TC4钛合金薄板激光焊接头疲劳性能研究

研究了TC4钛合金薄板母材及其激光焊接头的拉伸和疲劳性能.结果表明:与母材相比激光焊接头的强度升高,延伸率下降;拉伸试样均断在母材.激光焊接头的疲劳寿命在低应力水平时高于母材,而在高应力水平时低于母材.在疲劳扩展区,母材为韧性穿晶断裂,熔合区则呈现出韧性和脆性相混合的断裂形貌;在瞬断区,母材由等轴韧窝组成,而熔合区主要为粗大的穿晶解理平面.     

Correlation of fatigue properties and microstructure in investment cast Ti-6Al-4V welds

The effect of microstructural characteristics on high-cycle fatigue properties and fatigue crack propagation behavior of welded regions of an investment cast Ti-6Al-4V were investigated. High-cycle fatigue and fatigue crack propagation tests were conducted on the welded regions, which were processed by two different welding methods: tungsten inert gas (TIG) and electron beam (EB) welding. Test data were analyzed in relation to microstructure, tensile properties, and fatigue fracture mode. The base metal was composed of an alpha plate colony structure transformed to a basket-weave structure with thin platelets after welding and annealing. High-cycle fatigue results indicated that fatigue strength of the EB weld was lower than that of the base metal or the TIG weld because of the existence of large micropores formed during welding, although it had the highest yield strength. In the case of the fatigue crack propagation, the EB weld composed of thinner platelets had a faster crack propagation rate than the base metal or the TIG weld. The effective microstructural feature determining the fatigue crack propagation rate was found to be the width of platelets because it was well matched with the reversed cyclic plastic zone size calculated in the threshold ΔK regime.     

Fatigue crack propagation rates and threshold stress intensity factors for welded joints of HT80 steel at several stress ratios

Fatigue crack propagation rates and threshold stress intensity factors were measured for welded joints and base metal by using 200 mm wide centre-cracked specimens. The fatigue crack propagation properties of welded joints were similar in spite of the different zones in which the cracks propagated (ie, in the heat-affected zone and in the weld metal) and the different welding process used (submerged arc welding and gas metal arc welding). They were, however, inferior to those of the base metal. It was revealed by observation of the crack closure that the fatigue cracks were fully open during the whole range of loading, due to the tensile residual stress distribution in the middle part of the welded joints. This observation also explains the lack of a stress ratio effect on the fatigue crack propagation properties of welded joints, and their inferiority to those of the base metal.     

TIG与FSW焊接工艺下2219铝合金疲劳裂纹扩展性能研究

目的 研究钨极惰性气体保护焊（TIG）和搅拌摩擦焊（FSW）对2219铝合金焊接接头疲劳性能的影响,并探究这2种不同焊接技术条件下焊接接头疲劳裂纹的产生与裂纹扩展原理,了解2种焊接接头的抗裂纹扩展能力,为工程实践应用提供数据参考。方法 采用疲劳裂纹扩展试验方法,测试上述2种焊接工艺条件下焊缝金属和热影响区组织的疲劳裂纹扩展速率da/d N和阈值,使用光学显微镜和扫描电子显微镜观察并分析金相组织和疲劳断口形貌特征。结果 疲劳裂纹倾向于沿裂纹处萌生,裂纹的存在成为主要的裂纹扩展源头,有利于加速裂纹向前延伸。热影响区由于组织结构不均匀,不同位置的晶粒尺寸存在明显差异,疲劳裂纹扩展路径倾向于沿靠近焊缝一侧向靠近母材区域扩展。TIG焊接工艺下焊缝金属和热影响区的裂纹扩展速率明显低于FSW焊接工艺下的焊缝金属和热影响区,与此同时,TIG焊接接头表现出优良的抗疲劳裂纹扩展性能。结论 通过此研究,建议2219铝合金焊接接头采用TIG焊接工艺,抗疲劳裂纹扩展效果更佳。     

The effect of microstructures on fatigue crack growth in Q345 steel welded joint

It is a traditional that the fatigue crack growth behavior is sensitive to microstructure in threshold regime, while it is sensitive to R‐ratio in Paris regime. Fatigue test is carried out for welded joints of a Q345 steel where the compact tension specimens with 3.8 and 12.5 mm thickness are used, and comparisons of fatigue crack growth behavior between base metal and a few different locations in the welded joint are considered in Paris regime. Welding residual stresses are removed by heat treatment to focus the study on the microstructural effect. It is shown that fatigue crack growth rate (FCGR) in the base metal is not sensitive to R‐ratio, but the FCGR increases in the overheated zone, the fusion zone and the weld metal zone with R‐ratio increasing. To the low R‐ratio, FCGR in the three zones is smaller than that in the base metal, but they approximate the same with base metal under the high R‐ratio. The mechanism of fatigue crack growth is analyzed through crack path in microstructures and SEM fractograph. The coarse‐grained ferrite in the base metal is of benefit to relaxation of the average stress at the crack tip, and the fatigue crack growth predicts branching and deflection within above different locations in the welded joint. These tortuous crack paths with crack branching and deflection will promote crack closure as well as crack‐tip stress shielding and then resulted in higher crack growth resistance.     

Mikrostrukturelle und mechanische Eigenschaften von laserstrahlgeschweißtem Magnesiumfeinblech AZ31‐HP mit und ohne Zusatzwerkstoffe

Microstructural and mechanical properties of laser welded sheets of magnesium AZ31‐HP with and without filler wires This paper describes Nd:YAG laser beam welding experiments carried out on rolled 2.5 mm thick magnesium sheet AZ31‐HP. For the butt welds in flat position, filler wires AZ31X and AZ61A‐F were used, diameter 1.2 mm. The microstructure and mechanical properties of the different laser beam welded joints were examined and compared with one another. The obtained results show that the laser beam welding of AZ31‐HP sheet is possible without hot crack formation, both without and with filler wires. The determined tensile strength, ductility, fracture toughness and microhardness of laser beam welded joints without filler wire were not effected by AZ31X nor AZ61A‐F. By use of these filler wires loss of zinc was minimized and the shape of weldments was optimized. The values of fracture strength, yield strength and microhardness of the joints and base material are quite similar. It is found that the ductility of the joints is lower than the base materials due to the heterogeneous microstructure of the fusion zones and geometrical notches of the weld seams. Both, weld and base material of AZ31‐HP, showed stable crack propagation. Furthermore, for base material slightly lower fracture toughness values CTOD than for the joints were determined.     

MICROSTRUCTURE AND FATIGUE PROPERTIES OF A WELDED DUPLEX STAINLESS STEEL

Abstract— In response to the increasing structural applications in duplex steels for welded structures, fatigue behaviour of a SAF 2304 grade duplex stainless steel was investigated, considering both the base metal and GTAW welded joints. Fatigue curves and fatigue limits under rotary bending fatigue were obtained. The study focused attention on the microstructural features of fatigue crack propagation of the two series of experiments, thereby permitting an evaluation of the tortuous crack path of welded joints and the mechanisms related to threshold microstructural barriers.     

Fatigue strength of mash seam welded joints

Reversed bending fatigue tests have been conducted using four series of mash seam welded joints obtained from the coupling of two different steels and plate thicknesses. Fatigue strength was evaluated and the effects of material property changes resulting from welding were studied. Fatigue strength of all series of the welded joints decreased slightly compared with that of the base steel. Type of steel and plate thickness in the welded samples exerted very little influence on fatigue strength. In the welded joints between steels with the same plate thickness, fatigue failure took place at a location away from the weld zone in the plate with the lower strength, while in the welded joints between plates of different thickness, failure occurred at the shoulder between the thin and thick plate, i.e. at the weld zone. Regardless of the type of steel and the plate thicknesses joined, fatigue strengths of the mash seam welded joints were slightly higher than those of the laser welded butt joints.     

焊接方法对铝合金焊接接头微弧氧化色差的影响

目的 分析铝合金焊接接头微弧氧化过程中色差产生的原因。方法 采用单激光和激光-MIG复合焊2种焊接方法焊接2A12铝合金,利用RGB值定性描述不同焊接试样的色差差异大小,采用金相、SEM和微区XRD观察2A12铝合金单激光和激光-MIG复合焊接头微弧氧化前后的组织、微观形貌和表面物相组成。结果 经微弧氧化处理后,2A12铝合单激光焊焊件的焊缝和母材之间无明显色差,2A12铝合金激光-MIG复合焊焊件的焊缝和母材之间存在明显色差,结合金相组织、表面和截面的SEM形貌以及表面EDS和XRD测试分析结果可知,成分和表面熔融物颗粒的大小不同是铝合金焊接接头微弧氧化色差形成的主要原因,焊接接头的组织对铝合金焊接接头微弧氧化色差的产生没有影响。结论 单激光焊接接头微弧氧化后的氧化色差较激光-MIG复合焊接头的小;铝合金(2A12)焊接接头产生氧化色差主要是因为焊接接头的成分和表面熔融物颗粒大小不同,而组织对色差无影响。     

不同强度级别双相不锈钢激光焊接头的组织与力学性能

目的 为了合理制定不同强度等级DP钢同种和异种接头的激光焊接工艺,研究激光焊接工艺对接头组织性能的影响。方法 采用SEM、硬度试验、拉伸试验等手段,研究不同强度等级DP钢同种和异种激光焊接接头的微观组织和力学性能。结果 对于同种DP钢激光焊接,由于接头各个区域经历的热循环不同,因此其马氏体体积分数和形态、含碳量等存在明显差异。在焊缝熔合区,由于冷却速度较高,因此马氏体体积分数较高且为细条状,硬度高于母材硬度。在热影响区,由于马氏体发生了回火分解,因此其硬度值低于母材硬度,且软化的程度和范围大小与DP钢的强度级别相关。软化的热影响区成为接头的薄弱区域,降低了接头的拉伸性能。在异种DP钢激光焊接接头中,焊缝熔合区的硬度也明显高于母材硬度。靠近高强度级别母材侧的热影响区范围更大,软化程度更明显,接头硬度分布不再对称。接头的抗拉强度与低等级DP钢母材的抗拉强度基本一致。结论 激光焊接工艺对不同强度等级DP钢同种和异种接头组织性能的影响存在较大的差异,DP钢强度级别越高,接头或接头对应侧的热影响区软化程度越明显,这在制定焊接工艺以及焊后处理工艺过程中需要予以考虑。     

Monotonic and Cyclic Deformation Behavior of MIG‐CMT Welded and Heat‐Treated Joints of Aluminum Cast and Wrought Alloys

While the fatigue behavior of die cast aluminum as well as welded aluminum wrought alloys have been subject of several studies, no systematic work has been carried out on hybrid structures made as a combination of welded sand castings and wrought alloys. Aim of the present study is to correlate the monotonic and cyclic deformation behavior of thin sheet welded joints with the microstructure in the heat affected zone of the material combination sand cast EN AC‐Al Si7Mg0.3 and wrought alloy EN AW‐Al Si1MgMn (EN AW‐6082). The metal sheets were welded using a metal inert gas cold metal transfer process under variation of the welding gap, the heat treatment parameters, as well as the surface finishes. It was demonstrated by Wöhler diagrams based on bending fatigue tests that the fatigue life could be increased for the welded and heat treated specimens as compared to the as‐received cast specimens. By means of optical microscopy this effect was attributed to microstructural changes due to the optimized welding and heat treatment process. A detailed analysis of the mechanical tests was possible by the application of an optical 3D strain analysis.     

Effect of welding processes on fatigue crack growth behaviour of AISI 409M ferritic stainless steel joints fabricated using duplex stainless steel fillers

The present investigation aims to study the effect of welding processes such as shielded metal arc welding (SMAW), gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) on fatigue crack growth behaviour of the ferritic stainless steel (FSS) conforming to AISI 409M grade. Rolled plates of 4 mm thickness were used as the base material and AISI 2209 grade duplex stainless steel (DSS) was used as filler metal, for preparing single pass butt welded joints. Centre cracked tensile (CCT) specimens were used to evaluate the fatigue crack growth behaviour. From this investigation, it is found that the GTAW joints showed superior fatigue crack growth resistance compared with SMAW and GMAW joints. The reasons for the superior performance were discussed in detail.     

Laser,tungsten inert gas,and metal active gas welding of DP780 steel: Comparison of hardness,tensile properties and fatigue resistance

The microstructural characteristics, tensile properties and low-cycle fatigue properties of a dual-phase steel (DP780) were investigated following its joining by three methods: laser welding, tungsten inert gas (TIG) welding, and metal active gas (MAG) welding. Through this, it was found that the size of the welded zone increases with greater heat input (MAG > TIG > laser), whereas the hardness of the weld metal (WM) and heat-affected zone (HAZ) increases with cooling rate (laser > TIG > MAG). Consequently, laser- and TIG-welded steels exhibit higher yield strength than the base metal due to a substantially harder WM. In contrast, the strength of MAG-welded steel is reduced by a broad and soft WM and HAZ. The fatigue life of laser-and TIG-welded steel was similar, with both being greater than that of MAG-welded steel; however, the fatigue resistance of all welds was inferior to that of the non-welded base metal. Finally, crack initiation sites were found to differ depending on the microstructural characteristics of the welded zone, as well as the tensile and cyclic loading.     

6009铝合金光纤激光-MIG电弧复合焊和光纤激光焊工艺对比研究

采用光纤激光-MIG 复合焊和光纤激光焊分别对6009铝合金进行焊接,研究两种焊接方式下焊接接头的成型性、显微组织、拉伸性能、显微硬度、断口形貌的不同。研究表明：激光电弧复合焊的焊接速度是激光焊接的3倍;相比于激光焊,激光电弧复合焊焊缝中心显微组织更加细小;接头的抗拉强度达到母材的63%以上,而激光焊接的抗拉强度仅仅只有母材的38%;显微硬度试验表明：复合焊存在软化区,而激光焊接几乎没有软化区;断口分析表明：复合焊和激光焊的拉伸断口都是典型的韧窝状态,但是复合焊接的韧窝更加均匀。     

The Effects of Electrode Force on the Mechanical Behaviour of Resistance Spot‐Welded 5083‐O Aluminium Alloy Joints

Abstract: In this study, the effects of electrode force on the static and fatigue strength of spot welded joints of 5083‐O aluminium alloy sheets were investigated. The thickness of the sheet joints was 1.5 mm. Tensile‐shear joints with one spot weld were considered and three different load levels for electrode force were selected as 2500 N, 3000 N and 3500 N while the welding time and electric current were fixed during resistance spot welding process. Also, micro‐structures and micro‐hardness of cross‐sectional area of the test samples were investigated. The results show that increasing the electrode force from 2500 N to 3000 N has no major impact on the nugget size and fatigue strength of the specimens, but increasing the electrode force from 3000 N to 3500 N, despite reducing in the diameter of the nuggets, increases the fatigue life of the joints significantly. The results also indicate that increasing the electrode force increases the life associated with the crack initiation phase of total fatigue lifetime.     

Effect of Notch Location on Fatigue Life Prediction of Strength Mismatched HSLA Steel Weldments

Welding of high strength low alloy steels (HSLA) involves usage of low, even and high strength filler materials (electrodes) than the parent material depending on the application of the welded structures and the availability of the filler material. In the present investigation, the fatigue crack growth behaviour of weld metal (WM) and heat affected zone (HAZ) regions of under matched (UM), equal matched (EM) and over matched (OM) joints has been studied. The base material used in this investigation is HSLA-80 steel of weldable grade. Shielded metal arc welding (SMAW) process has been used to fabricate the butt joints. Centre cracked tension (CCT) specimen has been used to evaluate the fatigue crack growth behaviour of the welded joints. Fatigue crack growth experiments have been conducted using servo hydraulic controlled fatigue testing machine at constant amplitude loading (R=0). A method has been proposed to predict the fatigue life of HSLA steel welds using fracture mechanics approach by incorporatin     

Microstructure and tensile properties of laser beam welded Ti–22Al–27Nb alloys

Ti–22Al–27Nb alloys were welded using the laser beam welding process. The microstructure characterization and the tensile properties of the laser beam welded joints were investigated. The experimental results showed that a well-quality joint could be obtained using laser beam welding method. The fusion zone of the welded joint was composed of B2 phase. The tensile strength of the joints at room temperature was basically comparable to that of the base metal and the tensile ductility of the joints achieved 56% of the base metal. The average tensile strength of the welded joints at 650 °C was tested to be about 733 MPa, with the elongation of 2.93%.     

钛/铝异种合金脉冲激光焊接接头裂纹产生机理

目的 对0.8 mm厚的Ti6Al4V钛合金和2 mm厚的AA6060铝合金薄板进行脉冲激光焊接,分析异种轻合金激光焊接裂纹产生的机理及界面结合机理。方法 采用扫描电镜、EDS能谱以及显微硬度计等微观表征分析方法,对焊接接头的形貌特征、成分以及显微硬度进行分析,探索焊接接头处裂纹产生的原因。结果 钛/铝脉冲激光焊接性较差,接头存在严重的裂纹缺陷,裂纹多集中在焊缝与铝母材交界处以及焊缝中心区域位置,主要以热裂纹为主;接头焊缝可能存在大量的Ti-Al金属间化合物以及少量未熔的钛,其界面层主要成分推测为层状TiAl和外层锯齿状的TiAl3;接头整个焊缝区域的平均显微硬度为HV0.1420,其硬度水平远远高于焊缝两侧铝合金母材,也高出钛合金母材很多。结论 钛铝金属间化合物使钛铝焊接接头焊缝区脆性增大,另外接头焊缝区存在较大的组织应力、热应力、拉压应力、拘束应力等复杂应力,致使焊缝内存在较严重的裂纹缺陷。     

高低温循环试验下磁脉冲焊接接头性能研究

磁脉冲焊接是一种高效的固相焊接工艺,对异种金属材料在汽车轻量化中的运用具有积极意义.通过对5052Al/HC420LA板件磁脉冲焊接接头进行不同条件下的高低温循环试验,对比焊接接头在高低温循环试验前后的力学性能变化,研究了高低温循环冷却方式、循环次数对焊接接头性能的影响.利用扫描电子显微镜(SEM)研究了焊接接头微观形貌特征,分析了高低温循环试验前后焊缝微观界面的特征及其变化.研究表明：不同高低温循环试验条件下5052Al-HC420LA铝-钢磁脉冲焊接接头的连接强度相比于5052铝合金的母材强度下降了5%~25%;冷却速度越快,高低温循环次数越多,接头力学性能下降越明显;接头在高低温循环试验前后出现了母材失效与焊缝失效两种剪切失效模式;水冷冷却的接头比空冷冷却更易产生微观裂纹.     

Fatigue behaviour of laser repairing welded joints

This paper presents a fatigue study in Nd-YAG laser surface repairing welded joints in specimens of two base materials used in mould production. The tests were carried out in a servo-hydraulic machine in tension, under constant amplitude loading, with two stress ratios R = 0 and R = 0.4. Welded specimens were prepared with U notches and filled with laser welding deposits. The fatigue results are presented in the form of S–N curves obtained in welded and non-welded conditions. Complementary measurements of hardness and residual stresses profiles were carried out along the surface of laser welded specimens to understand the observed fatigue behaviour. The melted material was the weaker region, with lower values of hardness and higher tensile residual stresses, presenting also a high number of defects that are potential failure sites. The presence of such defects can explain the relatively poor fatigue strength of the laser repairing joints in comparison to base materials.