7075铝合金高速搅拌摩擦焊材料流动行为及性能研究

目的 针对7075–O铝合金高焊速、高转速搅拌摩擦焊接缺陷多、质量差等问题,研究焊接接头材料流动对焊缝性能的影响。方法 选用焊接速度1 000 mm/min,搅拌转速分别为1 000、1 200、1 600、1 700 r/min的条件对7075–O铝合金板进行搅拌摩擦焊接,分析不同焊接工艺参数下焊接接头的显微组织及力学性能。同时,利用Fluent软件模拟7075–O铝合金搅拌摩擦焊接过程中的材料流动场分布,分析焊接材料流动与缺陷形成的关系。结果 利用7075–O铝合金三维流动模型,预测出高焊速条件下焊缝前进侧形成一个低压区,孔洞等缺陷易出现在此区域,数值模拟预测与试验结果吻合。在高焊接速度1 000 mm/min、焊接转速1 200 r/min时,焊缝表面光滑平整,焊核区域的硬度分布更加均匀。结论 随着搅拌转速从1 000 r/min增大到1 700 r/min,热输入量逐渐增大,孔洞缺陷由隧道型孔洞转变为不连续的小孔。同时,随着搅拌转速的增大,焊缝高硬度区域的宽度先增大而后降低。当搅拌转速为1 200 r/min时得到了优质的焊接接头,焊缝焊核区硬度分布均匀,硬度值最高为176HV。     

铝合金超声辅助搅拌摩擦焊接接头组织性能研究

目的探究超声振动对铝合金搅拌摩擦焊的作用效果。方法分别采用普通搅拌摩擦焊和超声辅助搅拌摩擦焊方法,对7075铝合金进行焊接试验,并对焊接接头的微观组织、力学性能、断口形貌进行分析。结果普通搅拌摩擦焊焊缝中生成了隧道型缺陷,施加超声振动后,缺陷消失,形成了无缺陷的良好接头,且与普通搅拌摩擦焊相比,超声辅助搅拌摩擦焊焊缝热影响区晶粒长大程度较小,焊核晶粒细化。接头强度明显提高,达到铝合金母材强度的71.5%,接头断裂模式为韧窝和准解理的混合断裂形式。结论超声振动促进了塑性金属的流动,能有效抑制孔洞、隧道型缺陷等的形成,同时超声振动能在提升金属塑性的同时,降低焊缝的热输入。     

6082-T6回填式搅拌摩擦点焊热-流耦合分析

为了解释了回填式搅拌摩擦点焊的连接机理,本文根据6082-T6铝合金回填式搅拌摩擦点焊焊接过程的特点,建立了简化的热源模型,利用有限元分析软件ANSYS模拟出焊接过程中的温度场,进而耦合得到其应力场.结果表明:随着焊接过程的进行,铝合金6082-T6最高温度分布在袖筒1/2处,焊点处粘塑性金属的最大流动速度出现在铝合金上表面袖筒内侧区域;通过分析模拟过程中流体流动的流线与试验测量所得接头形貌照片,得到流场的分布规律.     

Effect of welding parameters on microstructure and mechanical properties of friction stir welded joints of AA7039 aluminum alloy

A high strength Al–Zn–Mg alloy AA7039 was friction stir welded by varying welding and rotary speed of the tool in order to investigate the effect of varying welding parameters on microstructure and mechanical properties. The friction stir welding (FSW) process parameters have great influence on heat input per unit length of weld, hence on temperature profile which in turn governs the microstructure and mechanical properties of welded joints. There exits an optimum combination of welding and rotary speed to produce a sound and defect free joint with microstructure that yields maximum mechanical properties. The mechanical properties increase with decreasing welding speed/ increasing rotary speed i.e. with increasing heat input per unit length of welded joint. The high heat input joints fractured from heat affected zone (HAZ) adjacent to thermo-mechanically affected zone (TMAZ) on advancing side while low heat input joints fractured from weld nugget along zigzag line on advancing side.     

Dissimilar titanium/aluminum friction stir welding lap joints by experiments and numerical simulation

Dissimilar lap joints were produced by friction stir welding (FSW) out of Ti6Al4V titanium alloy and AA2024 aluminum alloy sheets. The joints, welded with varying tool rotation and feed rate, were studied by analyzing the maximum shear strength, Vickers microhardness and optical observations. A dedicated numerical model, able to take into account the presence of the two different alloys, was used to highlight the effects of the process parameters on temperature distribution, strain distribution, and material flow. The combined analysis of experimental measurements and numerical predictions allowed explaining the effects of tool rotation and feed rate on the material flow. It was found that tool rotation had a larger impact on the joint effectiveness with respect to feed rate. A competition between material mixing and heat input occurs with increasing tool rotation, resulting in higher joint strength when lower values of tool rotation are used.     

螺纹搅拌针直径对铝/钢填丝搅拌摩擦焊接头组织及性能的影响

目的 采用填丝搅拌摩擦焊方法 ,研究螺纹搅拌针直径对6061铝合金/304不锈钢搅拌摩擦焊接接头组织及性能的影响.方法 通过使用3种不同直径的螺纹搅拌头,观察不同结构搅拌头对焊缝成形及接头微观形貌的演变规律,并对其进行力学性能测试,研究搅拌头结构对接头性能强化的影响.结果 随着螺纹搅拌针直径由M4增加到M6,焊缝表面成形逐渐粗糙,同时在接头焊缝中易产生大尺寸钢屑;另外,随着螺纹搅拌针直径的增加,接头界面处容易生成HOOK缺陷,同时在界面附近区域易出现钢屑的聚集;接头的抗拉强度随螺纹搅拌针直径的增加,呈明显下降的趋势.当螺纹搅拌针直径为M4时,接头的抗拉性能达到最大值156 MPa.结论 通过采用直径为M4的螺纹搅拌头,能够获得具有最优综合性能的接头.     

2219铝合金搅拌摩擦焊接头组织和性能的不均匀性研究

目的 针对2219铝合金搅拌摩擦焊接头受焊接热作用和机械搅拌作用的影响,极易产生组织和力学性能不均匀的情况,深入研究接头的局部力学性能,为焊接工艺优化提供理论指导.方法 采用显微组织分析与数字图像相关(DIC)技术测试相结合的方法,对2219铝合金搅拌摩擦焊接头的组织和局部力学性能进行表征,并建立搅拌摩擦焊接头各区域的局部力学性能模型.结果 2219铝合金搅拌摩擦焊接头的力学性能薄弱区为热机影响区.试样断裂前该区域局部应力达到345 MPa,局部应变为18.9％,而此时母材应变仅为1.91％.结论 热机影响区的组织在焊接热作用和机械搅拌的双重作用下发生了粗化和软化,导致该区的力学性能降低,是整个焊接接头的薄弱区域.     

On the effect of tool offset in hybrid-FSW of copper-aluminium alloy

Tool offset is one the most significant parameters in joining of dissimilar materials by friction stir welding (FSW) process. An investigation is carried out on the effect of tool offset toward thermal history, material flow pattern, mechanical properties, welding force, and weld joint morphology. It was found that offsetting toward aluminum side along with a plasma-assisted heat source is an efficient approach to address one of the most important apprehensions in aluminum-copper solid-state welding process. The offset influences the amount of intermetallic at the joint interface and in-effect impacts on final strength and material flow behavior. The optimum and continuous layer of intermetallic produces the maximum weld joint strength. The specimen welded with optimum tool offset shows the highest strength using 55 A plasma current in hybrid friction stir welding process.     

铝合金搅拌摩擦焊接头隧道型缺陷研究

焊接热输入不足导致铝合金搅拌摩擦焊接头中常出现隧道型缺陷，本文通过产热分析发现：选择与被焊材料摩擦系数斗较大的材料作为搅拌头制造材料；在圆柱体搅拌头的指头上制造螺纹提高焊接产热；提高旋转速度或者降低焊接速度来提高焊接线能量；减小搅拌指头半径r1是改善和消除隧道型缺陷的4种有效途径。     

Mechanical properties of friction stir butt‐welded Al‐5086 H32 plate

Al‐5086 H32 plates with a thickness of 3 mm were friction stir butt‐welded using different welding speeds at a tool rotational speed of 1600 rpm. The effect of welding speed on the weld performance of the joints was investigated by conducting optical microscopy, microhardness measurements and mechanical tests (i.e. tensile and bend tests). The effect of heat input during friction stir welding on the microstructure, and thus mechanical properties, of cold‐rolled Al‐ 5086 plates was also determined. The experimental results indicated that the maximum tensile strength of the joints, which is about 75 % that of the base plate, was obtained with a traverse speed of 200 mm/min at the tool rotational speed used, e.g. 1600 rpm, and the maximum bending angle of the joints can reach 180^o. The maximum ductility performance of the joints was, on the other hand, relatively low, e.g. about 20 %. These results are not unexpected due to the loss of the cold‐work strengthening in the weld region as a result of the heat input during welding, and thus the confined plasticity within the stirred zone owing to strength undermatching. Higher joint performances can also be achieved by increasing the penetration depth of the stirring probe in butt‐friction stir welding of Al‐5086 H32 plates.     

铝基复合材料搅拌摩擦焊搅拌头设计

文中介绍了铝基复合材料搅拌摩擦焊搅拌头材料选择和结构设计方案。根据铝基复合材料复杂的微观和宏观结构,选定钢结硬质合金GT35制造搅拌头,并与选用工具钢制作的普通搅拌头进行对比。对比结果表明,普通搅拌头焊后磨损严重,焊缝质量较差。对搅拌头形状和尺寸进行了设计：最初的“一字凹凸槽”设计存在不同心德患,给加工制造造成困难;后改为分体式搅拌头,采用螺纹连接。采用这种搅拌头能得到表面光滑,宏观形貌良好的接头。     

Microstructure and mechanical properties of spray formed 7055 aluminum alloy by underwater friction stir welding

Ultra-high strength spray formed 7055 aluminum alloy in which Zn is supersaturated solid solution requires strict control of heat input in welding process. In this paper, underwater friction stir welding is carried out in order to reduce heat input comparing with traditional friction stir welding and further improve the joint performances by varying welding temperature history. Through comparing the thermal cycle curves and distribution of residual stress of the plate welded in different media, the reason why the joint welded underwater shows a better performance is figured out. The result shows that tensile strength, hardness and plasticity of underwater welded joint are better than that welded in air. The underwater joint has a fine grained microstructure without “S line” defect, a typically distinct boundary between the weld nugget zone and the thermal mechanically affected zone and a narrow heat affected zone. The main strengthening phase in underwater joint is MgZn₂ .     

Evaluation of the microstructure and mechanical properties of friction stir welded 6005 aluminum alloy

Abstract

The microstructural change related with the hardness profile has been evaluated for friction stir welded, age hardenable 6005 Al alloy. Frictional heat and plastic flow during friction stir welding created fine and equiaxed grains in the stir zone (SZ), and elongated and recovered grains in the thermomechanically affected zone (TMAZ). The heat affected zone (HAZ), identified only by the hardness result because there is no difference in grain structure compared to the base metal, was formed beside the weld zone. A softened region was formed near the weld zone during the friction stir welding process. The softened region was characterised by the dissolution and coarsening of the strengthening precipitate during friction stir welding. Sound joints in 6005 Al alloys were successfully formed under a wide range of friction stir welding conditions. The maximum tensile strength, obtained at 507 mm min^-1 welding speed and 1600 rev min^-1 tool rotation speed, was 220 MPa, which was 85% of the strength of the base metal.     

Microstructure and mechanical properties of mild steel joints prepared by a flat friction stir spot welding technique

With the successful application of the flat spot friction stir welding technology to aluminum alloys, this technique was expanded to the spot lap welding of 1 mm thick mild steel in this study. It reveals that sound joints can be successfully obtained with smooth surfaces and without any internal welding defects. Two welding strategies based on the welding parameter can be used to obtain the welds that fracture through plug failure mode at high shear tensile strength. One way is to weld the sheet at low heat input in the first step and the second step is used to generate large stir zone and flatten the sample surface. However, the microstructure in the stir zone is not homogeneous and a coarse columnar grain structure forms at the bottom of the stir zone. Another way is to make the stir zone penetrate into the lower sheet during the first step and the second step is only aimed to flatten the sample surface. In this case, the total heat input can be reduced and the microstructure of the stir zone can be remarkably refined. The sound joints fractured along the circumstance of the stir zone and reached about 6600 N during the shear tensile tests.     

Joint properties of dissimilar Al6061-T6 aluminum alloy/Ti–6%Al–4%V titanium alloy by gas tungsten arc welding assisted hybrid friction stir welding

Hybrid friction stir butt welding of Al6061-T6 aluminum alloy plate to Ti–6%Al–4%V titanium alloy plate with satisfactory acceptable joint strength was successfully achieved using preceding gas tungsten arc welding (GTAW) preheating heat source of the Ti alloy plate surface. Hybrid friction stir welding (HFSW) joints were welded completely without any unwelded zone resulting from smooth material flow by equally distributed temperature both in Al alloy side and Ti alloy side using GTAW assistance for preheating the Ti alloy plate unlike friction stir welding (FSW) joints. The ultimate tensile strength was approximately 91% in HFSW welds by that of the Al alloy base metal, which was 24% higher than that of FSW welds without GTAW under same welding condition. Notably, it was found that elongation in HFSW welds increased significantly compared with that of FSW welds, which resulted in improved joint strength. The ductile fracture was the main fracture mode in tensile test of HFSW welds.     

纯铝板搅拌摩擦焊温度场数值模拟

建立了搅拌摩擦焊热源模型,利用有限元分析软件ABAQUS模拟了搅拌摩擦焊的温度场,研究了焊接速度、搅拌头轴肩尺寸和垫板材质对搅拌摩擦焊接过程中试板的温度场的影响。结果表明：随着焊接速度的提高,焊件上各点的峰值温度降低,经历高温区的时间减少;轴肩摩擦热是热输入的主要来源,随着搅拌头轴肩尺寸的增加,焊缝中心高温区同一等温线上宽下窄的分布特征越来越明显;垫板材质明显影响焊件底部的温度和分布;适当的焊接参数、搅拌头尺寸及散热条件对获得较好的焊缝质量极为重要。     

水下搅拌摩擦焊对铝/铜接头组织与性能的影响

目的 采用搅拌摩擦焊,对比分析大气环境和水下环境下铝/铜接头的组织与性能,以期获得力学性能更优异的铝/铜焊接接头。方法 利用搅拌摩擦焊,在焊接速度为40 mm/min、旋转速度为1 000 r/min的条件下,分别在大气环境和水下环境下对厚度为9 mm的6061铝合金板和T2纯铜板进行焊接。然后,对铝/铜界面、焊核区进行扫描电镜及能谱分析,并对铝/铜界面及焊核区进行物相分析,确定产物相组成。最后,对铝/铜试样进行拉伸及硬度检测。结果 铝/铜接头均无裂纹、气孔等缺陷。铜颗粒弥散分布在焊核区,铝/铜界面形成金属间化合物层。水下搅拌摩擦焊下界面元素扩散距离明显变短,且金属间化合物厚度更薄。铝/铜接头的金属间化合物为AlCu和Al4Cu9。大气环境焊接下接头的抗拉强度为130.6 MPa,断裂方式为脆性断裂;水下焊接下接头的抗拉强度为199.5 MPa,断裂方式为韧性断裂。水下环境下的接头硬度值更高,其中热影响区的硬度最低值约为65HV。结论 水下搅拌摩擦焊铝/铜接头无裂纹、气孔等缺陷。组织上,水下搅拌摩擦焊的铝/铜接头界面元素扩散距离更短,硬脆的金属间化合物更少;性能上,水下搅拌摩擦焊的铝/铜接头强度更高,抗拉强度达到199.5 MPa,达到母材的74.4%。     

Friction stir welding for the transportation industries

This paper will focus on the relatively new joining technology—friction stir welding (FSW). Like all friction welding variants, the FSW process is carried out in the solid-phase. Generically solid-phase welding is one of the oldest forms of metallurgical joining processes known to man. Friction stir welding is a continuous hot shear autogenous process involving a non-consumable rotating probe of harder material than the substrate itself. In addition, FSW produces solid-phase, low distortion, good appearance welds at relatively low cost. Essentially, a portion of a specially shaped rotating tool is plunged between the abutting faces of the joint. Once entered into the weld, relative motion between the rotating tool and the substrate generates frictional heat that creates a plasticised region around the immersed portion of the tool. The contacting surface of the shouldered region of the tool and the workpiece top contacting surface also generates frictional heat. The shouldered region provides additional friction treatment to the weld region as well as preventing plasticised material being expelled. The tool is then translated with respect to the workpiece along the joint line, with the plasticised material coalescing behind the tool to form a solid-phase joint as the tool moves forward. Although the workpiece does heat up during FSW, the temperature does not reach the melting point. Friction stir welding can be used to join most aluminium alloys, and surface oxide presents no difficulty to the process. Trials undertaken up to the present time show that a number of light weight materials suitable for the automotive, rail, marine, and aerospace transportation industries can be fabricated by FSW.     

2024铝合金水下搅拌摩擦焊热力耦合仿真分析

目的 优化搅拌摩擦焊接工艺参数,以提高接头的力学性能。方法 基于ABAQUS软件建立了热力耦合有限元模型,使用耦合欧拉-拉格朗日方法对典型的航空航天用板材2024铝合金的水下搅拌摩擦焊接过程进行了仿真研究。分析了搅拌摩擦焊接过程中板材的温度场分布和材料变形情况,同时研究了前进侧和后退侧相应位置材料的流动特征,进一步讨论了搅拌头冷却速度和摩擦因数对焊接温度和材料流变场的影响。结果 当摩擦因数较小时,针对焊接过程的有限元模拟将会失败;前进侧和后退侧材料变形和流动差异显著;焊接温度和等效应变随摩擦因数的增大而升高,随冷却速度的增大而降低。结论 当摩擦因数为0.8时,能较好地完成焊接。相对于空冷,水冷能明显缩短高温持续时间。     

Formation and retention of local melted films in AZ91 friction stir spot welds

The formation of local melted films during friction stir spot welding of as-cast AZ91D and thixomolded AZ91 material is investigated. The average temperatures close to the tip of the rotating pin vary from 438 to 454 °C during the dwell period in friction stir spot welding. These measured temperature values are higher than the melting temperature of α-Mg + Mg₁₇Al₁₂ eutectic (437 °C). It is suggested that the temperature in the stir zone during the dwell period is determined by the relative proportions of α-Mg and (α-Mg + Mg₁₇Al₁₂) eutectic material, which are incorporated during friction stir spot welding. Based on the stir zone temperature measurements and a detailed examination of material located at the root of the pin thread it is suggested that material is moved downwards via the pin thread and into the stir zone during the dwell period in friction stir spot welding. Evidence of local melted film formation is observed in the stir zone of AZ91 spot welds. It is suggested that melted films are retained since their dissolution rate is much slower in the high temperature stir zone than it is when melted films is formed in the stir zone during Al 7075-T6 friction stir spot welding. The spontaneous melting temperature, solute diffusion rate and the thermodynamic driving force for droplet dissolution are much higher during Al 7075-T6 friction stir spot welding.