铜/钛异种金属焊接微观组织及力学性能研究

研究采用电子束偏置铜侧的方法完成了T2铜和TC4的异种金属焊接,并采用光学显微镜（OM）、扫描电镜（SEM）、显微硬度及抗拉强度测试等方式分析其微观组织及力学性能特征。研究结果表明：铜侧焊接具有成形较好的焊缝,焊缝表面鱼鳞纹较均匀,成形较好,无明显的微裂纹、气孔以及夹渣现象,电子束焊接可实现单侧焊接双面成形。钛合金侧焊缝可观察到宽度25～40μm的金属间化合物层,金属间化合物层由多种反应产物组成,金属间化合物层的存在将恶化接头的力学性能。在偏铜侧1.5 mm焊接时,抗拉强度可达到152 MPa,相当于T2 Cu抗拉强度的66%,拉伸断口表现为脆性解理断裂,引起断裂的主要物相为CuTi相。     

Friction Stir Welding of Dissimilar Al/Al and Al/Non-Al Alloys: A Review

Metallurgical and Materials Transactions B - Friction stir welding is a solid-state welding technique that has many advantages over traditional fusion welding, and has been widely adopted in the...     

Investigation on Metallurgical Structure and Mechanical Properties of Dissimilar Al 2024/Cu FSW T-joints

In this research, T-joining of AA2024-T4 and commercially pure copper were performed successfully using friction stir welding. Effect of welding parameters on metallurgical and mechanical characteristics of the joints was studied. For this purpose, tensile strength, microhardness, and macro- and microstructures of the joints were investigated. Also, the fracture surfaces were examined using XRD and SEM. The best results were obtained for the 1130 rpm rotation speed (ω) and 12 mm/min travel speed (v), with the UTS of 156 MPa (~70% of Cu strength). The microhardness test showed that TMAZ and base metal of Al side had the maximum hardness amounts (148 and 155 HV, respectively). Generally, increase in the ω²/v ratio caused the nugget zone and HAZ grain size to increase. The results revealed the formation of Al₂Cu and Al₄Cu₉ intermetallic compounds in the border zone of the joints. The fractography results showed the occurrence of cleavage fracture in all the samples.     

超细晶Cu/AI异种材料搅拌摩擦焊组织与性能研究

超细晶材料综合性能优异,但组织热稳定性较差,焊接后接头组织容易发生异常长大,使其性能急剧下降。因此,合适的连接工艺对大尺寸超细晶结构件的应用具有重要工程意义。以超细晶铜、粗晶铝以及粗晶铜、粗晶铝作为结构母材,采用热输入量小的搅拌摩擦焊（FSW）工艺进行连接探索,系统观察了铜铝接头组织与性能。结果表明,超细晶铜与铝接头界面处元素互扩散能力较强,形成较多的Al4Cu9 金属间化合物;在焊接过程中,当搅拌头转速为1000 r/min,焊接速度为50 mm/min时,粗晶铜与铝接头硬度可达HV 211,超细晶铜与铝焊接接头可获得良好的力学性能。     

Effects of Ultrasonic Vibration on Material Flow and Thermal Cycles in Friction Stir Welding of Dissimilar Al/Mg Alloys

Comparative experiments are performed in friction stir welding (FSW) of dissimilar Al/Mg alloys with and without assistance of ultrasonic vibration. Metallographic characterization of the welds at transverse cross sections reveals that ultrasonic vibration induces differences in plastic material flow in two conditions. In FSW, the plastic material in the peripheral area of shoulder-affected zone (SAZ) tends to flow downward because of the weakening of the driving force of the shoulder, and a plastic material insulation layer is formed at the SAZ edge. When ultrasonic vibration is exerted, the stirred zone is divided into the inner and outer shear layers, the downward material flow trend of the inner shear layer disappears and tends to flow upward, and the onion-ring structure caused by the swirl motion is avoided in the pin-affected zone. By improving the flow behavior of plastic materials in the stirred zone, ultrasonic vibration reduces the heat generation, accelerates the heat dissipation in nugget zone and changes the thermal cycles, thus inhibiting the formation of intermetallic compound layers.

     

Global and Local Mechanical Properties and Microstructure of Friction Stir Welds with Dissimilar Materials and/or Thicknesses

This article studies the properties of a wide range of friction-stir-welded joints with dissimilar aluminum alloys or thicknesses. Two aluminum alloys, namely, 2024-T3 and 7075-T6, are selected for the study and are welded in ten different combinations of alloys and thicknesses. The welding parameters are optimized for each configuration, and a systematic study of the effects of material and thickness combinations on the microstructural features, global and local mechanical properties, and fracture mechanisms of the welds is carried out. It is shown that dissimilar alloys are extruded into each other, the texture is heterogeneous in the weld zone, and that there is no significant diffusion of alloying elements between the alloys. For most configurations, the local and global mechanical properties decrease as the thickness ratio increases. The local yield strength and plasticity parameters substantially vary next to the weld centerline, hence requiring their implementation in finite element method (FEM) models. Machining to obtain a constant thickness significantly influences the mechanical properties of the welds. The fracture mechanism is found to be a mixture of ductile and brittle fractures and to qualify as “quasi-cleavage.”     

The Effect of Cu Powder During Friction Stir Welding on Microstructure and Mechanical Properties of AA3003-H18

Friction stir welding (FSW) was used to join 3003-H18 non-heat-treatable aluminum alloy plates by adding copper powder. The copper powder was first added to the gap (0.1 and 0.2 mm) between two plates and then the FSW was performed. The specimens were joined at various rotational speeds of 800, 1000, and 1200 rpm at traveling speeds of 70 and 100 mm/min. The effects of rotational speed, second pass of FSW, and direction of second pass also were studied on copper particle distribution and formation of Al-Cu intermetallic compounds in the stir zone. The second pass of FSW was carried out in two ways; in line with the first pass direction (2F) and in the reverse direction of the first pass (FB). The microstructure, mechanical properties, and formation of intermetallic compounds type were investigated. In high copper powder compaction into the gap, large clusters were formed in the stir zone, while fine clusters and sound copper particles distribution were obtained in low powder compaction. The copper particle distribution and amount of Al-Cu intermetallic compounds were increased in the stir zone with increasing the rotational speed and applying the second pass. Al₂Cu and AlCu intermetallic phases were formed in the stir zone and consequently the hardness was significantly increased. The copper particles and in situ intermetallic compounds were symmetrically distributed in both advancing and retreating sides of weld zone after FB passes. Thus, the wider area was reinforced by the intermetallic compounds. Also, the tensile test specimens tend to fracture from the coarse copper aggregation at the low rotational speeds. At high rotational speeds, the fracture locations are placed in HAZ and TMAZ.     

Friction Stir Brazing: a Novel Process for Fabricating Al/Steel Layered Composite and for Dissimilar Joining of Al to Steel

A novel process of friction stir brazing (FSB) for fabricating Al/steel layered composite (by multipass) and for joining Al to steel (by single pass) was proposed to avoid the wear of pin by steel, in which a tool without pin was used. FSB of 1.8-mm-thick Al sheet to steel sheet was conducted using a cylindrical tool with 20-mm diameter but without pin and using 0.1-mm-thick zinc foil as filler metal. For the rotational speed of 1500 rpm, sound joints were reliably obtained at the medium range of traverse speed of 75 to 235 mm/min, which fractured within Al parent sheet during tensile shear test. Furthermore, for peel test on the sound joints, Al and steel parent sheets tended to crack and deform, respectively. Metallographic examination showed that most Zn was extruded and the resultant interfacial structure consisted of several Al-Fe intermetallic compounds (IMCs) with a little Zn, less than 3 at. pct. The thickness of IMCs can be controlled to be less than 10 μm by properly increasing traverse speed (e.g., 150 mm/min). The metallurgical process of FSB was investigated by observing the microstructure of the longitudinal section of a friction stir brazed joint obtained by the suddenly stopping technique.     

Characterization of the Influence of Tool Pin Profile on Microstructural and Mechanical Properties of Friction Stir Welding

In this study, the effect of tool pin profile on mechanical properties, microstructural, material flow, thermal and strain distributions of friction stir welding of AA5083 was investigated. Two different tools with cylindrical and square pin profiles were employed to produce the welds. A numerical model is developed for investigating the effect of tool pin profiles on material flow, thermal and strain distributions based on thermo-mechanically coupled rigid-viscoplastic 3D FEM. Then, optical microscopy was employed to characterize the microstructures features of the weld. Finally, tensile test was carried out to characterize the mechanical properties of the weld. Obtained results showed that square pin profile produced finer grain structure and higher ultimate strength relative to cylindrical one. These results may be related to higher eccentricity, larger stirred zone, and higher temperature in the weld zone of the square pin profile.     

High-Speed Friction Stir Welding of AA7075-T6 Sheet: Microstructure,Mechanical Properties,Micro-texture,and Thermal History

Friction stir welding (FSW) is a cost-effective and high-quality joining process for aluminum alloys (especially heat-treatable alloys) that is historically operated at lower joining speeds (up to hundreds of millimeters per minute). In this study, we present a microstructural analysis of friction stir welded AA7075-T6 blanks with high welding speeds up to 3 M/min. Textures, microstructures, mechanical properties, and weld quality are analyzed using TEM, EBSD, metallographic imaging, and Vickers hardness. The higher welding speed results in narrower, stronger heat-affected zones (HAZs) and also higher hardness in the nugget zones. The material flow direction in the nugget zone is found to be leaning towards the welding direction as the welding speed increases. Results are coupled with welding parameters and thermal history to aid in the understanding of the complex material flow and texture gradients within the welds in an effort to optimize welding parameters for high-speed processing.     

Mechanical Properties,Microstructure and Crystallographic Texture of Magnesium AZ91-D Alloy Welded by Friction Stir Welding (FSW)

The objective of the study was to characterize the properties of a magnesium alloy welded by friction stir welding. The results led to a better understanding of the relationship between this process and the microstructure and anisotropic properties of alloy materials. Welding principally leads to a large reduction in grain size in welded zones due to the phenomenon of dynamic recrystallization. The most remarkable observation was that crystallographic textures appeared from a base metal without texture in two zones: the thermo-mechanically affected and stir-welded zones. The latter zone has the peculiarity of possessing a marked texture with two components on the basal plane and the pyramidal plane. These characteristics disappeared in the thermo-mechanically affected zone (TMAZ), which had only one component following the basal plane. These modifications have been explained by the nature of the plastic deformation in these zones, which occurs at a moderate temperature in the TMAZ and high temperature in the SWZ.     

Improvement of Interfacial Strength with the Addition of Ni in Al/Cu Dissimilar Joints Produced via Laser Brazing

Metallurgical and Materials Transactions A - Dissimilar metal joining between Al and Cu is effective to reduce the cost and weight of electrical components. In this study, dissimilar laser lap...     

Effect of Laser Welding Parameters on the Microstructure and Mechanical Properties of Dissimilar Hastelloy X/Haynes 188 Joints

Metallurgical and Materials Transactions A - Laser welding is currently a versatile and reliable assembly technique. To save weight in aerostructures and propulsion units and to reduce thermal...     

Effects of Pulse Current on Transient Liquid Phase (TLP) Diffusion Bonding of SiCp/2024Al Composites Sheet Using Mixed Al, Cu, and Ti Powder Interlayer

The effects of pulse current on transient liquid phase (TLP) diffusion bonding of SiCp/2024Al composites sheet were investigated at 853?K (580?°C) using a mixed slurry of Al, Cu, and Ti powder interlayer. The process parameters were as follows: the pulse current density of 1.15 × 10² A/mm², the original pressure of 0.5?MPa, the vacuum of 1.3 × 10^?3 Pa, and the bonding time from 15 to 60?minutes. Moreover, the bonding mechanism in correlation with the microstructural and mechanical properties variation was analyzed.     

硫脲介质ICP-OES测定多金属矿石中的银铝铋钴铜铁锰镍铅锑钛锌

建立了混合酸体系预处理试样,电感耦合等离子体发射光谱法(ICP-OES)测定多金属矿石中共生(伴生)具有综合回收价值元素的方法。试样经氢氟酸、硝酸、高氯酸消解,盐酸浸取,硫脲络合后,用ICP-OES同时测定矿石中Ag、Al、Bi、Cu、Co、Fe、Mn、Ni、Pb、Sb、Ti、Zn 12种元素,采用Thermo Scientific i TEVA ICP软件,在Subarray谱图扣除可能的背景及元素之间的谱线重叠干扰。实验结果表明,除Al、Fe外,各元素的检出限为1.13~6.20μg/g,测定结果的精密度(RSD)均小于10%。经国家一级多金属矿石标准物质验证,测定结果与标准推荐值吻合。     

稀土金属中14种非稀土杂质的ICP-MS法同时测定

本文研究了用 ICP- MS仪器同时测定稀土金属中 Mg、Al、Ti、Cr、Mo、Mn、Co、Ni、Cu、Zn、Pb、W、Nb、Ta等 14种非稀土杂质。研究了各稀土基体对被分析元素的基体效应 ,选择了相匹配的内标元素。比较了标准曲线法与标准加入法的测定结果。确定了用内标元素校正基体效应及仪器漂移 ,以标准曲线法直接测定。进行了加料回收和精密度实验 ,回收率在 94%～ 113%之间 ,RSD<10 %。被分析元素的检出限为 0 .0 1～ 0 .2 0 ng/ m L,测定下限为1～ 2 0 μg/ g。