贯穿型隧道状缺陷,缺陷位于焊缝前进侧冠状区与环形区交界处;随着焊接速率的增大,缺陷有逐渐向焊缝底部延伸的趋势。分析认为该缺陷的形成机理如下:冠状区塑性材料同时受到搅拌针和轴肩共同作用,环形区塑性材料主要受到搅拌针作用,致使环形区与冠状区结合处呈现出流动差异性,导致在前进侧产生隧道状缺陷。     

异种铝合金搅拌摩擦焊材料流动行为研究

采用异种铝合金交替排列的方法,研究了搅拌摩擦焊接过程中材料的变形和流动行为。结果表明:采用垂直焊缝交替排列的焊缝表面形成了两套弧纹,其中粗大弧纹是由于在焊接方向上两种铝合金交替排列而产生的周期性变化所致;受焊速和转速的影响,材料在前进侧流动剧烈且混合均匀,而后退侧因材料流动较弱仍与母材保持连续分布状态;由于材料塑性变形程度的差异,在轴肩影响区、搅拌针影响区和母材之间形成了明显的分界面。     

镁合金搅拌摩擦焊接组织特征研究

通过对镁合金AZ31进行搅拌摩擦焊获得了成型良好的焊缝,采用金相显微镜对焊缝组织进行了分析,并采用透射电镜和X射线能谱仪对晶粒形貌和晶界析出的第二相进行了观测分析。结果表明,镁合金搅拌摩擦焊可以获得组织致密的焊缝,焊缝区域根据组织特点可以分为焊核区、热机影响区和热影响区;焊核区"洋葱环"之间呈现层片状结构,晶界强化相数量减少且尺寸变小;热机影响区在前进侧和焊核区有明显的分界,晶粒呈细长条状,后退侧和焊核区分界相对不明显,晶粒变形较小;热影响区在前进侧较窄,组织与母材组织相比变化较小,而后退侧热影响区较宽,晶粒尺寸有所增长,这与搅拌摩擦过程中金属切削迁移的堆积过程有关。     

2024铝合金搅拌摩擦焊接头塑性变形行为研究

为了研究搅拌摩擦焊卷焊管坯的力学性能及接头塑性变形行为,以5 mm厚的2024退火态铝合金搅拌摩擦焊板坯为对象,采用网格法测试接头塑性变形分布,用EBSD测量接头各区域晶粒尺寸及位相,并结合SEM观察接头第二相的分布,研究了接头力学性能、应变分布与微观组织之间的关系.研究表明:搅拌摩擦接头强度与母材等强,延伸率下降44%;接头前进侧距离焊缝中心8～17 mm的母材较早出现了应变的集中,局部应变可达23%,而焊核区和接头返回侧母材发生的变形较小,平均应变分别为3%和11%,各区域应变的不均匀主要是由于接头各区晶粒尺寸及位相的差异造成的,导致接头整体延伸率的下降.     

铝合金厚板搅拌摩擦焊焊缝局部金属的塑性流动特征

以0.02mm厚铜箔为标示材料,采用带三角平面圆锥形搅拌针对20mm厚7075-T6铝板进行焊接。通过测试沿焊缝厚度方向上温度场分布及观察标示材料分布状态,分析焊缝局部金属塑性流动行为特征。结果表明,沿焊缝厚度方向上自上而下的金属温度逐渐降低;焊缝上、下表面温度差约为90℃;同一厚度上相对称的两点,位于前进边金属的温度高于返回边约15℃。位于焊核区上部的铜箔呈细小颗粒状均匀分布;下部铜箔则呈层片状分布,且向前进边偏移。焊核区由多个呈纹路状、有序排列的洋葱环结构相互层叠而成,这与焊缝塑化金属沿轴向迁移方式发生变化有关。     

线性摩擦焊接头形成过程及机理

分析了异质钛合金线性摩擦焊接头焊合线近域组织结构,结合飞边形貌及组织特点,探讨了线性摩擦焊接头的形成机理。结果表明,在线性摩擦焊接过程中摩擦界面温度超过钛合金基体材料相变点,焊后摩擦界面两侧均有高温塑性层残留并发生再结晶,焊缝区为完全再结晶组织,TC11侧焊缝区为细小针状组织,TC17侧焊缝区为亚稳态β组织。异质钛合金线性摩擦接头形成机理研究表明,在线性摩擦焊接过程中以及焊后摩擦界面始终存在,界面两侧的高温黏塑性金属没有发生机械混合,界面两侧原子发生了扩散迁移现象,在接头结合界面处形成扩散过渡区。摩擦焊通过扩散与再结晶的共同作用形成焊接接头。     

TC4钛合金惯性摩擦焊焊缝微观组织形成的研究

利用光学显微镜、扫描电镜、薄膜透射电镜研究了惯性摩擦焊缝组织的形成。结果表明，焊缝组织沿径向有较大的变化。心部为细小的等轴组织，焊口为片状组织，从心部到焊口形成了Ｖ字形焊缝。     

LC52厚板搅拌摩擦焊组织性能分析

采用搅拌摩擦焊方法对厚度为15mm的LC52铝合金板进行了单道焊接试验,并对焊缝的微观组织与力学性能进行了分析.试验结果表明,在旋转速度为1500r/min,且焊接速度为60mm/min时,可以获得较好的焊缝组织,其抗拉强度达到了338MPa.焊核区内是细小均匀的等轴晶,平均晶粒大小在4μm左右.焊缝两侧热机影响区的组织存在较大差异,前进侧热机影响区为塑性变形角较小的窄条形组织,后退侧热机影响区为塑性变形角较大的扁平块状组织.热影响区的组织发生了粗化.焊缝中的部分强化相η'相因过时效转变为η相是焊缝强度低于基材强度的主要原因.     

Process parameters/material location affecting hooking in friction stir lap welding: Dissimilar aluminum alloys

Influence of spindle and weld speeds, metal location, direction of spindle rotation, and tool pin length on hooking in lap FSW of dissimilar aluminum alloys and the effect of hook on tensile and fatigue weld strength was studied. Optical images of the cross-section of the specimen welded at different process parameters were analyzed. The results indicate that increased spindle speed, reduced weld speed, higher tool pin length, clockwise spindle rotation, and locating the stronger material at the bottom of the joint increased the size of the hooking defect. Higher weld speeds and very high spindle speeds resulted in lower hook size on the advancing side (AS) compared to the retreating side (RS) of the joint. Welding with low weld speed would result in higher advancing side hook size compared to the retreating side. Friction stir weld joints fabricated with anti-clockwise spindle rotation has been found to have extremely low hook both on the AS and the RS of the joint. The tensile and fatigue strengths of the weld joints and plates are degraded by the hook. The fatigue strength of welded alloys could be improved by a double pass weld, the second pass welded immediately adjacent to the first pass.     

Flow patterns in friction stir welds of AA5083 and AA6082 alloys

The flow patterns in dissimilar friction stir welds of AA5083-O and AA6082-T6 alloys have been studied. It was observed that material flows (pushes but does not mix) more from the advancing side into the retreating side. Material flow from the retreating side to the advancing side only occurs in the tool shoulder domain, and the pull is greatest at the transition region between the tool shoulder domain and the tool pin domain. It was also observed that materials tend to extrude out only in the thermomechanically affected zone of the retreating side, which was influenced by rotation of both the tool shoulder and the tool pin. The finest grains were present in the regions closest to the tool edge in the retreating side. The volume fraction of recrystallized grains increases down into the deeper part of the nugget from the flow arm region. Microhardness measurements revealed that regions of lowest hardness values were the nugget and the heat affected zone of the AA6082-T6 alloy side. The welding speeds had no influence on the microhardness values per se, but affected the mixing proportions in the flow arm and in the nugget stem.     

Simulation and experimental investigation of FSP of AZ91 magnesium alloy

A thermo-mechanical simulation of the friction stir processing (FSP), using the DEFORM 3D software based on Lagrangian implicit, was developed and verified by the experimental results. Simulation can successfully predict the temperature and effective strain distributions. Material flow around the tool pin was examined using the point tracking. It was found that the major part of material flow occurs at the advancing side, and consequently, stirred zone (SZ) stretches toward the advancing side. However, material at the retreating side moves slightly in backward direction. The material deformation and the peak temperature influence on the microstructural characters and can determine the width of SZ. Based on the simulation, effective strain and temperature histories of material around the tool pin were also calculated. The amount of effective strain and peak temperature required for recrystallization at the advancing and retreating sides as well as at the bottom of SZ was determined. Therefore, the width of SZ can be predicted by the simulation.     

Dissimilar friction stir lap welding of AA 5754-H22/AA 6082-T6 aluminium alloys: Influence of material properties and tool geometry on weld strength

Dissimilar friction stir welding (FSW) of heat (AA 6082-T6) and non-heat (AA 5754-H22) treatable aluminium alloys, in lap joint configuration, was performed in this work. The base material plates were 1 mm thick. Welds were performed combining different plates positioning, relative to the tool shoulder, in order to assess the influence of base materials properties on welds strength. Three different tools were tested, one cylindrical and two conical, with different taper angles. Welds strength was characterized by performing transverse and tensile–shear tests. Strain data acquisition by Digital Image Correlation (DIC) was used to determine local weld properties. The results obtained enabled to conclude that the dissimilar welds strength is strongly dependent on the presence of the well-known hooking defect and that the hooking characteristics are strongly conditioned by base materials properties/positioning. By placing the AA 6082-T6 alloy, as top plate, in contact with the tool shoulder, superior weld properties are achieved independently of the tool geometry. It is also concluded that the use of unthreaded conical pin tools, with a low shoulder/pin diameter relation, is the most suitable solution for the production of welds with similar strengths for advancing and retreating sides.     

Effect of tool geometry and process condition on static strength of a magnesium friction stir lap linear weld

Friction stir lap linear welding is conducted on overlapped AZ31 magnesium plates with different welding tools. Welds are made mainly with the orientation such that the weld retreating side on the upper plate is to be placed under load. Welding tools consist of a concave shoulder and a pin having a cylindrical, or triangular, or pie shape. This work addresses the effects of tool geometry and process condition on lap shear strength of welds. The shape of the hook formed due to upward bending of the plate interface on the retreating side and the strength of friction stir processed material are quantitatively characterized. Compared to the cylindrical tool, the triangular tool effectively suppresses the hook on the retreating side due to enhanced horizontal material flow. This primarily leads to a 78% increase in optimized weld strength. A ‘pure’ shear surface present on the tool pin significantly reduces weld strength.     

工具形状及工艺过程对搅拌摩擦增材成形及缺陷的影响

采用2mm厚的2195-T8铝锂合金作为增材板条,利用5种不同形状的搅拌工具进行搅拌摩擦增材工艺实验。利用金相观察和硬度测试的分析方法,重点探讨搅拌工具形状与工艺过程对增材成形、界面缺陷及硬度分布的影响。结果表明:圆柱状和三角平面圆台状搅拌针下增材界面上下材料无明显混合,偏心圆柱状和三凹圆弧槽状搅拌针有利于增材界面上下材料混合及减小界面钩状缺陷;增材前进侧界面形成致密无缺陷冶金连接,而后退侧界面材料混合不充分,钩状缺陷易伸入焊核区,且弱连接缺陷起源于此。四层增材中,相邻两层焊接方向相反的增材工艺使除顶层增材外其他增材两侧钩状缺陷向焊核区外侧弯曲,弱连接缺陷得到改善;顶层增材后退侧钩状缺陷伸入焊核区。增材焊核区有明显软化现象,但不同增材工艺下焊核区硬度分布均匀,表明搅拌摩擦增材制造可获得性能均匀的增材;相比于单道焊接工艺,来回双道焊接工艺使单层增材焊核区进一步软化;四层增材中,越靠近顶部的增材,其焊核区平均硬度越大。     

Simulation of material flow in friction stir processing of a cast Al–Si alloy

The objective of the current paper is using DEFORM-3D software to develop a 3-D Lagrangian incremental finite element method (FEM) simulation of friction stir processing (FSP). The developed simulation allows prediction of the defect types, temperature distribution, effective plastic strain, and especially material flow in the weld zone. Three-dimensional results of the material flow patterns in the center, advancing and retreating sides were extracted using the point tracking. The results reveal that the main part of the material flow occurs near the top surface and at the advancing side (AS). Material near the top surface was stretched to the advancing side resulting in a non-symmetrical shape of the stir zone (SZ). Furthermore, macrostructure and temperature rise were experimentally acquired to evaluate the accuracy of the developed simulation. The comparison shows that the stir zone shape, defect types, powder agglomeration, and temperature rise, which were predicted by simulation, are in good agreement with the corresponding experimental results.     

搅拌针端部挤压区内塑性金属的流动行为

以0.02 mm厚的铜箔作为标示材料、1 mm和2 mm厚的2024铝合金薄板作为基材,采用不同的叠加方式组成叠层并进行搅拌摩擦焊接(Friction stir welding, FSW)试验,分析搅拌针端部挤压区塑性金属的流动行为及其对焊缝成形的影响。结果表明,在FSW焊接过程中,焊缝上部被塑化的金属不断地沿着搅拌针螺纹旋向往搅拌针端部迁移、长大,形成挤压区。此挤压区由位于搅拌针两侧的扩展区和位于搅拌针端面下方的变形区组成。其中,变形区的金属一部分来自从焊缝上部迁移而来的塑性金属;另一部分来自搅拌针端面下方母材经旋转摩擦作用而发生塑性变形的金属。挤压区塑性金属的流动方式分为轴向挤压迁移、水平摩擦迁移和绕流迁移三种。对厚板进行FSW焊接时,挤压区的塑性金属倾向以绕流迁移方式为主,导致焊缝内部形成疏松区或孔洞型缺陷。