异种铝合金单层板与双层板对搭接搅拌摩擦焊

将一块厚4 mm的LF5铝板与两块厚2 mm的6063铝板组成并种铝合金对搭接复合接头,进行搅拌摩擦焊工艺试验并优化焊接参数,获得优质焊缝.重点研究搅拌头转速、搅拌针偏移量对复合接头抗拉强度的影响,并对焊缝表面及横截面宏观形貌、焊缝“洋葱环”组织形貌、焊缝缺陷等进行观察.分析在搅拌针选取不同偏移量的条件下,双层板一侧的...     

Dissimilar friction welding of aluminium alloys to other materials

Friction welding makes it easier to set welding conditions and also confers greater reproducibility than other welding processes. Through being a solid-phase process, friction welding moreover makes it relatively easy to join dissimilar materials. Other advantages of friction welding include good operability, the lack of any need for special skills, and a convenient capability for incorporation in assembly lines without showers of sparks and similar hazards being generated. Friction welding is therefore extensively used in a wide variety of industries, such as automotive engineering, printing, etc. Joining of dissimilar materials as a characteristic friction welding application has been well researched,¹ reported,² and thoroughly explained with reference made to practical examples.³ In the current situation of materials development advancing apace in pursuit of various objectives, available data relating to joining of dissimilar materials remains scant. To meet resource- and energy-saving objectives, machinery and plant, transport machinery, etc. are now required to embody lighter weight in a well-established trend that can only serve to expand the use of light metals. Compared with ferrous metals, however, friction welding of light metals has been little documented.     

Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy

Dissimilar friction stir welding between 5052 Al alloy and AZ31 Mg alloy with the plate thickness of 6 mm was investigated. Sound weld was obtained at rotation speed of 600 r/min and welding speed of 40 mm/min. Compared with the base materials, the microstructure of the stir zone is greatly refined. Complex flow pattern characterized by intercalation lamellae is formed in the stir zone. Microhardness measurement of the dissimilar welds presents an uneven distribution due to the complicated microstructure of the weld, and the maximum value of microhardness in the stir zone is twice higher than that of the base materials. The tensile fracture position locates at the advancing side (aluminum side), where the hardness distribution of weld shows a sharp decrease from the stir zone to 5052 base material.     

Lapped friction stir welding between ductile cast irons and stainless steels

This study investigated the influence of preheating temperature and welding speed on the microstructure of dissimilar lapped friction stir welding (FSW) of ductile cast iron FCD450 and 304 stainless steel. The stainless steel was placed on FCD450, and then FSW was carried out at a tool rotational speed of 200, 400, and 600 rpm and welding speed between 1 and 10 mm/s. Preheating was conducted at 573 and 773 K. Martensitic structure was formed in HAZ of FCD450 without the preheating, while the preheating resulted in the formation of a pearlite structure. Even when the preheating was employed, however, stir zone (SZ) of FCD450 had the chill structure at a lower welding speed, because the SZ temperature exceeded the eutectic temperature. Formation of the chill structure in the SZ could be prevented at a higher welding speed. This study showed that FSW would be available as a dissimilar welding method between ductile cast iron and stainless steel.     

基于不旋转轴肩的铝镁异种材料搅拌摩擦焊

焊具是搅拌摩擦焊的核心,对焊接质量起至关重要的作用. 利用不旋转轴肩焊接系统对6061-T6铝和AZ31B镁合金进行连接,重点分析传统和不旋转轴肩焊接系统下接头成形和力学性能等. 结果表明,与传统工艺相比,采用不旋转轴肩工艺的接头表面成形更加光滑,焊核区以典型铝镁混合的叠层结构为主,且铝镁冶金结合界面呈弯曲状,有效地增强了铝镁异种材料的机械咬合效果;焊缝区金属间化合物层明显减小,其主要是由不旋转轴肩增强焊核区材料的搅拌效果并起到“热沉”的作用所致. 采用不旋转轴肩的接头最大抗拉强度为137 MPa,较传统工艺提高了28%.     

High temperature wear and friction properties of duplex surface treated bearing steels

Duplex treatments by thermo reactive diffusion (TRD) chromizing and puls plasma nitriding were carried out on AISI 52100 and 8620 bearing steels. Tribological behaviors of TRD chromized and duplex treated bearing steels were investigated against Al₂O₃ ball in ball-on-disc system at room temperature and 500 °C. The samples were pack chromized in a furnace at temperature of 1000 °C for 5 h. After chromizing, the samples were puls plasma nitrided for 5 h at 500 °C. The coated steels were characterized using scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), X-ray diffraction (XRD), scratch and microhardness testing. Plasma nitriding of chromized steels increased the total thickness of the compound layer. The subsequent plasma nitriding increased the surface hardness to 2135 HK_0.025 due to the formation of CrN and Cr₂N. The surface hardness and scratch resistance of coating can be increased with duplex treatment of chromizing followed by plasma nitriding, resulting in high wear resistance. Tribological tests indicated that puls plasma nitriding process decreased the coefficient of friction values and wear rate of the chromized steels at room temperature and 500 °C. Also, examination of the worn surface of the samples showed that particularly at high temperature, the oxidized compact layer occurs and tribo-oxidation played an important role in oxidation behaviour of the steels after the duplex treatment.     

Dissimilar spot welding of aluminium alloy and galvannealed steel by metal flow-application of friction anchor welding to aluminium alloy and Zn-coated steel

ABSTRACT

Lap joints of an upper Al alloy (1.0-mm-thick A5052) and lower hot dip galvanized steel (1.2-mm-thick GI steel) were welded by a novel spot welding process for dissimilar metal lap joints using a new tool with the tip made of spherical ceramics, i.e. ‘Friction Anchor Welding.’ As a result, the rotating tool was plunged only to 1.3–1.4 mm from the Al alloy surface, and accordingly, a steel projection was not formed in the Al alloy sheet. Further, the Al alloy near the rotating tool was removed. However, near this removed area, the Zn layer on the GI steel melted and was removed by friction heat, and consequently, the GI steel and the Al alloy were welded. Thus, the tensile shear strength reached about 2.6 kN/point.     

搅拌摩擦焊应用及焊接设备简介

介绍了搅拌摩擦焊的工艺过程，分析了搅拌摩擦焊焊缝及焊接过程的优缺点。对搅拌摩擦焊的应用和常用搅拌摩擦焊设备作了简要的描述。     

Stability of the retained austenite in low-alloyed transformation induced plasticity-aided steels during friction stir welding

To clarify the possibility to maintain the retained austenite even in the joint area of the low-alloyed transformation induced plasticity-aided steel sheets, friction stir welding (FSW) was investigated with a special focus on the effects of the FSW tool rotation rate and initial microstructure on the microstructural evolution and mechanical properties. The experimental results clarified that the lower tool rotation rate and the use of a finer initial microstructure are preferable in order to obtain the retained austenite and the retained austenite obtained by FSW with preferable conditions contributed to maintaining both the strength and ductility of the joints.     

牙轮扩孔器异材钢焊接工艺

牙轮扩孔器是海上石油钻井中的关键设备,由于受海底地质条件的影响,设计选用35CrMo和35CrMo、35CrMo和35、35CrMo和Q235-B、35和35钢焊接结构,由于多种材质组合焊接,结构焊接性能很差,容易形成热裂纹。我们经过认真研究和试验,制定了正确的焊接工艺,保证了产品质量。     

Effect of friction stir welding process on microstructural characteristics and corrosion properties of steels for naval applications

ABSTRACT

Electrochemical properties and microstructure examinations have been performed on three Friction Stir Welded (FSW) shipbuilding steels (DH36, S690QL, 80HLES). Galvanic coupling has been assessed using Scanning ElectroChemical Microscopy (SECM) and an electrochemical mini-cell in order to subsequently identify possible FSW-related damages of these steels. The galvanic macro-coupling between the base material and the welded zone is measured by the SECM tip. The 80HLES steel has greater differences in surface hardness and electrochemical reactivity which lead to a galvanic coupling inducing an initiation to corrosion.     

Dissimilar spot welding of aluminium alloy and hot dip galvanised steel by metal flow: application of friction anchor welding to aluminium alloy and Zn-coated steel

Lap joints of an upper Al alloy (1.0 mm-thick A5052) and lower hot dip galvanized steel (1.2 mm-thick GI steel) were welded by a novel spot welding process for dissimilar metal lap joints using a new tool with the tip made of spherical ceramics, i.e. ‘Friction Anchor Welding’. As a result, the rotating tool was plunged only to 1.3–1.4 mm from the Al alloy surface, and accordingly, a steel projection was not formed in the Al alloy sheet. Further, the Al alloy near the rotating tool was removed. However, near this removed area, the Zn layer on the GI steel melted and was removed by friction heat, and consequently, the GI steel and the Al alloy were welded. Thus, the tensile shear strength reached about 2.6 kN/point.     

High strength lap joint of aluminium and stainless steels fabricated by friction stir welding with cutting pin

Abstract

Dissimilar lap joints of aluminium and stainless steel were first friction stir welded by the tool with a cutting pin. The results showed that sound joints could be obtained by this method. When the pin was inserted into the lower steel sheet, macrointerlocks were formed by the steel flashes plugging into the upper aluminium at both sides of the nugget bottom. At the aluminium/steel interface, a thin intermetallic compound (IMC) layer and the mechanical bonding of microinterlocks were formed. In addition, the aluminium near the interface was also strengthened by grain refinement and IMC particles. Therefore, the beneficial effect of the macrointerlocks provided by the steel flashes was removed, the shear strength of the joint reached 89·7 MPa, which was even higher than that of the base metal of aluminium.     

工艺参数对钛/铝异种合金回填式搅拌摩擦点焊连接质量的影响

采用回填式搅拌摩擦点焊工艺(Refill friction stir spot welding,FSpW)对厚度均为2 mm的5A02-O铝合金和TC4钛合金板材进行焊接。通过改变停留时间和回填速度,探究不同工艺参数对接头微观组织和力学性能的影响。结果表明,在选定工艺范围内,焊点成型良好,搅拌区晶粒细小,热影响区晶粒长大但有限,搅拌套作用区界面原子扩散距离比搅拌针作用区更大,停留时间6 s获得的焊点界面原子扩散距离和金属间化合物(IMC)厚度在1 μm左右。随着回填速度提高,接头承载载荷总体呈现上升趋势,但仍有数值波动,回填速度为30 mm/min,停留时间为6s获得接头拉剪载荷最低为4861 N,回填速度为90 mm/min,停留时间为6 s获得接头拉剪载荷最高为6617 N,拉剪后宏观断面较为平整,断裂模式为剪切断裂,微观断口由韧窝组成。     

Metallurgy of arc welding of structural steels and welding materials

To improve the formation of the welded joint in narrow-gap welding, investigations were carried out into the method of welding with double modulation of the electrode wire feed rate and pulsed feed of the welding arc.     

搅拌摩擦焊工艺参数窗口的建立与接头性能

搅拌摩擦焊的工艺参数对焊缝的表面成形和接头性能有着决定性的影响.以3mm铝合金2024板材对接焊为代表,通过大量的工艺参数试验,考查了多种焊接参数组合下的焊接接头质量,并在此基础上建立了工艺参数窗口.结果表明,在转速375～475r/min,焊接速度150～235mm/min的工艺参数窗口内,接头可以获得母材80%以上的抗拉强度.通过对拉伸断口的显微分析,发现靠搅拌区上方的材料塑性较好,搅拌区底部材料抗变形能力较差,接头区沿厚度方向分层严重.