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。     

热成形淬火对QP1180/22MnB5激光拼焊板组织与性能的影响

目的 对QP1180和22MnB5激光拼焊板进行热成形试验,以解决超高强钢板材焊后的软化问题。方法 选择QP1180和22MnB5异种高强钢作为母材进行激光自熔焊,对焊后的激光拼焊板进行热成形试验,通过体式显微镜、扫描电子显微镜、液压拉伸试验机和维氏硬度计等手段,分析热成形前后激光拼焊板微观组织和力学性能的变化。结果 与焊态拉伸试样相比,热成形试样抗拉强度提高了135%,断后伸长率降低了55%,拉伸试样都在22MnB5母材处断裂,均为塑性断裂。在热成形后,对焊接接头进行组织分析,发现QP1180母材区马氏体含量增加,22MnB5母材区和临界热影响区组织由珠光体和铁素体转变为马氏体,焊接接头热影响区各亚区的组织均转变为大小不同的板条马氏体。硬度测试结果表明,焊态试样焊接接头的QP1180临界区存在软化现象,硬度值最低为335HV,22MnB5侧硬度值由母材处向焊缝升高,母材硬度最低为170HV;而在热成形后,QP1180临界区软化现象消失,硬度值趋于平缓,22MnB5母材处硬度比焊态试样硬度高了2倍。结论 与焊态试样相比,经热成形后激光拼焊板的焊后软化问题得到了解决。     

车用DP600和DC54D涂胶与未涂胶电阻点焊研究

对异种钢不同板厚涂胶与未涂胶DP600双相钢和超低碳DC54D电阻点焊进行了研究。深入分析了不同焊接时间下焊接接头显微组织、显微硬度、拉剪性能及扫描断口。研究结果表明,随着焊接时间的延长,焊点直径增大。当焊接时间为2周波时,热影响区为"半月形",延长焊接时间,熔核形状由"蝶形"转变为"椭型"。由于DC54D对熔核区碳含量的稀释作用,熔核区显微硬度低于热影响区硬度。拉伸-剪切试验中,当焊接时间为13-19周波时,涂胶与未涂胶接头拉剪强度趋于稳定。未涂胶接头的最大拉剪强度为5.45kN,涂胶接头的最大拉剪强度为5.15kN。当焊接电流为9kA、电极压力为2.6kN、焊接时间为13-19周波时,涂胶的焊接接头能得到优异的力学性能,但是比未涂胶接头略差。未涂胶与涂胶接头断裂均发生在DC54D侧。     

DP1180汽车用双相钢连续冷却转变过程中的相变规律

为研究DP1180汽车用双相钢连续冷却转变过程中的相变特性,对不同冷却速率下的DP1180双相钢试样进行了金相检验及显微硬度测试,绘制了该双相钢的连续冷却转变曲线,并分析了DP1180钢在连续冷却过程中的相变规律.结果表明:对于DP1180汽车用双相钢,其连续冷却转变曲线分为铁素体转变区、贝氏体转变区和马氏体转变区.当...     

旋转速度对高强度钢Q&P980搅拌摩擦焊接头组织与性能的影响

为了促进高强度钢在汽车领域的应用,解决高强度钢在采用常规熔化焊进行焊接时出现的问题,利用搅拌摩擦焊接技术对1. 2 mm厚的高强度钢QP980进行焊接试验,并利用激光共聚焦显微镜、扫描电子显微镜、万能试验机和显微硬度计等手段研究旋转速度对高强度钢QP980搅拌摩擦焊接头的微观组织和力学性能的影响。研究发现,在不同旋转速度下均获得了没有缺陷的焊缝,接头组织呈典型的"碗状"组织形貌。旋转速度为200 r/min时,接头搅拌区组织仍为马氏体与铁素体组织,但晶粒尺寸相比母材明显细化且马氏体含量相比母材增多。随着旋转速度的提高,马氏体含量会继续增多,旋转速度为400 r/min时搅拌区组织基本全部为马氏体组织,旋转速度为600 r/min时搅拌区组织为马氏体和贝氏体的混合组织。接头显微硬度结果显示,搅拌区的硬度明显高于母材,搅拌区与母材之间存在一个软化区。旋转速度为400 r/min时,接头抗拉强度最高,达到1 070MPa,为母材的99%,基本等同于母材的抗拉强度;接头的断后伸长率为11. 2%,达到母材的50%。旋转速度为200 r/min时,接头断裂于搅拌区,其他旋转速度下接头均断裂于软化区,断裂于软化区的断口形貌呈现韧性断裂特征。     

Q960E超高强钢焊接接头组织和性能研究

目的 对Q960E超高强钢的焊接工艺进行研究以获得高强高韧的焊接接头。方法 选择超高强钢Q960E作为母材、FK1000ER120S–G焊丝作为填充材料进行MAG焊,采用改变焊接电流的方式来研究焊接热输入对焊接接头组织和性能的影响。结果 当焊接电流为155～230 A时,均获得了全焊透无明显缺陷的焊缝。随着焊接热输入的增大,焊接接头中各亚区宽度增大,其中焊缝区变化最为显著,在最小热输入条件下焊缝宽度为3.98 mm,在最大热输入条件下焊缝宽度增至5.53 mm。对焊接接头进行组织分析发现,焊缝组织主要为针状铁素体和板条马氏体;完全相变区组织主要为板条马氏体;未完全相变区组织主要为回火马氏体和部分重结晶形成的马氏体。硬度测试表明,在热影响区的回火区发生了软化现象,最低硬度仅为290HV;在完全相变区发生了硬化现象,硬度最大值可达500HV。在不同热输入条件下,焊接接头各亚区硬度变化趋势一致,焊接接头抗拉强度为995～1 076 MPa,拉伸试验均断裂在热影响区,断后伸长率为9.33%～10.21%,断裂时存在颈缩现象,为韧性断裂。随着热输入的增加,粗晶区马氏体板条束宽度增大,未完全相变区...     

Q&P980镀锌高强钢电阻点焊工艺及液态金属脆化裂纹分布EI北大核心

通过设计电阻点焊工艺的正交实验,确定了Q&P980镀锌高强钢的点焊工艺参数范围,并对其焊接接头进行显微组织表征和力学性能分析。结果表明:熔核区组织以交错分布的板条马氏体为主;热影响区组织由板条马氏体、残余奥氏体和铁素体组成,马氏体板条平均宽度在不完全淬火区最大为4.86μm。显微硬度测试发现,焊接接头硬度值呈“W”形对称分布,硬度峰值出现在细晶区,达到559HV,硬度最低值出现在不完全淬火区,为338HV,呈现明显的软化现象。对焊接接头进行室温拉伸,最大拉剪载荷的峰值为27.92 kN,其断口形貌呈现典型的韧窝状,属于韧性断裂。由于Zn的熔点较钢基体低,镀锌高强钢点焊时易发生Zn层优先熔化并沿晶界向基体渗透,在焊接接头处可观察到明显的液态金属脆化裂纹。     

TC1 电阻微焊接接头显微组织及力学性能

目的 研究不同工艺参数（焊接电流、焊接时间）对金属箔材精密电阻微焊接头机械性能的影响。方法 采用电阻微焊接技术对0.05 mm 厚的TC1 箔材进行点焊连接试验,通过拉伸-剪切试验对焊接接头进行力学性能检测,利用硬度网格法结合金相观察,对焊接不同区域进行有效预测。结果 当焊接电流为400 A时,焊核直径随着焊接时间的增加而明显增大,而采用更高的焊接电流时,焊接时间对焊接直径没有显著影响。焊点接头的剪切力随着电流的增大而增大;在所有参数条件下,过长焊接时间都造成了焊点接头剪切力不同程度的减小。此外,由于微观组织的变化,不同焊接区域显现出不同硬度值,其中焊核硬度>母材硬度>热影响区硬度。结论 焊接电流对TC1 电阻微焊接接头力学性能影响较大;硬度网格法可以有效预测焊接不同区域。     

电弧电流对AZ31B/DP980激光诱导电弧焊接接头成形及力学性能的影响

采用激光诱导钨极惰性气体保护(tungsten inert gas, TIG)电弧焊接技术,在未添加任何夹层和镀层的条件下,通过优化工艺,获得了AZ31B镁合金和DP980高强钢高质量搭接焊接头,重点研究TIG电弧电流对焊接接头成形和力学性能的影响规律。结果表明：电弧电流的增大会提高镁合金在高强钢的润湿铺展能力,提升焊缝宽度的同时减小润湿角。镁合金/钢焊接接头的最大拉伸载荷随着电弧电流的增大先升高后降低,接头断裂模式由沿界面断裂转变为沿焊缝断裂。当TIG电流为80 A、激光功率为350 W时,焊接接头最大平均拉伸载荷达到279 N/mm。焊缝宽度和界面层厚度的增大以及激光匙孔的钉扎作用共同提升了镁合金/钢的接头性能。     

DP780高强钢胶接点焊的多元非线性回归模型

基于Box-Behnken Design(BBD)设计方法,开展DP780高强钢胶接点焊的试验研究。以接头的失效载荷、熔核直径为目标量,将焊接电流、焊接时间、电极压力以及各参数之间的交互作用作为影响目标量的因素,建立DP780高强钢胶接点焊接头多元非线性回归模型。试验验证表明,建立的多元非线性回归数学模型具备高的显著性且拟合程度高,可实现对接头失效载荷、熔核直径的有效预测;胶焊接头的失效载荷、熔核直径随焊接电流增大及焊接时间的延长而增大,随电极压力的减小而递增;基于回归模型获得最优工艺参数:焊接电流8.3 kA,焊接时间150 ms,电极压力0.3 MPa,对应参数下接头的失效载荷达到16 369 N。借助超声C扫图像甄别出焊核外存在胶层烧灼气化区,当焊接时间较短时,焊接电流的增加会提供更多的热输入量,导致胶层烧灼气化面积增大,进而降低接头的静力学性能。     

DP590双相钢点焊接头的正交试验及超声检测分析

对DP590双相钢点焊接头进行正交试验,研究不同工艺因素对点焊接头失效载荷和焊核直径的影响,确定最优点焊工艺参数,并探讨点焊接头压痕深度的超声测量方法.采用超声波水浸聚焦入射法对1.5 mm厚的DP590双相钢点焊接头进行超声C扫描,获得接头焊核直径,利用超声A扫信号,计算点焊接头压痕深度,并与实际测量结果对比.研究表明:焊接参数对DP590点焊接头的失效载荷与焊核直径的显著性影响一致,从大到小依次为焊接电流、焊接时间、电极压力;DP590点焊接头最优的焊接工艺参数为:焊接时间70 ms,焊接电流15.0 k A,电极压力6.5 k N,在此参数下接头的抗拉强度为9 521.4 N;超声A扫信号计算得到的点焊接头表面压痕率与实际压痕率的误差在2.5%~9.7%,超声计算所得压痕深度与实际测量压痕率较为接近.     

Resistance spot welding macro characteristics of the dissimilar thickness dual phase steels

In the present work, macro characteristics of the dissimilar thickness dual phase steel resistance spot welding joints were described in terms of melting rate, indentation rate, nugget diameter and indentation diameter. The results revealed that the melting rate of the DP600 side was higher than that of the DP780 side and the indentation rate of the DP600 side was lower than that of the DP780 side of the welded joints. The base metal lap order had the important effect on nugget diameter, and the DP780/DP600 spot welded joints tended to get the larger nugget diameter than DP600/DP780 spot welded joints with the same process parameters. The indentation diameters of DP600 and DP780 sides depended on the electrode geometry and force.     

Failure analysis of dissimilar thickness resistance spot welded joints in dual-phase steels during tensile shear test

Investigating the failure mode and failure mechanism of the dissimilar thickness dual phase sheets resistance spot welding joints was the objective of this study. Three distinct failure modes were observed during the tensile shear test: interfacial, partial interfacial and pullout failure. The results of the stress analysis of welded joints show that the tensile stress leads to the interfacial failure and the shear stress leads to the pullout failure. Due to more serious stress concentration and heat affected zone (HAZ) softening of DP780 side, the fracture is initiated from the DP780 steel.     

Dissimilar Resistance Spot Welding of Q&P and TWIP Steel Sheets

Dissimilar resistance spot welding of twinning induced plasticity (TWIP) and quenching and partitioning (Q&P) steel grades has been investigated by evaluating the effects of clamping force, welding current, and welding time on the microstructure, shear tension strength, and fracture of welded samples. The spot welding of TWIP and Q&P steels promotes the occurrence of an asymmetrical weld nugget with a greater dilution of TWIP steel because of its lower melting temperature and thermal conductivity. As a result, weld nuggets exhibit an austenitic microstructure. TWIP steel undergoes a grain coarsening in the HAZ, whereas Q&P steel undergoes some phase transformations. Welded samples tend to exhibit higher shear tension strength as they are joined at the highest welding current, even though an improper clamping force can promote excessive metal expulsion, thereby reducing the mechanical strength of the welded joints. Shear tension welded samples failed through interfacial fracture with partial thickness fracture mode for a low welding current, while partial thickness with button pull fractures were observed when a high welding current was used. The weld spots predominantly failed at the TWIP side. However, as TWIP steel can work harden significantly in the more resistant welded joints, the failures occur, instead, at the Q&P side.     

Nucleus geometry and mechanical properties of resistance spot welded coated–uncoated DP automotive steels

In this study, mechanical properties of resistance spot welding of DP450 and DP600, galvanized and ungalvanized automotive sheets have been investigated. The specimens have been joined by resistance spot welding at different weld currents and times. Welded specimens have been examined for their mechanical, macrostructure and microstructure properties. Depending on the weld current and time, effects of zinc coating on tensile properties, microhardness values as well as microstructure nugget geometry and nucleus size ratio have been investigated. X-ray diffraction analysis has been used to investigate the phase that formed at the joint interface. Result of the experiment show that nugget diameter, indentation depth and tensile load-bearing capacity are affected by weld parameters. Coating prevents full joining at low parameters. Microhardness increased in heat-affected zone and weld metal.     

The effects of the welding current on heat input,nugget geometry,and the mechanical and fractural properties of resistance spot welding on Mg/Al dissimilar materials

Investigating the joining capability of magnesium AZ31 alloy sheets and aluminium 1350 alloy sheets with the application of resistance spot welding was the objective of this study. The weld current values used in the welding process of Al–Mg sheets were 22, 23, 25, 27, 29, 31, and 33 kA. The studies examined the nugget geometries of joined specimens, recorded the scanning electron microscopy (SEM) images of the welded zone and the fracture surface, and recorded the energy-dispersive spectroscopy (EDS, semi-quantitative) analyses. The results of the experiment confirmed that nugget geometry was different for the Al and Mg sides. Tensile shear tests carried out on the welded joints determined their strength and failure mode. The increase in the weld current and duration resulted in an increase in the nugget size and the weld strength. According to observations, the tensile load bearing capacity (TLBC) increased up to 29 kA of the weld current value. It was also found that tearing during fracture occurred in two different ways.     

Modeling of resistance spot welding of multiple stacks of steel sheets

Weld quality is a major challenge for resistance spot welding of multiple stacks of steel sheets. Because of the differences in mechanical and physical properties of steel sheets and the sheet gage variation, the contact state between sheets and welding current flow throughout the stack joint is complicated. As a result, discrepant weld sizes at the faying interfaces become an issue. In this study, a coupled thermal–mechanical/thermal–electrical incremental model has been developed to reasonably predict the weld nugget formation process of resistance spot welding of a sheet stack made of 0.6 mm thick galvanized SAE1004+1.8 mm thick galvanized SAE1004+1.4 mm thick galvanized dual-phase (DP600) steel using published thermal, electrical, and mechanical properties. It was found that the weld nugget on the faying interface of DP600 forms earlier than that on the other interface, which agrees well with the experimental results. Based on the coupled model, the effects of the sheet gage combination and steel grade combination were examined. The results show that, for a multiple stacks of steel sheets SAE1004 + SAE1004 + DP600, the critical ratio of sheet thickness between the top and bottom sheets is approximately 1:3. The model could provide an important guidance in the selection of the welding variables, sheet gage and steel grade to meet the weld quality of steel component.